JP2000289138A - Patterned decorative panel and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a lightweight patterned decorative panel not generating unevenness, wrinkles or air bubbles on the surface thereof, excellent in design effect and easy to work. SOLUTION: A patterned sheet 6 wherein a pattern layer 4 is held between an org. fibrous substrate 3 and a transparent resin layer 5 is arranged in the cavity of a lower mold 8b so that the transparent resin layer 5 is turned downwardly and a fibrous substrate 2 different from the org. fibrous substrate 3 is superposed thereon and a foamable resin material 1 is supplied to the fibrous substrate 2 from above and molds 8a, 8b are closed and the foamable resin material is foamed and molded to obtain a patterned decorative panel.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight patterned decorative panel suitably used for renovating a bathroom, a toilet, a shower room, a sanitary room, and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, bathrooms, toilets, shower rooms,
As a wall material used for repairing the interior of a plumbing space such as a sanitary room, for example, a polyvinyl chloride-based wallpaper sheet, an SMC panel with a pattern on the surface, and the like have been used.

[0003]

However, the thickness of the above-mentioned polyvinyl chloride-based wallpaper sheet is generally thin, and therefore, there is a drawback that irregularities and steps on the base before repairing are picked up and the surface becomes uneven. Furthermore, the application of the wallpaper sheet requires care so as not to generate wrinkles and air bubbles, and requires skilled skills. In addition, S with a pattern on the surface
The MC panel is excellent in design without generating irregularities or wrinkles on the surface, but has a drawback that it is not light. An object of the present invention is to provide a decorative panel with a pattern that does not generate irregularities, wrinkles, bubbles, or the like on its surface, has excellent design properties, and is light and easy to work.

[0004]

In order to achieve the above-mentioned object, the patterned decorative panel of the present invention has the following configuration. That is, the patterned decorative panel of the present invention is the following patterned decorative panel of (1) to (6). (1) In order from the front side, the transparent resin layer 5 and the pattern layer 4
A decorative panel with a pattern, comprising: a first foamed resin layer 30 having an organic fibrous base material; and a second foamed resin layer 20 having a fibrous base material different from the organic fibrous base material. (2) The decorative panel with a pattern according to the above (1), further comprising a third foamed resin layer 10 outside the second foamed resin layer 20. (3) The decorative panel according to the above (1) or (2), wherein the fibrous base material in the second foamed resin layer 20 is an inorganic fibrous base material. (4) The decorative panel with a pattern according to the above (3), wherein the inorganic fibrous base material is a glass mat. (5) The patterned decorative panel according to any one of (1) to (4), wherein the organic fibrous base material in the first foamed resin layer 30 is a polyester nonwoven fabric. (6) The first foamed resin layer 30, the second foamed resin layer 20, and / or
Alternatively, the decorative panel with a pattern according to any one of the above (1) to (5), wherein the foamed resin material in the third foamed resin layer 10 is a urethane foam resin.

The present invention also relates to a method for producing a decorative panel with a pattern according to any one of the above (1) to (6). The manufacturing method is such that a patterned sheet 6 having a pattern layer 4 sandwiched between an organic fibrous base material 3 and a transparent resin layer 5 is placed on the lower side of a molding die with the transparent resin layer 5 side facing downward. 8b, a fibrous base material 2 different from the organic fibrous base material 3 is superimposed thereon, the foamed resin material 1 is supplied from above, and the molding dies 8a and 8b are closed and foamed. It is characterized by being molded. Here, the “transparent” resin layer is used to include the “translucent” resin layer.

[0006]

Embodiments of the present invention will be specifically described below with reference to the drawings. FIG. 1 is a schematic cross-sectional view of an example of a decorative panel with a pattern according to the present invention. As shown in FIG. 1, the patterned decorative panel includes, in order from the front side, a transparent resin layer 5, a pattern layer 4, a first foamed resin layer 30 having an organic fiber base material, and (the organic fiber It is composed of a second foamed resin layer 20 having an organic or inorganic) fibrous base material different from the base material.

