JP2001198999A - Thermosetting resin decorative plate, decorative sheet used therefor, and method for manufacturing thermosetting resin decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a thermosetting resin decorative plate not having a strain or unevenness in a design and not having a crack or a craze. SOLUTION: A decorative sheet 5 obtained by laminating a woven fabric 3 or a knitted fabric on a thermoplastic resin sheet 1 decorated with a design 2 or the like via an adhesive layer 4 is used. A fibrous base material is coated or impregnated with an uncured thermosetting resin liquid, the sheet 5 is laminated on the base material so that the fabric is contacted with the base material, pressurized or thermally pressurized to cure the thermosetting resin liquid and its laminate is adhered and integrated. Since the fabric 3 or the knitted fabric is laminated on or integrated between the base material obtained by coating, impregnating with the resin and curing the resin and the sheet 1 of the front side, the sheet 1 laminated at the front side is not broken or not deformed and hence stable and excellent quality of no flow or no unevenness of the design is obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention belongs to the technical field of thermosetting resin decorative boards suitably used for bathroom interior materials, bathtubs, wash basins, home interior materials, trays, home appliance cabinets and the like.

[0002]

2. Description of the Related Art Conventionally, when a decorative sheet is further laminated and adhered to the surface of a thermosetting resin decorative board, it is difficult to bond the decorative sheet to the cured resin layer. Laminated and bonded. For example, if necessary, a decorative sheet made of a thermoplastic resin, an adhesive layer,
Laminating and adhering simultaneously with molding via an easy-adhesion primer layer (see, for example, JP-A-60-122149, JP-A-3-218832, JP-A-4-37508, etc.), heat resistance and A decorative sheet made of dimensionally stable paper is laminated and adhered simultaneously with molding (for example, Japanese Patent Publication No. 26-4540,
Japanese Patent Application Laid-Open No. 9872/1987 and Japanese Patent Application Laid-Open No. 62-152733) are known.

[0003]

In the former described in the prior art, since the thermoplastic resin is softened by heating, the decorative sheet is deformed by heat and stress during molding of the thermosetting resin decorative board. Frequently, the pattern collapses or causes unevenness. Since this phenomenon varies depending on variations in molding conditions and variations depending on sheet lots, the quality is not stable.

Further, in the case of the latter, distortion or flow of the picture does not occur, but on the other hand, printing is not as clear and precise as the former because of the unevenness and absorption of the fiber of the paper. This tends to cause unevenness in the picture. This tendency is particularly pronounced when the picture is provided solidly over the entire surface. In addition, since the resulting decorative sheet has no flexibility and flexibility, there is also a problem that a crack or a crack is easily generated when a force such as a bending force or an impact force is applied during molding.

Therefore, it is conceivable to use a decorative sheet made of a thermosetting resin. However, the cured thermosetting resin sheet has no chemical reactivity and thus has insufficient adhesion to other layers of the decorative board. In addition, since the decorative sheet as a whole is harder than the above and there is nothing to reinforce or release stress, cracks and cracks are more easily generated by bending during molding, so there is no possibility of practical application. .

The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a thermosetting resin having no distortion or unevenness in a pattern and no cracks or cracks. It is intended to provide a resin decorative board.

[0007]

Means for Solving the Problems In order to achieve the above object, a thermosetting resin decorative plate of the present invention comprises a thermosetting resin in a fibrous base material which is cured by being coated or impregnated with a thermosetting resin. A woven or knitted fabric is laminated and integrated on the surface in contact with the thermoplastic resin sheet, and a thermoplastic resin sheet is further laminated and bonded thereon.

The decorative thermosetting resin sheet of the present invention having the above structure is manufactured using a decorative sheet having a structure in which a woven or knitted material is laminated on one surface of a thermoplastic resin sheet via an adhesive. You. Further, a decorative sheet provided with a sealing layer for filling and flattening the unevenness on the side facing the thermoplastic resin sheet in the weave of the woven fabric or the stitch of the knitted fabric may be used.

