JP2003191388A - Decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that up to the present time, melamine resin decorative sheets exhibit excellent performances such as heat resistance, wear resistance and chemical resistance so that they have been widely used in various applications, however, as they are rigid and thermosetting, they are short of bending processability and it is impossible to provide such performances as water repellency, oil repellency and wiping properties on their surfaces. <P>SOLUTION: The problem is solved by a decorative sheet manufacture by laminating a resin-coated decorative paper, an impregnated paper prepared by impregnating a thin paper with a melamine resin and a core paper impregnated with a thermosetting resin and molding them. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel decorative material used as a surface material for building materials, furniture, etc., and more specifically, stain resistance, chemical resistance, abrasion resistance, wiping property, water repellency, etc. The present invention relates to a decorative material having excellent surface performance and processability such as bending workability and cutting property.

[0002]

2. Description of the Related Art Conventionally, melamine resin decorative boards have been widely used in places where heat resistance, chemical resistance, abrasion resistance and the like are required, such as counters, tables and kitchen counters. As the melamine resin decorative board, a transparent overlay paper impregnated with melamine resin, a decorative paper impregnated with melamine resin on a decorative base paper mixed with titanium oxide and having a concealing property, and kraft paper Generally, a thick paper and a plurality of core papers impregnated with a phenolic resin are laminated and then hot-pressed with a hot press.

While such a melamine resin decorative board has excellent surface performance as described above, it has a problem that it is difficult to add a new function because the surface is a thermosetting resin and has a crosslinked structure. is there. Further, since it is hard, there remains a problem that workability such as bending workability and cutting property is insufficient.

On the other hand, a decorative material obtained by arranging resin-coated unimpregnated paper on the surface and stacking the core paper as described above has a resin-selectivity of the resin and is water repellent depending on the resin type. Surface properties such as oil repellency, abrasion resistance, and scratch resistance can be imparted. However, the permeation of the coated resin is not always sufficient, the reinforcing effect between the papers is difficult to obtain, and the strength between the papers is weak, so that there are problems such as weak resistance to cellophane tape (registered trademark), low hardness and easy scratches. The color tone of the resin impregnated in the core paper is more noticeable than the surface.

[0005]

DISCLOSURE OF THE INVENTION The present invention has been made as a result of an examination in view of such a situation.
An object of the present invention is to provide a decorative board having various surface performances and workability.

The resin-coated decorative paper in the present invention means a resin such as silicone resin, acrylic resin, acrylic-silicone resin, urethane-based resin, acrylic-urethane-based resin on the surface of printing paper having a basis weight of 23 to 100 g / m 2. resin,
Resin such as urethane / silicon resin, unsaturated polyester resin, vinyl ester resin is 10 g / m2 or more,
It is preferable to use one coated at 10 to 50 g / m 2. Among these, it is preferable to use an acrylic resin when it is desired to ensure weather resistance, water resistance,
Silicon-based resin is selected in order to impart surface performance such as stain resistance. Further, when it is desired to make the permeation from the surface layer into the space between papers good and to particularly increase the strength of the paper layer, it is preferable to set the average molecular weight of the resin to several hundreds or less, or to react after permeation with a low molecular weight substance during coating. Resins of the type such as urethane resins, unsaturated polyester resins, vinyl ester resins are preferred.

Further, in order to impart wear resistance, slip resistance, scratch resistance and the like, an additive material, for example, fine powder of silica, aluminum hydroxide, alumina or the like may be blended.

For the impregnated paper placed under the decorative paper, thin paper made of cellulose paper having a basis weight of 18 to 25 g / m 2 is used as a base material. When the basis weight is 18 g / m 2 or less, the strength is insufficient and the strength is insufficient, which causes problems such as cutting during resin impregnation and breaking during handling, which is not preferable. If it is 25 g / m 2 or more, the cost becomes high and the performance becomes unnecessary, which is not suitable.

