JP2002192657A - Decorative laminated sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative laminated sheet which shows high dimensional stability and heat resistance while retaining an outstanding surface performance of a conventional high pressure melamine resin decorative laminated sheet. SOLUTION: This decorative laminated sheet is characterized in that the top layer of the sheet is formed of a polyether sulfone resin layer, and the thickness of a polyether sulfone resin is preferably 100-500 μm and its glass transition temperature is preferably 200 deg.C or higher. When a polyether sulfone layer is joined to a decorative layer, it is preferable to use at least one kind of a high-molecular weight resin selected from the group of a polyester resin, a polyisocyanate and a polyacrylate.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board having excellent heat resistance and stain resistance, and having extremely good dimensional stability against environmental changes in a use atmosphere. Specific applications include, for example, vehicles that can be applied to all interior materials for building materials that conventionally use high-pressure melamine decorative boards as surface decorative materials, and that require high durability by taking advantage of extremely high dimensional stability and crack resistance. It can be expected to be used effectively for interior materials. In addition, by selecting the thickness of the decorative board according to the part to be used and combining the conventional laminating technology of melamine resin decorative boards, panels in places where high rigidity and water resistance are required, such as toilet booths and partition boards It also provides chemical materials.

[0002]

2. Description of the Related Art Conventionally, decorative materials such as melamine resin decorative boards, polyester decorative boards, and PVC decorative sheet-attached decorative boards have been widely used as main interior materials. Among them, the melamine resin decorative board has a long track record as a surface decorative material, and has been widely used because its surface properties such as excellent surface hardness and stain resistance and abundant colors and patterns can be selected in design. . However, while having such excellent surface performance, the dimensional change due to changes in atmospheric humidity is large, there is a problem of warpage compared to other decorative materials, and because the surface is hard and high strength material, cutting processing, panel bonding Secondary processing such as processing is difficult. Polyester decorative panels and decorative panels with PVC decorative sheets are also used as general-purpose materials, but they do not have the same surface hardness, abrasion resistance, and chemical resistance as melamine resin decorative panels, and greatly reduce durability and maintainability. Further, when the base material is a wood-based material such as plywood or particle board, there is a disadvantage that long-term water resistance tends to cause a problem.

[0003] In the field of vehicle use, metal-based melamine resin decorative boards have been frequently used, but the use environment is harsh.
There is a situation where it is necessary to improve the warpage stability of the decorative board due to the dimensional change described above. In addition, demand for curved surface processing (especially, external bending processing with a convex decorative surface) has increased due to demands for vehicle livability and changes in the orientation of interior design. Replacement was increasing.

On the other hand, in recent years, as social needs for environmental protection represented by the dioxin problem at the time of industrial waste treatment and PVC incineration have increased, new measures have been required for cosmetic materials. In response, demands for cost reduction and weight reduction are becoming stronger. Amid such market changes, the high durability of the high-pressure melamine resin decorative board has been evaluated again. Recycling of the interior material itself is also considered important, but in the case of melamine resin decorative boards and metal-based melamine resin decorative boards, substrates such as plywood or base metal sheets that are pasted and the decorative resin layer Is difficult to separate, making material recycling difficult.

[0005]

SUMMARY OF THE INVENTION The present inventor has solved the above-mentioned drawbacks of various general-purpose decorative boards,
As a result of intensive studies on how to add functions that meet today's market needs in order to develop cosmetic materials suitable for vehicle interior use, heat resistance, dimensional stability, stain resistance, etc. It is intended to provide a novel decorative board having excellent durability and high designability.

