JP2001246715A - Decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent warpage of a decorative panel 11 as a whole. SOLUTION: A decorative layer is impregnated with a melamine resin and a base material is impregnated with at least either one of a melamine resin, a diallyl phthalate resin and a polyester resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative plate in which a substrate impregnated with a synthetic resin and a decorative layer are integrally bonded by heating and pressing.

[0002]

2. Description of the Related Art Conventionally, as this type of decorative board, for example, one described in Japanese Patent Publication No. 3-13061 is known. That is, as shown in FIG.
Base layer 54 in which a plurality of core papers are impregnated with a thermosetting resin
And a decorative layer 56 obtained by impregnating a light-transmitting transparent paper with a thermosetting resin. The base layer 54 and the decorative layer 56 are integrally bonded by heating and pressing. On the surface of such a decorative plate 51, a decorative pattern is printed by an opaque printed portion 58 and a transparent printed portion 59.

[0003] Then, the light beams L1, L
2 strikes, the light beam L10 incident on the opaque printing portion 58
Are reflected at the surface of the opaque printed portion 58. On the other hand, the light beam L20 incident on the transparent printing unit 59 is
The light passes through the decorative layer 56 and is reflected on the surface of the base layer 54. In other words, there is a difference between the positions of the light rays incident on the opaque printing section 58 and the light rays L20 incident on the transparent printing section 59, respectively. Thus, the light beams L10, L20
Due to the difference in the reflection positions, a visual effect of giving the appearance of a three-dimensional pattern 57 is obtained.

[0004]

However, the conventional decorative board 51 has a problem that warpage occurs due to a temperature change or the like because the thermal expansion coefficients of the base material and the resin impregnated in the decorative layer are different. .

The present invention has been made in view of the above problems, and an object of the present invention is to provide a decorative board capable of preventing warpage.

[0006]

Means for Solving the Problems In order to solve the above problems, according to the first aspect of the present invention, in a decorative board provided with a resin-impregnated base material and a decorative layer impregnated with a thermosetting resin, The thermosetting resin impregnated in the decorative layer is a melamine resin, and the resin impregnated in the base material is a melamine resin,
The gist is that it is at least one of a diallyl phthalate resin and a polyester resin.

In a second aspect of the present invention, in a decorative board comprising a resin-impregnated base material and a decorative layer impregnated with a thermosetting resin, the decorative layer comprises a light-transmitting resin layer. A printing layer is formed on the resin layer, and the thermosetting resin impregnated in the decorative layer is a melamine resin, and the resin impregnated in the base material is a melamine resin, a diallyl phthalate resin and a polyester resin. The gist is that there is at least one of them.

According to a third aspect of the present invention, in the decorative board according to the first or second aspect, three to ten core papers are provided. Hereinafter, the “action” of the present invention will be described.

According to the first aspect of the present invention, the thermosetting resin impregnated in the decorative layer is a melamine resin. Further, the thermosetting resin impregnated in the base material is at least one of a melamine resin, a diallyl phthalate resin and a polyester resin. Since these resins have relatively similar thermal expansion coefficients, they do not heat when integrating the base material and the decorative layer, nor do they generate warpage due to temperature changes or the like.

[0010] According to the second aspect of the present invention, there is no possibility that the substrate and the decorative layer are heated when they are integrated with each other, and no warping occurs due to a temperature change or the like. Further, the shadow of the printing layer is projected on the base material, so that a three-dimensional design can be provided.

According to the third aspect of the present invention, since three to ten core papers are provided, it is possible to give a proper strength to the base material layer. Therefore, it is possible to prevent the decorative board from being easily bent or damaged.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS (First Embodiment) Hereinafter, a first embodiment of the present invention will be described in detail with reference to the drawings.

As shown in FIG. 1, the decorative board 11 includes a base layer (resin-impregnated base) 12 having a thickness of 0.4 to 3.0 mm. The base layer 12 is composed of a laminate 14 in which a plurality of core papers 13 are laminated, and the laminate 14 has a melamine resin, a diallyl phthalate resin, or a polyester resin, or a melamine resin, a diallyl phthalate resin, a polyester resin. Among them, at least two or more resins are impregnated. Specifically, the number of core papers 13 is five. The number of core papers 13 is preferably set in the range of 2 to 15 in order to give the required thickness and strength as decorative board 11.

A barrier layer 16 having a thickness of 0.1 to 0.2 mm is provided on the surface of the base material layer 12 (the upper surface in FIG. 1). The barrier layer 16 has a light-shielding property, and is formed by impregnating white titanium paper 17 with a melamine resin as a thermosetting resin.

