JP2002370314A - Postforming decorative sheet and bending processing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a postforming decorative sheet preventing the generation of a damage or staining at the time of handling and capable of improving workability or efficiency at the time of bending processing, and a bending processing method therefore. SOLUTION: The postforming decorative sheet is characterized in that a thermoplastic film with a melting point of 180 deg.C or higher is laminated to the surface of the decorative layer of the decorative sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board for a post-form having a thermoplastic film attached thereto and a method for bending the same. More particularly, the decorative board surface can be protected from scratches and dirt. The present invention relates to a decorative board for a post foam having excellent workability, such as being capable of performing a bending process without removing a thermoplastic film when performing the bending process, and a method of bending the same. The decorative board of the present invention is suitably used, for example, as a material for kitchen doors, wash counters, and the like.

[0002]

2. Description of the Related Art FIG.
As shown in FIG. 1, a thin paper base material that becomes transparent after molding is impregnated with a melamine resin liquid and dried to form a surface layer 1, and a decorative paper or a pigment-impregnated paper printed on the lower side thereof is coated with a melamine resin liquid. A decorative layer 2 made of impregnated paper impregnated and dried with
It is constituted by a core material layer 4 obtained by impregnating a kraft paper with a phenol resin liquid and drying. In addition, the melamine resin decorative layer 2
In some cases, a shielding layer 3 made of impregnated paper obtained by impregnating and drying a phenol resin liquid or a melamine resin liquid on a titanium oxide penetration paper is provided between the phenol resin core layer 4 and the phenol resin core layer 4.
These resin-impregnated base materials are obtained by setting them in the configuration shown in FIG. When using this decorative board for kitchen doors, attach the decorative board to a wood board, such as a particle board or MDF (medium density fiber) board, with an adhesive, and apply the decorative board to parts other than the plane. By heating and performing bending according to the shape of the wooden board and bonding, a material integrated with the wooden board can be obtained.

[0003] The surface of the decorative layer of the decorative plate is generally coated with a thermoplastic film or coated with a polyvinyl alcohol solution or the like in order to prevent scratches and stains due to handling in a later step. However, conventionally used films are often made of polyethylene, polypropylene or the like having a low melting point, so that the surface of the decorative surface during post-form processing may be one.
When heated to a temperature of 30 to 180 ° C., it is melted, and tears or welding to the surface of the decorative board is caused to deteriorate the surface glossiness of the decorative board. there were. For this reason, at the time of post-form processing, it is necessary to remove the film at a portion to be heated in advance (film cut) and to perform bending after exposing the decorative surface.

[0004] However, the above-mentioned processing method not only requires man-hours to remove the film from the processing portion, but also exposes the exposed decorative board surface to a high temperature directly at the time of bending.
There is a problem that the gloss of the surface may be affected, and furthermore, it becomes impossible to protect the portion from which the film has been removed at the time of bending processing and subsequent handling of the decorative board, leading to a decrease in yield. . In addition, the coating of a polyvinyl alcohol solution or the like usually had many unfavorable points, such as the necessity of a forced drying step after the coating, stickiness remaining on the coated surface and poor workability.

[0005]

SUMMARY OF THE INVENTION The present invention provides a decorative board for a post foam and a method for bending the same, which can prevent scratches and dirt during handling and improve workability and efficiency during bending. Things.

[0006]

Means for Solving the Problems The present invention is characterized in that (1) in a decorative board for a post foam, a thermoplastic film having a melting point of 180 ° C. or more is attached to the decorative layer side surface of the decorative board. (2) The decorative sheet for postform according to (1), wherein the thermoplastic film is polyethylene terephthalate, (3) the decorative sheet for (1) or (2), wherein the thermoplastic film is polyethylene terephthalate. A method for bending a decorative board for a post foam, wherein the bending is performed without removing a thermoplastic film.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention is characterized in that a heat-resistant thermoplastic film is attached to the entire surface of a decorative layer of a decorative plate after heat and pressure molding.