[0006]

According to the present invention, (1) the outermost surface layer of the decorative plate is made of polyether sulfone resin (hereinafter referred to as PES).
Characterized by being formed of a layer.
(2) The thickness of the PES layer is 100 to 5
00 μm and glass transition temperature (hereinafter abbreviated as Tg)
(3) wherein the temperature is 200 ° C. or more;
Item (1) or (2), wherein the bonding between the PES layer and the decorative layer forming the design is integrally formed via one or more high molecular weight resins selected from polyester resins, polyisocyanates, and polyacrylates. It is a decorative board described.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The decorative board of the present invention is characterized in that PES is arranged on a surface layer of the decorative board. By arranging PES on the surface layer of the decorative board, the dimensional stability is improved while maintaining the advantages of the melamine resin decorative board such as surface hardness, heat resistance, and stain resistance. In the present invention, P
The thickness of the ES layer is 100 to 500 μm and the Tg is 20
A temperature of 0 ° C. or higher is preferred in terms of heat resistance, design effect, moldability, cost, and the like. Even if the thickness is less than 100 μm, there is no problem as the decorative board of the present invention, but since Tg of PES is generally high temperature, it is difficult to form a thin film, resulting in a significant increase in cost. If it exceeds 500 μm, the transmittance may be reduced, which may lead to a reduction in design properties, which makes it difficult to set molding conditions and also hinders cost. Also,
When Tg of PES is less than 200 ° C., heat resistance is reduced,
It tends to lead to a decrease in surface hardness. PES used in the present invention is not particularly limited, and is commercially available, such as Victrex PES manufactured by Sumitomo Chemical.

In the decorative panel of the present invention, the design required for the decorative panel is expressed by a decorative layer immediately below the PES layer, and the bonding between the PES layer and the decorative layer is made of a polyester resin.
One of the features is that they are integrally formed via at least one kind of high molecular weight resin selected from polyisocyanate and polyacrylate. This is because these high molecular weight resins are excellent in compatibility or adhesion with PES. Among these, a polyester film is most preferable because the most stable lamination molding is achieved. The polyester film is not particularly limited, and is commercially available such as PES-120EF manufactured by Toagosei. The Tg of the polyester film is 1 from the viewpoint of the heat resistance of the decorative board.
It is preferably at least 00 ° C., and those which soften or melt at the molding temperature and penetrate into decorative base paper are preferably used. Also,
The thickness of the polyester film is preferably from 30 to 200 μm from the viewpoint of the heat resistance of the decorative board and the adhesion to the decorative layer.
If it is less than 30 μm, the adhesion between the decorative layer and the PES layer may be insufficient, and if it exceeds 200 μm, the heat resistance will be reduced. Also, make a decorative print on the back of the PES,
A method of lamination molding with a core layer via a binder can also be adopted.

[0009] In the decorative board of the present invention, PES is disposed on the surface layer, and the core layer used is usually that used for decorative boards. The core layer forms the decorative board to a predetermined thickness according to the number of plies. Examples of the core layer include phenol resin impregnated paper, acrylic resin impregnated paper, diallyl phthalate resin impregnated paper, and the like. In addition, for vehicle interior use, it is necessary to use a metal plate as the core layer for strength, durability, flame retardancy,
It is preferable from the viewpoint of bending workability. For general building materials, an inorganic board, a wood-based substrate, or the like can be used as a core layer as necessary for cost reduction and the like. On both sides or one side of the core layer, a decorative layer is laminated and formed with a binder interposed therebetween. As the binder, one or more high molecular weight resins selected from the above-mentioned polyesters, polyisocyanates and acrylates are preferably used. This is because these resins have excellent adhesion to the core layer. When hiding unevenness occurs in the cosmetic appearance due to the influence of the core layer, it is also possible to insert a barrier layer for shielding the base color at the interface between the decorative layer and the core layer.

An example of the structure of the decorative board of the present invention is shown below. In general building material applications, for example, a PES film, a polyester film, a printing decorative base paper, a polyester film, and a plurality of phenolic resin-impregnated papers are laminated in this order and heated and pressed. All or a part of the phenolic resin-impregnated paper can be replaced with an inorganic board, a wood-based substrate, or the like. . Further, a metal-based decorative board for vehicle interior use is obtained by, for example, laminating a PES film, a polyester film, a printing base paper, a polyester film, and an aluminum plate.