In the method of manufacturing a decorative board, an uncured thermosetting resin solution is applied or impregnated on a fibrous base material, and the decorative sheet having the above-described structure is placed on the fibrous base material. The knitted fabric and the fibrous base material are laminated so as to be in contact with each other, and the thermosetting resin liquid is cured by applying pressure or heat and pressure, and the laminated body is bonded and integrated.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS As a fibrous base material to be coated or impregnated with a thermosetting resin, paper, woven or knitted fabric, woven fabric, non-woven fabric, felt, mat and the like are used. Among them, as the paper, titanium paper, high-quality paper, kraft paper, Japanese paper, etc. can be used, and as the woven or knitted fabric, those described below can be used, and as the nonwoven fabric, woven fabric, felt or mat, glass fiber, asbestos, Fibers made of inorganic fibers such as potassium titanate fiber, alumina fiber, silica fiber, and carbon fiber, and organic resin fibers such as polyester and vinylon can be used.

Examples of the thermosetting resin include a melamine resin, a diallyl phthalate resin, a guanamine resin, an unsaturated polyester resin, an epoxy resin, a polyurethane resin, and the like, and, if necessary, a polymerization initiator, a crosslinking agent, an extender, a coloring agent, and the like. Is used.

Impregnating the state in which the resin is filled in the gaps between the fibers by penetrating into the fibrous base material layer, does not permeate into the inside of the fibrous base material layer at all, or reaches the back surface even if it permeates If the state where the coating is not performed is defined as coating, the coating and impregnation may be performed in the present invention. Specific means for this coating or impregnation include roll coating, flow coating, comma coating, dipping, brush printing, pouring, and the like. Then, a fibrous base material coated or impregnated with a thermosetting resin is pressurized or heated and pressurized to cure the thermosetting resin and to form the desired shape into FRP.
(This is a broader definition than the commonly used definition of FRP.)

An example of a fibrous base material to which a thermosetting resin is applied or impregnated is SMC (sheet molding compound). The method of manufacturing the same is as follows. For example, one side of a first separator film such as a polyethylene terephthalate film may be used. Resin prepolymer, curing catalyst, accelerator, curing retarder, air drying agent and the like, and a resin compound obtained by kneading fillers such as calcium carbonate, talc, clay, etc. by applying by a knife coat method or the like, After spraying chop strands obtained by cutting glass rovings obtained by bundling glass fibers, a resin compound similar to that applied to one surface of the first separator film is applied to one surface of the second separator film. After applying by a coating method, the first separator film and the second separator The films are overlapped so that the resin compound application surfaces of both separator films face each other via the sprinkled chop strands, and the resin compound is impregnated and defoamed into the sprinkled chop strands by pressing with roll pressure. Humidifying and curing. The resin used for producing the SMC is not particularly limited, but usually includes many unsaturated polyesters and epoxies.

Next, an outline of an SMC molding method for producing an FRP article using the above-mentioned SMC will be described. An equipment capable of applying heat and pressure to a pair of opposing dies,
Usually, using a large heat press with a mold installed,
After cutting the SMC to the required dimensions in the mold, peeling the film on the front and back and placing it, and stacking several if necessary,
Heating and pressurizing is performed at a temperature of 00 to 180 ° C. and a pressure of 30 to 200 kg / cm ² for 1 to 10 minutes, followed by curing by a reaction such as cross-linking polymerization or addition polymerization, followed by molding.

As the thermoplastic resin sheet, methyl (meth) acrylate, ethyl (meth) acrylate, (meth)
Acrylic resin such as homo- or copolymer of (meth) acrylate such as butyl acrylate, ethylhexyl (meth) acrylate, etc. (The notation of (meth) acrylate is "acrylate or methacrylate" ), Polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyarylate, ethylene / isophthalate / terephthalate copolymer, polyester-based thermoplastic elastomer, polyester resin such as amorphous polyester, polyvinyl chloride, chloride Vinyl resin such as vinyl / acrylic copolymer, vinyl chloride / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer, ethylene / vinyl acetate copolymer, polystyrene, acrylonitrile / styrene copolymer, acrylonitrile Butadiene-styrene copolymer and styrene-based resins, polycarbonate, polyimide,
A resin such as polyphenylene sulfide is selected. The thickness of the thermoplastic resin sheet used in the present invention is 20
About 100 μm. Also, a large number of minute through holes may be formed as needed.