The white titanium paper 17 has a basis weight of 100 g.
/ M ^2, and those manufactured by Arjowings are used. The basis weight of the white titanium paper 17 is 60 to 2
It is preferably set in the range of 00 g / m ² ,
It is even more preferred to set it to 00 g / m ² .
The white titanium paper 17 contains ash, and its amount is 2%.
It is 5% by weight. The ash content is preferably set in the range of 10 to 35% by weight, and more preferably set in the range of 20 to 35% by weight.

A decorative layer 19 having a thickness of 0.1 to 0.2 mm is provided on the surface of the barrier layer 16 (upper surface in FIG. 1). The decorative layer 19 is made of a resin-impregnated transparent paper 20, and the resin-impregnated transparent paper 20 is impregnated with a melamine resin (shown by a dotted line in FIG. 1) as a thermosetting resin.

The transparent paper 20 is manufactured by Daifuku Paper Co., Ltd. and has a product number of "MOL-D-100". The basis weight of the transparent paper 20 is 100 g / m ² . The basis weight of the transparent sheet 20 is preferably set in a range of 20 to 250 g / m ^2, more preferably more to set the range of 100 to 160 g / m ^2. Further, the transparent paper 20 contains ash of 0% or an extremely small amount (1% or less) of ash. The ash content contained in the transparent paper 20 is preferably as small as possible. This is because if the amount of ash is large,
This is because the transparency of 0 decreases.

As shown in FIGS. 1 and 2, on the surface of the decorative layer 19 (upper surface in FIG. 1), that is, on the surface of the transparent paper 20,
A printing unit 21 provided with a white ink applied by a gravure printing method is provided. As the white ink, "HFL" (trade name, manufactured by Dainichi Seika Kogyo Co., Ltd.) is used. A portion other than the printing portion 21 is a non-printing portion 22 to which no ink is applied. The surfaces of the printing section 21 and the non-printing section 22 are coated with a melamine resin impregnated in the transparent paper 20. Since the melamine resin is almost transparent, the printed portion 21 can be visually recognized from the surface of the decorative layer 19.

The printing section 21 has a large number of square patterns alternately arranged, and when the surface of the decorative layer 19 is viewed as a whole,
It has a check-like geometric pattern. Incidentally, the square patterns of the printing unit 21 are squares having the same area, and each side has a length of 5 mm. Makeup layer 19
Area ratio of the printing unit 21 to the total area of the surface
Is set to The area ratio of the printing unit 21 is 30 to 7
It is preferably set to a range of 0%, and more preferably set to a range of 40 to 60%.

According to the decorative plate 11 configured as described above, as shown in FIG.
When L2 strikes, the light beam L1 incident on the printing unit 21 is reflected on the surface of the printing unit 21. On the contrary,
The light beam L2 incident on the non-printing portion 22 passes through the transparent decorative layer 19 and is reflected on the surface of the barrier layer 16. That is, there is a difference between the light ray L1 incident on the printing unit 21 and the light ray L2 incident on the non-printing unit 22, respectively, at the reflected positions. Therefore, a shadow K is projected on the surface of the barrier layer 16, and the outline of the shadow K and the outline of the printing unit 21 appear to be displaced. Thereby, the check pattern of the printing unit 21 on the surface of the decorative layer 19 can be made to look three-dimensional, and the visual effect can be enhanced.

Next, a method of manufacturing the decorative board 11 will be described. As shown in FIG. 3A, transparent paper having a basis weight of 100 g / m ² (the content of titanium oxide is 0 to 1% by weight or less) 20
Is printed by the gravure printing method on the surface of. Next, the transparent paper 20 is impregnated with a melamine resin,
Thereafter, drying is performed at a temperature of 140 ° C. to obtain the decorative layer 19. As shown in FIG. 3 (b), white titanium paper having a basis weight of 100 g / m ² was impregnated with melamine resin,
Drying at a temperature of 0 ° C. gives the barrier layer 16.

Subsequently, as shown in FIG. 3C, five core papers which have been impregnated with melamine resin in advance and dried, the barrier layer 16 and the decorative layer 19 manufactured by the above-described method are sequentially stacked. Combine and sandwich between hot press plates made of stainless steel. And press temperature 140 ° C and press pressure 7.85
Each layer 12, 16, 19 is hot-pressed for about 10 minutes at MPa. Then, it cools and presses for about 10 minutes,
2. The barrier layer 16 and the decorative layer 19 are integrally bonded.