The decorative board of the present invention can be produced by laminating the above-mentioned materials and laminating them under the same heating and pressurizing conditions as for a normal melamine resin decorative board. In the decorative board of the present invention, the above-mentioned forming method is different from a method using a melamine resin impregnated decorative paper such as a conventional melamine resin decorative board, by utilizing pressure and heat applied during laminating and forming each interlayer. Is a method of pressing a binder to be disposed into a decorative base paper. Another method is to simply provide PE on a conventional high-pressure melamine resin decorative board structure via a binder.
It is also possible to form an S layer. However, in this case, the reaction condensed water released from the melamine resin-impregnated decorative paper at the time of heat curing and the volatile matter remaining during the preparation of the impregnated paper are factors that greatly reduce the bonding strength between the PES and the decorative layer. Therefore, there is a disadvantage that the properties and form of the binder are greatly restricted. The former method, in which the decorative base paper is sandwiched between binders, has the advantage of facilitating interlayer bonding without the influence of moisture and the advantage of simplifying the production process without the need to impregnate the melamine resin into the decorative base paper. is there.

There are several important points in devising the present invention. (1) First, selection of a material constituting the surface layer. The decorative plate of the present invention in which the PES layer is disposed on the outermost surface realizes extremely high dimensional stability against changes in atmospheric humidity. Also,
Surface hardness, stain resistance, heat resistance, and the like were also comparable to those of the conventional high-pressure melamine resin decorative board. (2) Next is the selection of the binder. The binder is based on compatibility between the surface PES layer and the core material, and the interlayer strength is determined by the affinity of the binder for PES. As a result of examining various binder materials, polyester resins, polyisocyanates, and polyacrylates can be used, and among them, the most stable lamination molding of polyester films has been achieved.
Further, depending on the type and thickness of the binder layer, it is also possible to develop a technology that can easily separate and separate the decorative layer and the core layer or the substrate required for recycling.

The total thickness of the decorative board used in the present invention is adjusted to the required board thickness for each application and application site. 0.6-15.0mm is selected for construction materials and vehicles.
In general-purpose products, 0.8 to 1.2 mm is frequently used. 6
Applications requiring a thick decorative board exceeding mm include a partition board, a toilet booth, and the like. For how to adjust the product thickness,
Usually, a method similar to the method for manufacturing a melamine resin decorative board may be used, and a predetermined thickness is formed by the number of plies of the phenol resin-impregnated paper as the core layer. Instead of the phenol resin-impregnated paper, an acrylic resin-impregnated paper, diallyl phthalate-impregnated paper or the like may be used. Alternatively, there is a method in which a metal plate, an inorganic board, or a wood-based substrate is used as a core layer, and the decorative layer is laminated and formed on both sides or one side of the core layer with a binder interposed therebetween. In addition, when hiding unevenness occurs in the cosmetic appearance due to the influence of the core layer, it is possible to insert a barrier layer for shielding the base color at the interface between the decorative layer and the core layer.

Hereinafter, an example of the decorative board of the present invention will be described with reference to the drawings. In FIG. 1, PES film 1,
Polyester film 2 and base paper 3 as binder
To form a surface decorative layer 10, and further, a binder layer 4
(The above-mentioned polyester 2 can be used), the core layer 5 and, if necessary, the back layer 6 are laminated in this order. The PES film 1 needs transparency in expressing a printing color and a design. As described above, the thickness of the film is preferably set to 100 to 500 μm. The thickness of the decorative base paper 3 is important. In a method in which the decorative base paper 3 is sandwiched between binders from above and below and pressed into the base paper by heat and pressure during molding, the decorative base paper 3 preferably has a small rice yard and preferably 20 to 60 g / m ² . 60g / m
^If it exceeds ² , the reinforcement of the base paper may become insufficient depending on the type of the binder, and the peeling in the base paper and the water resistance may become a problem.

[0015]

EXAMPLES Hereinafter, the present invention will be described specifically with reference to Examples. Here, “%” indicates “% by weight”.