The thermoplastic resin sheet may be subjected to a decoration treatment, if necessary, to give a desired design appearance. When a desired pattern is applied as a decoration process, printing may be performed on the side of the thermoplastic resin sheet which is in contact with the thermosetting resin layer, or may be performed on the opposite side or both sides. Alternatively, the same or different thermoplastic resin sheets are laminated and bonded to each other,
A sheet formed with a pattern between both sheets (the back of the upper sheet or the front of the lower sheet) may be used. In this case, the printing method may be gravure, offset, silk screen, or the like, and the pattern ink used is a resin binder to which a coloring agent such as a pigment or a dye is added. Examples of the binder include cellulose acetate, cellulose acetate propionate, cellulose resin such as nitrified cotton, methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, and ethylhexyl (meth) acrylate. One or a mixture of two or more of acrylic resins such as (meth) acrylic acid esters alone or copolymers, vinyl chloride / vinyl acetate copolymers, two-component curable urethane resins, and the like are used as pigments. , Cadmium red, graphite, ultramarine, titanium white, inorganic pigments such as carbon black, brass foil powder, aluminum foil powder, brilliant pigments such as titanium dioxide-coated mica scales, quinacridone, polyazo, isoindolinone,
Organic pigments such as phthalocyanine blue are used. The pattern to be printed may be a natural product such as a wood grain pattern, a stone grain pattern, or a cloth grain pattern, a geometric pattern, a character, a symbol, or the like, or may be solid on the entire surface.

The decorative processing other than the pattern applied to the thermoplastic resin sheet includes, for example, metal thin films of gold, silver, chromium, aluminum and the like formed by vacuum evaporation, sputtering, etc., and granite cleavage formed by a method such as embossing or hairline processing. Surface, grain, tile joint, wood channel conduit, hairline,
There are uneven patterns such as cloth texture. Further, there is also a treatment of mixing and coloring the same inorganic pigment as described above. Further, a concealing layer may be provided on the side of the thermoplastic resin sheet which is in contact with the woven or knitted fabric so that the woven or knitted stitches of the woven or knitted fabric are concealed so as not to be visible. This prevents the appearance of the weave or stitch from affecting the design. However, when the appearance of the weave or stitch is utilized as a design, the concealing layer is not provided. As the concealing layer, a solid printing (coating) layer using an ink obtained by adding opaque pigments such as titanium white, carbon black, and brilliant pigment in the binder as described above, or a metal thin film such as aluminum or chromium is used. . When a decorative treatment is provided on the thermoplastic resin sheet, a concealable layer is provided on the woven or knitted fabric side with respect to the layer having the decorative treatment. Alternatively, a solid layer or a metal thin film on the entire surface of the decoration treatment may be used also as the concealing layer.

The fibers of the woven or knitted fabric constituting the decorative sheet by laminating and adhering to the thermoplastic resin sheet include polyester resin (polyethylene terephthalate, polybutylene terephthalate, etc.), nylon (nylon 6, nylon 66, etc.), acrylic resin, Organic fiber such as polyethylene, polypropylene, rayon, acetate, polyvinyl chloride, cellulose, pulp, vinylon, silk, hemp, cotton, wool, or glass fiber, asbestos, potassium titanate fiber,
Examples thereof include inorganic fibers such as alumina fibers, silica fibers, and carbon fibers. The fibers used have a thickness of 30 to 25.
A denier of about 0 denier (D), a density of about 20 to 100 pieces / cm, and a rice basis weight of about 10 to 400 g / m ² is suitable. In addition, it does not matter whether or not the pile (upright hair, tuft) processing is provided.