In this embodiment, the overlay layer is not provided on the resin-impregnated transparent paper 20, but the melamine resin-impregnated transparent paper may be further laminated on the printing unit 21 to form an overlay layer.

According to this embodiment, the following effects can be obtained. (1) Since the resin impregnated in the base material layer 12 and the decorative layer 19 have similar thermal expansion coefficients, the resin may be heated when the base material and the decorative layer are integrated, or even if the temperature changes. No warping occurs.

(2) The core paper constituting the base material layer 12 is
Since 10 to 10 sheets are provided, the base layer 12 can be given an appropriate thickness and strength. Therefore, it is possible to prevent the decorative plate 11 from being easily bent or broken. (Embodiment 2) Next, a second embodiment will be described focusing on parts different from the first embodiment.

The laminated structure of the decorative board 11 of the present embodiment is the same as that of the decorative board 11 of the first embodiment. The base material layer 12 is impregnated with a plasticized modified melamine resin. This plasticized modified melamine resin is obtained by adding ε-caprolactam as a plasticizer to the melamine resin and plasticizing it. It is obtained by adding ε-caprolactam to bleached kraft paper of the core paper 13 and further plasticizing it. The basis weight of the bleached kraft paper is preferably set in a range of 150 to 250 g / m ^2, more preferably more to set the range of 180-200 g / m ^2. In addition, bleached kraft paper contains 0 to 6% ash.

A method for manufacturing the decorative board 11 according to this embodiment will be described. The barrier layer 16 and the decorative layer 19 impregnated with the melamine resin are manufactured by the method described in the first embodiment. Next, the base material layer 12 is impregnated with the plasticized melamine resin in bleached kraft paper, and then dried at 140 ° C. to obtain a core paper 13. Incidentally, plasticized modified melamine is produced as follows. Melamine 1
A formaldehyde aqueous solution having a concentration of 37% is added at a ratio of 1.7 mol to the mol. Then, the aqueous solution is adjusted to pH 9.0 using sodium hydroxide,
By reacting for 60 minutes while heating to 90 ° C,
A plasticized modified melamine resin is obtained.

Subsequently, five resin-impregnated cores previously impregnated with a plasticized melamine resin, a light-shielding impregnated paper for the barrier layer 16, and a melamine resin-impregnated transparent paper (printed) for the decorative layer 19 are sequentially stacked. Match. Then, by heating and pressurizing the superposed products under the same conditions as in the first embodiment,
The base layer 12, the barrier layer 16, and the decorative layer 19 are integrally bonded. As a result, a decorative plate 11 in which the base layer 12 and the decorative layer 19 were the same color (white) was obtained.

Therefore, according to the present embodiment, substantially the same effects as those of the first embodiment can be obtained. In particular,
In the second embodiment, the core paper 13 of the base material layer 12 is used.
, Bleached kraft paper is impregnated with a plasticized modified melamine resin. Therefore, the base layer 12 and the decorative layer 19 can be made white, and the design of the appearance can be further improved.

(Embodiment 3) Next, a third embodiment will be described. Regarding the laminated structure of the decorative board 11 of the present embodiment,
This is the same as the decorative board 11 of the first embodiment. The barrier layer 16 of the present embodiment is made of gray titanium paper 35 instead of white titanium paper 17. This gray titanium paper 3
5 is basically the same as the white titanium paper 17,
The point that the basis weight is 80 g / m ² is mainly different from the white titanium paper 17 shown in the first embodiment. The gray titanium paper 35 uses a product name “OK-190” manufactured by Kishu Paper Co., Ltd.

Next, a method of manufacturing the decorative board 11 in the present embodiment will be described. According to the method described in the first embodiment, gray titanium paper impregnated with melamine resin (barrier layer 16) and melamine resin impregnated transparent paper (decorative layer 1)
9) is manufactured.

Next, a composite resin in which diallyl phthalate and a polyester resin are composited at a ratio of 30 to 70% by weight is prepared. The composite resin is impregnated into a gray-dyed core paper of the same color as the barrier layer 16 so as to have an impregnation amount of 45% by weight and a volatile content of 5%, and then is dried at 140 ° C. to produce a resin-impregnated core paper. .

Thereafter, the five core papers, the barrier layer 16 and the decorative layer 19 are superposed in order and heated and pressed under the same conditions as in the first embodiment so that the base layer 12 and the decorative layer 19 have the same color (gray). The decorative board 11 was obtained.
Therefore, according to the present embodiment, substantially the same effects as in the above embodiment can be obtained. In particular, in the third embodiment, the core layer is formed by impregnating a pale yellow composite resin into core paper dyed in the same color as the barrier layer 16 in gray. Therefore, the base layer 12 and the decorative layer 19 can be made to have the same color, and the design of the appearance can be further improved.