Example 1 A PES film 1 placed on the surface was 400 μm thick and had a Tg film thickness of 400 μm.
225 ° C, Tg 120 ° C with a thickness of 80 μm for the binder
Was used. The decorative base paper 3
A decorative paper pattern-printed on thin paper of 30 g / m ² of rice tsubo was used. The polyester film 2 was disposed under the decorative base paper 3, and an aluminum foil 4 having a thickness of 20 μm was disposed under the polyester film 2. More unbleached kraft paper of basis weight 145 g / m ² as a core layer thereunder, impregnated resin amount of 48% of phenol resin (a) shown below, the volatile content of 5% phenolic resin impregnated paper 5, and Beitsubo A phenol-impregnated paper 6 having a resin content of 30% impregnated with a phenol resin (b) shown below and a volatile content of 7% adjusted to 190 g / m ² of unbleached kraft paper was placed. Next, between the matte stainless steel plates, two sets of the above-described decorative plate material sets were inserted. At this time, the two sets of materials were back-to-back so that the stainless steel plate and the PES film 1 were in contact with each other, and a release film was sandwiched between the sets. The press was heated and cooled while maintaining the pressure at 100 kg / cm ² . The hot platen temperature was set to 160 ° C, and the product was heated so that the maximum product temperature was in the range of 138 ° C to 143 ° C, and then cooled to 40 ° C to obtain a decorative decorative board (Fig. 1) having a thickness of 0.8 mm. . Preparation of adhesive phenolic resin (a) varnish: Formaldehyde to phenol molar ratio of 1.25 reacted and dehydrated and concentrated to a viscosity of 12
The viscosity of the resol type phenol resin varnish of 0 cps / 20 ° C. was adjusted to 27 cps / 35 ° C. with methanol. Preparation of impregnating phenolic resin (b) Varnish: water-soluble resol type phenolic resin having a viscosity of 38 cps / 20 ° C. reacted at a molar ratio of formaldehyde to phenol of 1.3 was converted to a viscosity of 19 cps / 34 ° C. with methanol.
Was adjusted.

Example 2 As in Example 1, a 200 μm thick Tg 225 was formed on the outermost surface.
C. PES film 1 and then a thickness of 80 as a binder
A polyester film 2 having a Tg of 120 ° C. and a decorative base paper 3 having a pattern printed on thin paper of 30 g / m ² in U.S.M. 2m
m aluminum plate 7 (A3 specified in JIS H4000)
(003PH24) except that 003PH24) was placed, to obtain a metal-based decorative board (FIG. 2) having a product thickness of 1.5 mm in the same manner as in Example 1.

Example 3 As a core layer, 20% of titanium oxide of 100 g / m ² of rice tsubo was used.
The mixed bleached pulp was impregnated with the following melamine resin varnish (a) for impregnation, and two sheets of melamine resin-impregnated paper 8 having a resin content of 45% and a volatile content of 6% were impregnated with the phenol resin used in Example 1 therebetween. A total of 60 sheets of paper 6 alternately inverted every 5 sheets
Were placed. So that the upper and lower surfaces are symmetrical on both sides,
Polyester film 2, decorative base paper 3, polyester film 2, and PE same as those used in Example 1.
It superposed sequentially with S film 1. Press the pressure 10
And heating and cooling while maintaining the 0 kg / cm ^2. The hot platen temperature is 160 ° C, and the maximum product temperature is 145 ° C to 155
After heating so as to fall within the range of ° C., it was cooled to 40 ° C. to obtain a thick decorative board having a thickness of 13.2 mm (FIG. 3). Preparation of impregnating melamine resin varnish (a): viscosity 45 cp reacted at a molar ratio of formaldehyde to melamine of 1.7
s / 20 ° C water-soluble melamine resin with water, viscosity 23c
The temperature was adjusted to ps / 30 ° C., and a curing catalyst was added.