As the resin of the transparent resin layer, various resins can be used as long as they are transparent or translucent resin. Thermosetting resin such as unsaturated polyester resin, acrylic resin, epoxy resin, etc., polyethylene, polypropylene, nylon, polyester, fluorine film, polyethylene terephthalate, polybutylene terephthalate, polyvinyl chloride, polystyrene, acrylonitrile / butadiene / styrene copolymer And the like are preferably used. The thickness of the transparent resin layer is preferably a thickness that beautifully expresses a pattern (a pattern), and such a thickness is usually 10 to 2
It is about 00 μm, preferably about 25 to 100 μm. As these transparent resin layers (or sheets), those subjected to a corona discharge treatment for imparting easy adhesion or a treatment for imparting antibacterial properties (for example, an antibacterial fluorine coating treatment) are preferably used.

The pattern layer 4 is a layer having at least the pattern 4a, and may include an adhesive 4b and the like in addition to the pattern 4a. The material of the pattern 4a is an ink, a colored filler, or the like, and the colored filler is a crushed material of a natural mineral such as mica, a crushed material of an inorganic material such as a metal, an organic material such as a fiber, or a crushed material thereof. There are things.

The organic fibrous base material used for the first foamed resin layer 30 includes an organic polymer non-woven fabric or woven fabric or paper, and the non-woven fabric or woven fabric includes polyester fiber or polyvinyl alcohol fiber. Titanium paper, woodfree paper, kraft paper, Japanese paper and the like can be used as the paper, and polyester nonwoven fabric is preferable. This is because they have excellent surface smoothness and adhesiveness. Its thickness is 5
Those having a thickness of about 0 μm to 500 μm are preferred.

The fibrous base material different from the organic fibrous base material is an organic fibrous base material or an inorganic fibrous base material.
Here, when an organic fibrous base material is used, there are nonwoven fabrics, woven fabrics, papers, and the like of the above-mentioned organic polymers, which are different from each other.

When an inorganic fibrous base material is used, glass fiber, carbon fiber, potassium titanate fiber, alumina fiber,
Non-woven fabric or woven fabric such as silica fiber can be used, preferably a glass fiber non-woven fabric made of glass single fiber,
More preferably, a continuous strand mat,
It is a glass mat such as a chopped strand mat or a surface mat, and particularly preferably a continuous strand mat which is well impregnated with a foamed resin material. The thickness of the fibrous base material (different from the organic fibrous base material) is preferably about 50 μm to 1500 μm.

As the foamed resin material, urethane foaming resin, phenolic resin for foaming and the like can be used. Above all, a urethane resin for foaming, which reacts two liquids of a polyol component and an isocyanate component, is preferably used from the viewpoint of economy, and a hard polyurethane material having a density of 200 to 500 kg per cubic meter is particularly preferable. The expansion ratio is preferably about 3 to 5 times. This is to ensure the surface hardness of the panel and good panel formability.

FIG. 2 shows a patterned decorative panel (a schematic sectional view) of another example of the present invention. The decorative panel with pattern in FIG.
Second foamed resin layer 20 of patterned decorative panel shown in FIG.
Is a patterned decorative panel further including a third foamed resin layer 10 on the outside of the panel. Here, the third foamed resin layer 10 is a layer that does not include the fibrous base material 2. The thickness of the third foamed resin layer 10 is usually about 0 to 2 mm.

Next, a method for manufacturing a decorative panel with a pattern according to the present invention will be described. FIG. 3 is an explanatory view (cross-sectional view) of a method for manufacturing a decorative panel with a pattern according to the present invention. As shown in the figure, a patterned sheet 6 in which a pattern layer 4 is sandwiched between an organic fibrous base material 3 and a transparent resin layer 5, with the transparent resin layer 5 on the lower side and the organic fibrous base material 3 on the upper side. Like so
After being placed in the cavity of the lower die (female die) 8b, the fibrous base material 2 is placed thereon, the foamed resin material 1 is injected from above, and the fibrous base material 2 is covered with the release film 9, The foamed resin material 1 is foamed while the foamed resin material 1 is infiltrated into the fibrous base material 2 and the organic fibrous base material 3 while fitting the upper mold (male mold) 8a for molding, and pressure molding is performed. I do. At the time of pressurization, heating is preferably performed. After cooling, the mold is removed to obtain the patterned decorative panel according to the present invention.