Example 1 (1) A 37% aqueous formaldehyde solution was added at a ratio of 1.7 mol to 1 mol of the melamine resin, and the pH was adjusted to 9.0 with sodium hydroxide. After the reaction, 0.3 mol of ε-caprolactam was added as a plasticizer to 1 mol of melamine to prepare a plasticized modified melamine resin.

(2) Transparent paper of product number “MOL-D-100” manufactured by Daifuku Paper Co., Ltd. having a basis weight of 100 g / m ² and white color of “HFL” manufactured by Dainichi Seika Kogyo Co., Ltd. Gravure printing was performed with the ink, and a printing section and a non-printing section were provided.

(3) This plasticized modified melamine resin is impregnated into bleached kraft paper having a basis weight of 190 g / m ² and an ash content of 0 to 6% so as to have an impregnation amount of 50% and a volatile content of 6%, followed by drying. A plasticized modified melamine resin impregnated core paper was obtained.

(4) White titanium paper manufactured by Arjowings Co., Ltd. and transparent paper (2) each having a basis weight of 100 g / m ² were each impregnated with a melamine resin and dried at 140 ° C. to form a barrier layer and a decorative layer. did.

(5) Five core papers, a barrier layer and a decorative layer were laminated, and heated and pressed at 150 ° C. and 7.85 MPa to obtain a decorative plate of the same color. This decorative board uses a colorless and transparent plasticized modified melamine resin for the base material,
Both front and back surfaces could be made white, and the design of the appearance could be improved. Also, the dimensional change rate is JIS-69
With the standard value of 03, the length was reduced to 0.6% or less and the width was reduced to 1.1% or less.

Example 2 (1) Diallyl phthalate and polyester resin were mixed in 30
A composite resin was prepared at 70% by weight.

(2) The composite resin was weighed 190 g /
m ² , the amount of impregnation in bleached kraft paper containing 0 to 6% ash dyed gray with the same color as (OK-190 manufactured by Kishu Paper Co., Ltd.)
%, And dried at 140 ° C. to obtain a composite resin-impregnated core paper.

(3) Transparent paper of product number “MOL-D-100” manufactured by Daifuku Paper Co., Ltd. having a basis weight of 100 g / m ² and white of “HFL” manufactured by Dainichi Seika Kogyo Co., Ltd. Gravure printing was performed with the ink, and a printing section and a non-printing section were provided.

(4) Gray titanium paper having a basis weight of 80 g / m ² (trade name “OK-190” manufactured by Kishu Paper) and (3)
The transparent paper was impregnated with a melamine resin and dried at 140 ° C. to obtain a barrier layer and a decorative layer.

(5) Five core papers, a barrier layer and a decorative layer were laminated, and heated and pressed at 150 ° C. and 7.85 MPa to integrate them. In this example, since the yellow-colored composite resin was used for the kraft paper dyed in gray, it was possible to use a front and back gray system and improve the design of the appearance. Further, the dimensional change rate can be reduced to 0.6% or less in length and 1.1% or less in width in accordance with JIS-6903, and a decorative board without warpage was obtained.

(Embodiment 3) As in Embodiment 2, except that
The transparent paper (not printed) of (3) was laminated on the printing part and integrated by heating and pressing.

Comparative Example (1) Unbleached kraft paper having a basis weight of 190 g / m ² was impregnated with a phenol resin to obtain a core paper.

(2) Transparent paper of product number “MOL-D-100” manufactured by Daifuku Paper Co., Ltd. having a basis weight of 100 g / m ² and white color of “HFL” manufactured by Dainichi Seika Kogyo Co., Ltd. Gravure printing was performed with the ink, and a printing section and a non-printing section were provided.

(3) White titanium paper manufactured by Arjowings Co., Ltd. and transparent paper (2) each having a basis weight of 100 g / m ² were impregnated with a melamine resin and dried at 140 ° C. to form a barrier layer and a decorative layer. did.

Five core papers, a barrier layer and a decorative layer were laminated, and heated and pressed at 150 ° C. and 7.85 MPa to obtain a decorative plate. Cut these decorative boards into 1m square,
The substrate was exposed to an atmosphere at 80 ° C. for one hour, and the amount of warpage relative to a horizontal plane was measured.

Table 1 shows the results.

[0050]

[Table 1] The embodiment of the present invention may be modified as follows.