The woven fabric is obtained by intersecting warp (warp) yarns and weft (weft) yarns at right angles.
ave design), the basic plain weave, Aya (Aya) weave,
Sushi weaving is called the three original organization. Of these, plain weave
As shown in FIG. 1, is a simple structure in which warp yarns and weft yarns intersect one by one. Since the yarns intersect closely, the fabric surface is flat and durable. As shown in FIG. 2, twill weave is a combination of three or more warp yarns and weft yarns, which represent undulations in a diagonal direction (called ridges and oblique lines). Glossier and softer than 1/2,
There are many types, such as 3/1, 2/2. As shown in FIG. 3, satin weave has few texture points and has a long warp floating (warm satin) or a long weft floating (weft satin), and is soft and glossy. There is. The simplest complete structure is composed of five warp and weft yarns, each of which is referred to as a five-sheet satin, and includes an eight-sheet satin and a ten-sheet satin. Derivative weave is a derivative of the three original tissues. Rib weave is a plain weave that is expanded vertically or horizontally to show horizontal or vertical ridges. mat weave)
Is an enlarged plain weave with two or more threads in the vertical and horizontal directions. A steep weave represents an oblique line at an angle greater than 45 °, while a gentle weave has a gentler angle, all of which are twill weaves. The Yamagata Oblique (Aya Sugi) is an oblique line expressed in Yamagata, and this is the herringbone serge. There are many changes in the texture of the satin weave, but the day and night shushi weave is a combination of the fact that the gloss is different on the front and back surfaces. It is. Further, as shown in FIG. 4, a structure in which yarns in three directions are crossed diagonally can be used.

[0020] The knitted material has a stitch (loop) formed by a yarn,
Alternatively, they are connected in the horizontal (weft) direction to form a cloth, and are classified into a vertical knit and a horizontal knit according to the knitting direction. Among them, the horizontal knit is formed by forming a large number of stitches by using one thread and sequentially connecting the stitches to form a cloth. The organization includes a basic flat knitting (FIG. 5), a rubber knitting (FIG. 6), a pearl knitting (FIG. 7), which are called three original structures, and a number of changing tissues. In the warp knitting, many warp yarns are arranged in the same manner as in the manufacture of a woven fabric, and a knitted stitch is formed with each of the yarns to form a cloth. A single tricot stitch is the simplest of the warp knits, and is woven by alternately tangling a row of warp yarns with adjacent needles, as shown in FIG.
As shown in FIG. 9, a single atlas stitch is a structure in which a single row of warp yarns is tangled while skewed over several vertical rows, and is moved left and right to be knitted. As shown in FIG. 10, a single cord stitch is a structure in which a single row of warp meshes over two or more knitting needles. In addition, two needle stitches (two needle stitch), tricot stitches (tricot stitch), half tricot stitches (ha
lf tricot stitch), double tricot
cot stitch), satin tricot sti
tch) and double-sided edition (interlock stitch).

In the present invention, a decorative sheet is formed by laminating a woven or knitted layer on a thermoplastic resin sheet to form a decorative sheet. Better than non-woven fabric. Further, a decorative sheet using a knitted fabric is superior to a woven or nonwoven fabric in terms of followability to an uneven surface during molding.

As the adhesive for bonding the thermoplastic resin sheet and the woven or knitted material, a two-component curable urethane resin is preferably used. Specifically, an acrylic polyol, a polyester polyol, a polyol such as a polyether polyol as a main component, tolylene diisocyanate, xylene diisocyanate, aromatic isocyanate such as naphthalene diisocyanate, or hexamethylene diisocyanate, isophorone diisocyanate,
An adhesive using an aliphatic or alicyclic isocyanate such as hydrogenated tolylene diisocyanate as a curing agent. Further, an epoxy resin, an acrylic resin, a polyolefin resin, a polyvinyl acetate, a thermoplastic urethane resin, a polyamide resin, and the like can also be used. The application amount of the adhesive is 10 to 100 g /
m ² . Further, in order to hide the weave of the woven fabric or the stitch of the knit, a highly opaque pigment such as titanium white, carbon black, and a bright pigment may be added as necessary.