Here, the release film 9 is used for improving the releasability of the molding die and the molded product, and may be a polyethylene film or a polypropylene film. Depending on the type of the foamed resin material and the molding conditions, it may not be necessary to use these release films. The amount of the foamed resin material used is preferably about 600 to 1,000 g per square meter. The pressure molding may be performed under the condition that the polymerization reaction is completed. In the case of urethane resin, the temperature is about 30 to 40 ° C., and the foamed resin material is immersed in the fibrous base material 2 and the organic fibrous base material 3. After that, the time for fitting the lower mold 8b and the upper mold 8a is 7 to
It is about 15 minutes, preferably about 8 to 10 minutes. The thickness of the obtained decorative panel with a pattern is about 3 to 10 mm.

A patterned sheet having a pattern layer sandwiched between an organic fibrous base material and a transparent resin layer can be prepared by various methods. For example, a patterned sheet and an organic fibrous base material in which one side of a transparent resin layer such as a thermoplastic resin sheet is patterned with ink by gravure printing, silk screen printing, or the like, and an adhesive with the pattern layer-provided surface inside. Can be laminated. Various adhesives can be used as the adhesive that can be used at this time, but a preferable one is a two-component curable urethane resin adhesive. Further, the pattern may be any pattern (or picture) such as a wood pattern, a stone pattern, a cloth pattern, a geometric pattern, and the like.

The organic fibrous base material that can be used includes, as described above, an organic polymer nonwoven fabric, a woven fabric, and paper, and preferably a polyester nonwoven fabric. The basis weight is preferably 10 per square meter.
Up to 400 g (about 50 μm to 500 μm in thickness)
It is.

The inorganic fibrous base material that can be used is, as described above, glass fiber, carbon fiber, or the like, and is particularly preferably a continuous strand mat that is well impregnated with a foamed resin material. The basis weight is preferably 1
10 to 450 g per square meter (50 in thickness
μm-1500 μm).

Since the decorative panel according to the present invention has a patterned decorative sheet on its surface, it has a beautiful appearance and excellent design. In addition, the decorative sheet with the pattern and the organic fiber base material and the foamed resin reinforced with the inorganic or organic fiber base material are integrally formed, and are light because they contain a large amount of air bubbles.
Further, since the patterned sheet and the second foamed resin layer of the patterned decorative panel are performed through the organic fiber base material and the foamed resin adhered to the patterned sheet, they are strongly fixed to each other, In addition, separation between the first foamed resin layer and the second foamed resin layer hardly occurs.

[0020]

EXAMPLE 1 In a cavity of a lower mold (female mold) for molding, a corona discharge treatment and an antibacterial treatment were applied to one surface, and a pattern (picture) having a thickness of 100 μm was applied to the other surface. A patterned sheet in which an axially stretched polyethylene terephthalate sheet and a polyester nonwoven fabric having a thickness of 70 μm were adhered with a two-component curable urethane resin-based adhesive was placed with its patterned surface facing down. A continuous strand mat of 300 g per square meter is placed on this, and a urethane foaming stock solution in which a polyol component and an isocyanate component are mixed is poured from above onto the continuous mat so as to have an application amount of 1,000 g / square meter. On top, a polyethylene film (film for release) was placed. After fitting the upper mold for molding and the lower mold for molding, and impregnating the continuous strand mat and the polyester nonwoven fabric with the urethane foaming stock solution, 40
Pressure molding was performed for 8 minutes while heating and foaming at ５０50 ° C. The mold was released to obtain a decorative panel with a pattern in which the above-mentioned patterned sheet, continuous strand mat and urethane foam resin were integrated. The obtained decorative panel with a pattern as shown in FIG. 2 having a thickness of about 3 mm
Met.