Comparative Example 1 In accordance with the method for producing a high-pressure melamine resin decorative board usually performed,
The decorative print paper pattern pattern has been printed on the basis weight 100 g / m ² of titanium dioxide 26%混抄the bleached pulp, impregnated with a resin amount of 55% of the impregnating melamine resin varnish described below (b), volatiles 6. 4% melamine resin impregnated decorative paper 9 was obtained. Five sheets of the phenolic resin-impregnated paper 6 used in Example 1 were overlapped, and two sets of the decorative board material set were inserted between stainless steel plates in the same manner as in Example 1. At this time, the two material sets were back-to-back and incorporated with a release film in between. The press was heated and cooled while maintaining the pressure at 100 kg / cm ² . The hot platen temperature was set to 160 ° C., and the product was heated until the maximum product temperature reached 142 ° C., and then cooled to 40 ° C. to obtain a 1.15 mm-thick high-pressure melamine resin decorative board (FIG. 4). Preparation of melamine resin varnish (b) for impregnation: molar ratio of formaldehyde to melamine 1.7
The water-soluble melamine resin having a viscosity of 45 cps / 20 ° C. reacted with the above was adjusted to a viscosity of 21 cps / 30 ° C. with water, and a curing catalyst, an internal mold release agent, and an additive filler were added.

Comparative Example 2 For comparison with the metal-based decorative panel obtained in Example 2, a metal-based high-pressure melamine resin decorative panel was prepared in the same manner as in Comparative Example 1. The configuration is such that one phenolic resin-impregnated paper 6 is placed under the melamine resin-impregnated decorative paper 9 used in Comparative Example 1, and one phenolic resin-impregnated paper 5 used in Example 1 is used for bonding to an aluminum plate. Then, the same aluminum plate (single-side sanding treatment, plate thickness 1.2 mm) as that used in Example 2 was overlapped so that the sanding surface was in contact with the phenolic resin-impregnated paper 5. As in the case of Comparative Example 1, two sets of the above-described decorative plate material set were incorporated between the stainless steel plates so that the aluminum plates were back to back. The press was press-formed so that the maximum product temperature was in the temperature range of 140 to 145 ° C. to obtain a 1.62 mm-thick metal-based melamine resin decorative board (FIG. 5).

The characteristics of the decorative boards obtained in the respective Examples and Comparative Examples were measured. Table 1 shows the results.

[0022]

[Table 1]

(Measurement method) Dimensional change rate: According to the dimensional change rate test of JIS K6902. 2. Abrasion resistance test: According to JIS K 6902 abrasion resistance test. 3. Stain resistance test: In accordance with the JIS K 6902 stain resistance test. 4. Flexibility test: According to a flexural test of a decorative board for a vehicle according to JIS K6902.

[0024]

As is clear from the above description, the decorative board of the present invention has excellent surface performance of the conventional high-pressure melamine resin decorative board by forming the surface layer with a polyether sulfone resin layer. While maintaining, it shows high dimensional stability and heat resistance, and also enables simpler production than conventional production methods. Further, depending on the type and thickness of the binder layer, it is also possible to develop a technology that can easily separate and separate the decorative layer and the core layer or the substrate required for recycling.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a configuration of a decorative board obtained in Example 1.

FIG. 2 is a cross-sectional view illustrating a configuration of a decorative board obtained in Example 2.

FIG. 3 is a cross-sectional view illustrating a configuration of a decorative board obtained in Example 3.

FIG. 4 is a cross-sectional view showing a configuration of a decorative board obtained in Comparative Example 1.

FIG. 5 is a cross-sectional view illustrating a configuration of a decorative board obtained in Comparative Example 2.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 PES film 2 Polyester film (binder) 3 Decorative base paper 4 Aluminum foil 5 Phenol resin impregnated paper (for bonding) 6 Phenol resin impregnated paper 7 Aluminum plate (single-sided sanding) 8 Melamine resin impregnated paper (for concealing undercolor) 9 Melamine resin Impregnated decorative paper

Claims (3)

[Claims] 1. A decorative board, wherein the outermost surface layer of the decorative board is formed of a polyether sulfone resin layer. 2. A polyether sulfone resin having a thickness of 10
The decorative board according to claim 1, which has a glass transition temperature of 0 to 500 µm and a glass transition temperature of 200 ° C or higher. 3. The bonding between the polyethersulfone layer and the decorative layer forming a design is integrally formed via one or more high molecular weight resins selected from polyester resins, polyisocyanates and polyacrylates. Item 3. The decorative plate according to item 1 or 2.