The woven fabric or knitted fabric may be provided with a sealing layer for filling and smoothing the unevenness of the texture or stitch on the thermoplastic resin sheet side (front side). That is, at least the surface is flattened by impregnating or filling the resin into the woven or knitted fabric. By providing such a filling layer, it is possible to prevent the unevenness of the weave or stitch from being visually seen through the surface of the decorative sheet, or being visually protruded as physically uneven. As the resin used for the filling layer, a resin that penetrates into a weave or stitch and solidifies to smooth at least the thermoplastic resin sheet side (surface side) of the woven or knitted fabric is used. And it is necessary to have adhesiveness with the adhesive mentioned later. Specifically, the same resin as the resin exemplified as the adhesive can be used.

To this sealing layer, a highly opaque pigment such as titanium white, carbon black, or a brilliant pigment composed of flaky foil powder such as brass, aluminum, or mica coated with titanium dioxide is visually added. Also, the texture or stitch may be hidden. Alternatively, by using a resin having a refractive index the same or similar to that of the fibers of the woven or knitted fabric (for example, the same resin composition as that of the woven or knitted fabric), the interface between the filling layer and the fibers is made transparent to visually The texture or stitch may be made invisible, and as such a resin, the same as those exemplified above as the fibers of the woven or knitted material can be used.

Specific means for hardening the thermosetting resin layer by pressurizing or heating and for bonding and integrating the laminate are as follows: (1) Uncured thermosetting resin is applied between two flat plates. Or press molding in which the laminated body of the impregnated fibrous base material layer and the decorative sheet is sandwiched and both flat plates are pressed or heated and pressed, and (2) as is conventionally performed in the production of an unsaturated polyester decorative plate. A method in which a biaxially stretched polyethylene terephthalate film is attached to a □ -shaped mold with tension, and four corners are fixed to the mold, and the film surface is placed on the surface of an uncured resin and pressed. 3) A so-called stamping molding, in which a laminate is inserted into a cavity between the male and female molds and the two molds are pressed or heated and pressed, is used. The heating is performed to initiate or accelerate the crosslinking or polymerization reaction itself of the thermosetting resin, and may be omitted if heating is not necessary. The heating temperature is determined by the type and composition of the resin, but is usually about 40 to 150 ° C.

The shape of the thermosetting resin decorative plate may be a flat plate, a curved plate or the like. Further, if necessary, various substrates may be backed and laminated on the back surface of the decorative board of the present invention (the opposite side of the decorative sheet). As the backing substrate, a plate or sheet of a synthetic resin, metal, wood, or the like is appropriately used.

Uses of the thermosetting resin decorative board obtained by the present invention include (1) bathroom wall surfaces, floor surfaces, ceiling surfaces, bathtubs,
Wash basin, wash basin, (2) interior materials such as house walls, floors, ceilings, (3) meal trays, (4) home appliance cabinets, (5) vehicle interior and exterior materials, (6) And others.

[0028]

Embodiments of the present invention will be described below with reference to the drawings.

Example 1 A biaxially stretched polyethylene terephthalate film having a thickness of 75 μm was prepared as a thermoplastic resin sheet, and a pattern 2 was formed on the back side of the thermoplastic resin sheet 1 as shown in FIG. Processing was performed.
Specifically, a binder of a two-component curable urethane resin as an ink (main component: 100 parts by weight of acrylic polyol,
Curing agent: marble-like marble stone pattern by gravure printing method using a pigment (titanium white, red iron oxide, graphite, phthalocyanine blue) added to 1,6-hexamethylene diisocyanate (8 parts by weight). Printed.