Example 2 Using a phenol foaming stock solution instead of a urethane stock solution,
The same operation as in Example 1 was performed to obtain a decorative panel with a pattern.

[0022]

The patterned decorative panel of the present invention is obtained by integrally molding a patterned decorative sheet, an organic fibrous base material, and a foamed resin reinforced with a fibrous base material different from the organic fibrous base material. It has excellent design and is lightweight. Therefore, it is suitable for renovation of interiors such as bathrooms.It has an appropriate thickness, so it does not pick up irregularities or steps on the ground before renovation, and the panel can be easily attached with adhesive etc. No special skills are required. In particular, when a glass mat is used as the fibrous base material of the second foamed resin layer, there is an advantage that rigidity is high and warping is difficult. Further, the decorative panel with pattern of the present invention can be easily cut with a cutter or the like, so that workability at a construction site is also excellent. In addition, the patterned sheet and the second foamed resin layer of the patterned decorative panel are strongly adhered to each other because they are made of foamed resin via the organic fiber base material adhered to the patterned sheet. In addition, separation between the first foamed resin layer and the second foamed resin layer hardly occurs. According to the production method of the present invention, the patterned decorative panel of the present invention can be easily produced.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a patterned decorative panel according to an example of the present invention.

FIG. 2 is a schematic sectional view of a patterned decorative panel according to another example of the present invention.

FIG. 3 is an explanatory view (a schematic sectional view) of a method for producing a decorative panel with a pattern according to the present invention.

[Explanation of symbols]

1: foam resin material 1a: foam-containing resin 2: fibrous base material 3: organic fiber base material 4: patterned layer 4a: patterned 4b: adhesive 5: transparent resin layer 6: patterned sheet 7: foam 8a: molded Upper mold (male mold) 8b: Lower mold (female mold) 9: Release film 10: Third foamed resin layer 20: Second foamed resin layer having a fibrous base material 30: Organic fibrous base material First foamed resin layer 100 having foam: foamed resin material-containing patterned sheet

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Inventor Kenji Takada 1010 Ippongi, Toyama-shi, Toyama F-term within Hitachi Chemical Unit Co., Ltd. BA13 CB02 DG01C DG01D DG06E DG15C DH00C DH00D DH00E DJ01C DJ01D EA061 EC032 EC051 EH311 EJ022 EJ202 EJ422 EJ822 EJ913 EJ951 GB08 GB90 HB00B JK06 JL01 JL02 JL03 JL04 JL

Claims (7)

[Claims] 1. A transparent resin layer, a pattern layer, a first foamed resin layer having an organic fibrous base material, and a fibrous base material different from the organic fibrous base material in order from the front side. And a second foamed resin layer having the pattern. 2. The patterned decorative panel according to claim 1, further comprising a third foamed resin layer outside the second foamed resin layer. 3. The decorative panel with a pattern according to claim 1, wherein the fibrous base material in the second foamed resin layer is an inorganic fibrous base material. 4. The patterned decorative panel according to claim 3, wherein the inorganic fibrous substrate is a glass mat. 5. The patterned decorative panel according to claim 1, wherein the organic fibrous base material in the first foamed resin layer is a polyester nonwoven fabric. 6. The decorative panel with a pattern according to claim 1, wherein the foamed resin material in the first foamed resin layer, the second foamed resin layer and / or the third foamed resin layer is a urethane foam resin. 7. A patterned sheet in which a pattern layer is sandwiched between an organic fibrous base material and a transparent resin layer is placed in a cavity of a lower mold for molding, with the transparent resin layer side down. Then, a fibrous base material different from the organic fibrous base material is superimposed thereon, and a foamed resin material is supplied from above, and a molding die is closed and foam-molded. Manufacturing method of decorative panel with pattern.