The thermoplastic film used in the present invention is not particularly limited as long as it is not melted by the heat applied at the time of bending the decorative board and can be easily separated from the surface of the decorative board. In consideration of the heating temperature during processing, those having a melting point of 180 ° C. or higher are preferable, and those having a melting point of 200 ° C. or higher are more preferable. Films that can be used include polyethylene terephthalate (PE
T), a thermoplastic polyester resin such as polybutylene terephthalate (PBT), a polyamide resin and the like. PET is preferably used in consideration of versatility, cost, recyclability after use, and the like.

[0009] The thickness of the thermoplastic film is not particularly limited.
It is preferable to use one having a thickness of 0 μm. If it is less than 20 μm, workability at the time of peeling after sticking or bending a film may be poor. In addition, although those exceeding 60 μm can be used, the cost is usually increased, and the processing efficiency may be reduced due to the slow heat transfer during processing. In consideration of the balance between workability and cost, the thickness is more preferably 20 to 40 μm.

The side of the thermoplastic film used in the present invention to be bonded to the decorative plate may be a commonly used one such as an acrylic pressure-sensitive adhesive, and is not particularly limited. Therefore, it is more preferable to use a high heat-resistant acrylic pressure-sensitive adhesive, a silicon-based pressure-sensitive adhesive, or the like.

For attaching such a thermoplastic film to a decorative plate, a commonly used method can be applied. In other words, using a general film pressure bonding equipment, unwind the thermoplastic film in the form of a roll, and after aligning the adhesive-coated side of the film with the decorative plate surface, use a silicone rubber roll or the like. Crimp. The temperature at the time of pressure bonding is not particularly limited, but it is preferably performed in the range of 25 to 60 ° C., and particularly in the winter season, the temperature is preferably used within the above range so as to ensure the adhesion between the film and the decorative board. Is preferred.

In the present invention, by protecting the surface of the decorative board with the heat-resistant thermoplastic film, post-form processing can be performed by a commonly used bending method without cutting the film. As an example, the processing steps of the post-form decorative board of the present invention will be described below. A vinyl acetate-based adhesive is applied to a planar portion of a wooden board serving as a substrate. The wooden board and the decorative board are stuck together and crimped with a cold press. A synthetic rubber adhesive is applied to the bent portion of the wooden board. Using a general post-form molding machine, heat the bent part to 130 to 180 ° C with a far infrared heater, etc.
The decorative board is bent by a processing roll arranged according to the bending shape, and is bonded to a wooden board that has been processed in advance according to the bending shape.

For the production of the decorative board for post-form processing used in the present invention, an ordinary method can be applied. That is, prepreg is obtained by impregnating and drying melamine resin liquid using thin paper of 20 to 40 g / cm ^{2 for} the surface layer 1. Resin content (resin content weight% based on prepreg weight,
The same applies hereinafter) is adjusted to 50 to 60%. For the decorative layer 2, a decorative paper of 80 to 100 g / cm ² is used, and the same melamine resin liquid as that used for the surface layer 1 is impregnated and dried, and the resin content is adjusted to 50 to 60%. Shielding layer 3 is 80m2
Using a 100 g / cm ² titanium oxide penetrated paper, impregnated and dried with a phenolic resin solution, the resin content is adjusted to 40 to 50%, and a kraft paper of 190 to 200 g / cm ² is prepared for the core layer 4. The same phenol resin liquid as that used in the shielding layer 3 is impregnated and dried, and the resin content is adjusted to 30 to 35%.

In the present invention, the melamine resin liquid used for the surface layer 1 and the decorative layer 2 may be a liquid generally used for decorative boards. For example, formaldehyde (F) to melamine (M) is adjusted to a molar ratio (F / M) of 1.4 to 1.5, and a caustic soda aqueous solution is added in a reaction vessel to make the pH alkaline to pH 8.0 to 9.0. Those obtained by reacting for about 1.5 to 2 hours while refluxing at 95 ° C. or higher. In addition, when performing a bending process with a small curvature to a decorative board, it is preferable that the decorative board has flexibility after heat curing. As means for imparting flexibility, paratoluenesulfonic acid amide, guanamines,
Modification of resin with glyoxal and the like, polyacrylonitrile, polymethyl acrylate, polyvinyl butyral, modification or blend with a thermoplastic resin such as polyamide, or a method using a resin in which the molar ratio of formaldehyde to melamine is reduced, and the like. The selection is not limited, and the selection may be made in consideration of the flexibility and cost to be provided.