Next, as shown in FIG.
Thermoplastic resin sheet 1 and plain woven fabric 3 (made of viscose rayon, yarn count is 30S in both length and width, density is 36 / cm, width is 26 / cm, thickness is 0.26mm, rice basis weight 137 g / m ² ) with an adhesive layer 4 interposed therebetween to produce a decorative sheet. Specifically, a two-component curable urethane-based adhesive (base agent: acrylic polyol 10)
(0 parts by weight, curing agent: 8 parts by weight of 1,6-hexamethylene diisocyanate), and dry-laminated at an application amount of 50 g / m ² (when dried).

On the other hand, as the SMC, an unsaturated polyester resin (“Polylite KC-3” manufactured by Nippon Rehyhold Co., Ltd.) is used.
8 "): 30 parts by weight, styrene monomer: 12 parts by weight,
Calcium carbonate powder: 40 parts by weight, glass fiber: 30 parts by weight, methyl ethyl ketone peroxide: 1 part by weight,
A total of 124.5 parts by weight of components comprising zinc stearate: 1.5 parts by weight and a polymer solution for preventing shrinkage: 10 parts by weight was prepared.

Then, two SMCs having a thickness of 4 mm were stacked on top of each other with the separator films on the front and back thereof peeled off.
The decorative sheet 5 is overlapped so that the fabric 3 side is in contact with the SMC 6, cut slightly larger than the mold, set in the upper and lower molds 7, 7 as shown in FIG. The panel was formed by pressing and compressing. Molding conditions are: mold temperature 150 ° C, mold pressure 50
kg / cm ² and the molding time was 5 minutes. As a result, a bathroom wall panel (decorative board) in which the stone pattern was clearly dressed was obtained. In this wall panel, the decorative sheet 5 was not torn, and the round portion was good. Further, in the obtained wall panel, although a slight weave was visually observed from the surface, there was no uncomfortable feeling in the design appearance.

Example 2 As in Example 1, a marble stone pattern was printed on a polyethylene terephthalate film as a decorative treatment. Further, on the surface of the stone pattern, a white concealing ink comprising 100 parts by weight of an acrylic polyol and 8 parts by weight of 1,6-hexamethylene diisocyanate as a binder and titanium white as a pigment is entirely solid by gravure printing. Printing was performed to form a concealable layer having a thickness of 2 μm. Then, a thermoplastic resin sheet with this pattern and a double-sided knitted fabric (made of acrylic resin, having a thickness of 75 μm (average),
A decorative sheet was produced by laminating a rice basis weight of 170 g / m ² ) via an adhesive layer.

Using this decorative sheet, a panel was formed integrally with the SMC in the same manner as in Example 1. The obtained bathroom wall panel (decorative board) had a clear stone pattern, no breakage of the decorative sheet, and good roundness of the round portion. Further, the texture of the obtained wall panel could not be confirmed by visual observation at all even when observed from the surface.

Example 3 A bathroom wall panel (decorative panel) was prepared in the same manner as in Example 1 except that the fabric was provided with a sealing layer for filling the irregularities of the polyethylene terephthalate film side and flattening the unevenness. ) Was molded. The sealing layer used was a two-component curable urethane-based resin (base resin: 100 parts by weight of acrylic polyol, curing agent: 8 parts by weight of 1,6-hexamethylene diisocyanate, 5 parts by weight of titanium white), and the impregnation amount was 60 g / m ² , and a knife coater is applied to the coating surface.
It was applied over time. The bathroom wall panel obtained in Example 3 was also clearly decorated with a stone pattern, had no break in the decorative sheet, and had a good roundness of the round portion. Further, the obtained wall panel was observed from the surface, and the weave of the woven fabric could not be confirmed visually.

[0036]

As described above, the thermosetting resin decorative plate of the present invention is characterized in that the thermosetting resin is applied or impregnated and cured between the fibrous base material and the front side thermoplastic resin sheet. In addition, by adopting a configuration in which the woven or knitted fabric is laminated and integrated, the thermoplastic resin sheet laminated on the front side has no breakage, no distortion, and therefore has a stable and excellent quality with no pattern flow or unevenness. .