In the above embodiment, the pattern of the printing unit 21 is square. In addition to this shape, a triangular pattern shown in FIG. 4B or a polygonal pattern such as a pentagon or hexagon not shown may be used. Alternatively, the pattern may be changed to a circular pattern shown in FIG. 4C or a fan-shaped pattern shown in FIG. Also, instead of adjoining the printing units 21 as in the above-described embodiment, the printing units 21 may be separated as shown in FIG.

The color of the printing unit 21 may be changed to a color close to white, for example, gray, light blue, or light yellow.
Further, the color of the barrier layer 16 is set to a color close to white, for example, gray,
The color may be changed to light blue or light yellow.

Instead of using transparent paper 20 which is completely transparent, transparent paper 20 such as light milky white may be used. That is, the color may be changed to an arbitrary color as long as the transparent paper 20 is a light transmissive material.

The barrier layer 16 provided between the base layer 12 and the decorative layer 19 may be omitted. In this case, in order to prevent the color of the base layer 12 from affecting the decorative layer 19, a white ink is applied to the surface of the base layer 12,
It is preferable that the bleached kraft paper used for the core paper 13 is dyed in a desired design color.

Plywood or particle board may be used instead of the core paper 13 constituting the base material layer. With this configuration, manufacturing costs can be reduced. The decorative board 11 may be used in all fields such as interior materials of buildings, surface materials of furniture such as desks and closets, and decorative articles.

The printing unit 21 may be printed by any one of a gravure offset printing method, a silk screen printing method, a relief printing method, an offset printing method, etc., in addition to the gravure printing method.

Next, in addition to the technical ideas described in the claims, the technical ideas grasped by the above-described embodiment will be listed below. (1) a base material layer in which a thermosetting resin is impregnated in a laminate obtained by laminating a plurality of core papers; and a decorative layer in which a light-transmitting overlay paper is impregnated with a thermosetting resin; In a decorative board in which a material layer and a decorative layer are integrally bonded by heating and pressing, the thermosetting resin impregnated in the base layer is a melamine resin, and the thermosetting resin impregnated in the decorative layer is Is a decorative board characterized by being at least one of a melamine resin, a diallyl phthalate resin and a polyester resin.

(2) A laminate in which a plurality of core papers are laminated is impregnated with a thermosetting resin, and a light-transmitting overlay paper having a printed pattern on its surface is impregnated with the thermosetting resin. In the decorative board composed of a decorative layer and a base layer and a decorative layer integrally bonded by heating and pressing, the thermosetting resin impregnated in the base layer and the decorative layer is any A decorative plate characterized in that it is also a melamine resin.

[0059]

As described in detail above, according to the present invention,
It is possible to prevent the entire decorative board from being warped.

[Brief description of the drawings]

FIG. 1 is a sectional view of a decorative board according to first to third embodiments.

FIG. 2 is a view showing a pattern of a decorative board.

3 (a) to 3 (c) are views showing a process for manufacturing a decorative board.

FIGS. 4A to 4D show another embodiment, and FIGS. 4A to 4D show patterns of a decorative plate; FIGS.

FIG. 5 is a cross-sectional view of a decorative board according to the related art.

[Explanation of symbols]

12 ... base material layer (resin impregnated base material), 13 ... core paper, 14 ...
Laminate, 16: barrier layer, 19: decorative layer, 20: transparent paper, 21: printed part, 22: non-printed part.

 ──────────────────────────────────────────────────の Continued on the front page F term (reference) 4F100 AK01C AK36A AK36B AK36C AK41C AK43C AR00B BA02 BA03 BA04 BA07 BA10A BA10D BA11 DG10A DG10B EJ82A EJ82B EJ82C GB07 HB31D JB13C JD01B JL04

Claims (3)

[Claims] 1. A decorative board comprising a resin-impregnated base material and a decorative layer impregnated with a thermosetting resin, wherein the thermosetting resin impregnated in the decorative layer is a melamine resin, and the base material is impregnated with the resin. Wherein the resin is at least one of a melamine resin, a diallyl phthalate resin and a polyester resin. 2. A decorative board comprising a resin-impregnated base material and a decorative layer impregnated with a thermosetting resin, wherein the decorative layer comprises a light-transmitting resin layer, and a printing layer on the resin layer. Is formed, and the thermosetting resin impregnated in the decorative layer is a melamine resin, and the resin impregnated in the base material is at least one of a melamine resin, a diallyl phthalate resin, and a polyester resin. A decorative plate characterized by being. 3. The decorative board according to claim 1, wherein three to ten core papers are provided.