As the phenol resin liquid used for the shielding layer 3 and the core material layer 4, a commonly used phenol resin liquid can be used. For example, the molar ratio (F / P) of formaldehyde (F) to phenol (P) is set to 1.1 to 1.2, and an alkaline catalyst such as calcium hydroxide or barium hydroxide is used. ° C
For about 2 to 3 hours to produce a liquid resol-type phenol resin liquid. Further, as in the case of the melamine resin liquid, a method of adding paratoluenesulfonic acid amide or the like or using a resin in which the molar ratio of formaldehyde to phenol is reduced to improve the bending property of the decorative board is improved. May be applied.

The prepregs thus obtained are laminated according to the structure shown in FIG. 1, and a decorative plate is usually provided with a press plate having a mirror-finished surface. 160 ° C, pressure 7-10
By performing heating and pressing at 50 MPa for 60 to 60 minutes, a decorative board for post-form processing can be obtained. The decorative plate after the heat and pressure molding is usually cut into a predetermined size using a running saw or the like, and then sent to the above-mentioned protective film attaching step.

[0017]

The present invention will be described below in detail with reference to examples.

<< Production of Prepreg for Surface Layer 1 and Decorative Layer 2 >> Method for Producing Melamine Resin Liquid Molar ratio of formaldehyde to melamine (F / M)
Was charged to the reaction vessel so that the pH became 1.45, and potassium hydroxide was added to adjust the pH to 8.5, and the pH was adjusted to 95.
A reflux reaction was performed at 90 ° C. for 90 minutes. Thereafter, the mixture was cooled with water to 50 ° C. or lower, and 3 parts by weight of paratoluenesulfonic acid amide and 6 parts of an alkaline catalyst (acetoguanamine) were added to 100 parts by weight of the solid content of the melamine resin solution. Adjusted to 1.200. Preparation method of prepreg for surface layer 1 After dipping 30 g / cm ² of tissue paper into the melamine resin solution, a spiral rod is applied to the front side and a doctor blade is applied to the back side to adjust the amount of resin attached, and the temperature is set to 100 ° C. for 2 minutes. Dry,
A prepreg having a resin content of 55% by weight and a volatile agent content of 7% by weight was obtained. Preparation method of prepreg for decorative layer 2 After dipping 90 g / cm ² of decorative paper in the resin solution, a spiral rod is applied to the front side, and a doctor blade is applied to the back side to adjust the amount of resin attached, and 100 ° C. for 2 minutes. After drying, a prepreg having a resin content of 55% by weight and a volatile agent content of 8% by weight was obtained.

<< Production of Prepreg for Shielding Layer 3 and Core Material Layer 4 >> Method for Producing Phenol Resin Liquid The molar ratio of formaldehyde to phenol (F /
P) was charged to a reaction vessel so as to be 1.15, and barium hydroxide and slaked lime were added at a ratio of 1: 1 to adjust the pH to 8.
7, and reacted at 95 ° C. or higher for 2 hours. Thereafter, the temperature was lowered to 50 ° C. or lower by water cooling, and water was added to adjust the specific gravity to 1.180. Production method of prepreg for shielding layer 3 After dipping 90 g / cm ² of titanium oxide scoring paper in the phenolic resin solution, a spiral rod was applied to the front side and a doctor blade was applied to the back side to adjust the resin adhesion amount. ° C
For 2 minutes to obtain a prepreg having a resin content of 45% by weight and a volatile agent content of 7% by weight. Manufacturing method of prepreg for core material layer 4 After dipping 195 g / cm ² of kraft paper in the phenol resin solution, a spiral stick is applied to the front side and a doctor blade is applied to the back side to adjust the resin adhesion amount. Dried for 2 minutes, resin content 33% by weight, volatile agent content 7% by weight
Prepreg was obtained.

<< Manufacture of Post Form Decorative Plate >> Each prepreg obtained by the above method is laminated according to the structure of FIG. 1, and a mirror-finished press plate is arranged on each decorative layer surface, and set. 160 ° C, 8M using a press
It heated for 55 minutes at Pa, and obtained the decorative board for post foams with a thickness of 0.8 mm.