When a thermosetting resin decorative board is formed only with a thermoplastic resin sheet on which a pattern is printed, the adhesiveness with the thermosetting resin is insufficient, and the heat and pressure in the mold cause the thermoplastic resin sheet to be insulated. Dissolves and the printed pattern flows,
In the thermosetting resin decorative board of the present invention, the woven or knitted fabric laminated and adhered to the thermoplastic resin sheet exhibits the adhesion performance due to the impregnation action (anchoring effect) and the dimensional stability performance for preventing resin flow. And when using woven fabric, expansion and contraction during molding,
The prevention of distortion is improved, and the use of a knitted material improves the conformability to the uneven surface during molding.

Further, according to the method for producing a decorative thermosetting resin sheet of the present invention, the decorative sheet can be laminated and adhered simultaneously with the molding of the decorative sheet, and the decorative sheet is deformed by heat and stress during molding. Since it does not occur, it is possible to manufacture a decorative board without causing a pattern collapse.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a plain weave among three original textures of a fabric.

FIG. 2 is an explanatory diagram of a twill weave among three original textures of a fabric.

FIG. 3 is an explanatory diagram of a satin weave of three original fabrics.

FIG. 4 is an explanatory view showing another material different from the three original structures of the woven fabric.

FIG. 5 is an explanatory diagram of a flat knitted fabric among three original structures of a knitted fabric.

FIG. 6 is an explanatory diagram of a rubber knit among three original structures of a knitted fabric.

FIG. 7 is an explanatory diagram of a pearl knit among three original structures of a knitted fabric.

FIG. 8 is an explanatory diagram of a single tricot knit, which is one of the knitted structures.

FIG. 9 is an explanatory diagram of a single atlas knitting which is one of the changing structures of the knitted fabric.

FIG. 10 is an explanatory diagram of a single cord knitting, which is one of the changing structures of a knitted fabric.

FIG. 11 is a schematic sectional view of a thermoplastic resin sheet provided with a pattern.

FIG. 12 is a schematic sectional view of a decorative sheet formed by applying a pattern to a thermoplastic resin sheet and laminating and adhering a woven fabric.

FIG. 13 is a schematic cross-sectional view showing a state where a laminate is bonded and integrated in a mold.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Thermoplastic resin sheet 2 Picture (decoration processing layer) 3 Textile 4 Adhesive layer 5 Decorative sheet 6 SMC 7 Mold

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B29K 105: 08 B29K 105: 08 B29L 31:00 B29L 31:00 F term (Reference) 4F100 AK01C AK42 AK44 AT00 AT00C CA02 CA23 CB02 DG01A DG06A DG10A DG11A DG12B DG13B DH01 EH46 EJ20 EJ42 EJ82 EJ82A GB08 GB48 GB81 GB81 HB11 HB31 JB13A JB16C JK01 JL04 4F204 AA36 AD05 AD08 AD16 AD20 AD34 AG03 AHF AFA42 FG

Claims (4)

[Claims] 1. A woven or knitted fabric is laminated and integrated on a surface of a fibrous base material which is cured by being coated or impregnated with a thermosetting resin, and further a thermoplastic resin sheet is further formed thereon. Are laminated and adhered to each other. 2. A decorative sheet obtained by laminating a woven or knitted material on one surface of a thermoplastic resin sheet via an adhesive. 3. The decorative sheet according to claim 2, further comprising a filling layer for filling and flattening the unevenness of the side of the woven or knitted fabric facing the thermoplastic resin sheet. 4. The fibrous base material is coated or impregnated with an uncured thermosetting resin liquid, and the fibrous base material is coated on the fibrous base material.
Laminated so that the woven or knitted fabric and the fibrous base material are in contact with each other, and pressurizing or heating and pressing to cure the thermosetting resin liquid and bond and integrate the laminate. Of manufacturing a thermosetting resin decorative board.