<Example 1> A decorative board for post foam was used.
20μm thick PE coated with acrylic adhesive on one side
A T film (melting point: 256 ° C.) was pressed using a silicone rubber roll heated to 40 ° C. 13mm thick
After bonding to the particle board, the temperature of the bent portion was set to 170 ° C. using a post-form molding machine, and processing was performed so that the radius of the bent portion was 9 mm. FIG. 2 shows the shape of the processed part.

<Example 2> A 40-μm-thick PET film coated on one side with an acrylic pressure-sensitive adhesive (melting point: 256 ° C)
Was carried out in the same manner as in Example 1 except that was used.

<Comparative Example 1> A 60 μm thick polyethylene film coated on one side with an acrylic pressure-sensitive adhesive (melting point 12
(0 ° C.), but in the same manner as in Example 1.

<Comparative Example 2>
A 60 μm-thick polyethylene film (melting point: 120 ° C.) coated with an acrylic pressure-sensitive adhesive on one side was bonded by pressure bonding at 40 ° C. After adhering this to a 13 mm-thick particle board, a ruler was applied to a portion having a width of 50 mm from the periphery of the bent portion, and a 65 mm-wide film including the bent portion was cut by hand and removed. Thereafter, the temperature of the bent portion was set to 170 ° C. using a post-form molding machine, and R =
It was bent to 9 mm.

The following items were evaluated for the decorative boards subjected to post-form processing according to the above Examples and Comparative Examples. Table 1 shows the results. The evaluation method is as follows. Bending workability: The bending workability of the decorative board by a post-form molding machine was confirmed. State of film after bending: The state of the film at the processed part after bending was confirmed. Peeling property of film after bending: Peeling property when peeling the film at the processed part after bending was confirmed. Gloss on the surface of the decorative board in the bent part: After peeling off the film,
The difference in surface gloss between the bent part and the plane part was confirmed.

[0026]

[Table 1]

Examples 1 and 2 have a melting point of 180 ° C.
The above PET film was attached to a decorative board, and after bonding this to a wooden board, bending was performed without peeling the film. There was no problem in bending workability, and no melting or welding of the film due to heat was observed. The gloss of the decorative board surface was as good as that of the flat part where the hot bending was not performed. On the other hand, in Comparative Example 1, since a polyethylene film having a low melting point was used, the film was melted by heat at the time of bending to cause breakage and welding. As a result, the portion where the film is torn is inferior in glossiness due to heat during bending, and the welded portion causes a problem in the peelability of the film. As a result, the bent portion is more uniform than the flat portion. The surface gloss was not obtained, and it took time to remove the film. In Comparative Example 2, similarly, a polyethylene film having a low melting point was used, and processing was performed after peeling off the film at the bending portion. Gloss deterioration was observed.

[0028]

According to the present invention, there is provided a decorative board for a post foam, characterized in that a thermoplastic film having a melting point of 180 ° C. or more is adhered to the decorative layer side surface of the decorative board. It is a bending method that has excellent workability, such as being able to protect the surface of the decorative board from scratches and dirt, and performing bending without removing the thermoplastic film when performing bending. A decorative plate for a post form and a method for bending the same can be provided.

[Brief description of the drawings]

FIG. 1 is an example of the configuration of a decorative board for a post foam according to the present invention.

FIG. 2 is a schematic cross-sectional view of a bent portion of the decorative board for a post foam of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Surface layer 2 Decorative layer 3 Shielding layer 4 Core material layer 5 Post foam decorative board 6 Thermoplastic film 7 Wood board 8 Bending part

Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat II (reference) // B29L 7:00 B29L 7:00 9:00 9:00

Claims (3)

[Claims] 1. A decorative sheet for a post foam, wherein a decorative film having a melting point of 180 ° C. or more is adhered to the decorative layer side surface of the decorative sheet. 2. The decorative board for post foam according to claim 1, wherein the thermoplastic film is polyethylene terephthalate. 3. A method for bending a decorative board for a post foam, wherein the decorative board according to claim 1 or 2 is bent without removing a thermoplastic film.