An appropriate impregnation rate of the melamine resin into the thin paper is 200 to 500% by weight. If the amount is 200% by weight or less, the amount of the resin is insufficient, so that the resin does not sufficiently penetrate into the coated paper on the surface during molding, which is not preferable. 500
If the content is more than 10% by weight, it is not suitable for reinforcing the thin paper because the resin content becomes excessive.

The material of the core layer may be the same as that used in conventional melamine resin decorative boards. Specifically, kraft paper having a basis weight of 80 to 200 g / m 2 which has not been exposed to heat may be used, which is obtained by impregnating a thermosetting resin such as a phenol resin initial condensation product, an unsaturated polyester resin, or a vinyl ester resin. The impregnation rate is 40 to 60% by weight. When it is 40% by weight or less, the amount of the resin that has penetrated is insufficient, and the interlayer strength of the core layer may be insufficient, which is not preferable. If it is more than 60% by weight, the resin exudes to the outside at the time of molding or becomes an excessive quality, which is not suitable.

The present invention will be further described below with reference to examples and comparative examples.

Example 1 15 g / m 2 surface-coated printing paper of a silicone-modified acrylic resin obtained by blending a base acrylic resin with a silicone resin on a thin paper gravure-printed with a basis weight of 30 g / m 2, a basis weight of 25 g / m 2. An impregnated paper obtained by impregnating 200% by weight of melamine resin into a cellulose paper, and an unbleached kraft paper having a basis weight of 150 g / m 2 laminated with 5 core papers obtained by impregnating 60% by weight of phenol resin with respect to the kraft paper. Placed between 3 mm thick stainless steel plate, 140 ° C, 50 kg
The decorative material of Example 1 was molded by hot pressing at 30 cm 2 / cm 2 for 30 minutes. The surface performance and bending performance are shown in Table 1.

Example 2 The same gravure-printed thin paper as in Example 1 was coated with 15 g / m 2 of a coating material containing 2% by weight of aluminum hydroxide based on the solid content of acrylic resin. Five sheets of the same impregnated paper and core paper as used were laminated and thermocompression-molded under the same conditions as in Example 1 to form the decorative material of Example 2. The surface performance and bending performance are shown in Table 1.

Comparative Example 1 A decorative board of Comparative Example 1 was molded in the same manner as in Example 1 except that the gravure-printed thin paper not surface-coated with the silicone-modified acrylic resin was used. The surface performance and bending performance are shown in Table 1.

Comparative Example 2 Cellulose paper having a basis weight of 30 g / m 2 and 30 melamine resin was used.
An impregnated paper impregnated with 0%, a printing paper mixed with titanium oxide having a basis weight of 80 g / m2, a pattern paper impregnated with 100% by weight of a melamine resin, and five core papers used in Example 1 are laminated to form Example 1. The decorative plate of Comparative Example 2 was obtained by hot pressing under the same conditions. The surface performance and bending performance are shown in Table 1.

The performances of Examples and Comparative Examples are shown in the following table.

[Table 1]

Test method Contamination resistance According to the JISK6902 contamination resistance test. ◎ means no pollution. ◯: Contaminating material was contaminated with 1% iodine alcohol solution and 2% mercury chrome aqueous solution. △
Is contaminated with 1% iodine alcohol solution, 2% mercury chrome aqueous solution, crayons, and shoes. × indicates that the pollutant material in most parts is contaminated. Water repellency resistance Measured with a contact angle meter (model CA-X) of Kyowa Interface Science Co., Ltd. image processing type 3-point click method. Principle of measurement / A liquid sample is taken out from the tip of a needle and brought into contact with an individual sample to form a droplet, and the coordinates of the left end (L) and right end (R) of the droplet and the vertex (T) are obtained. The droplet diameter (2r) and height (h) are obtained from the three points L, R, and T, and the contact angle θ is calculated from the following equation. Tan θ = h / r → θ = 2 Tan-1 (h / r)

Cellotape resistance / office cellophane tape is adhered so as not to contain air, and the back surface is rubbed strongly. Attach the tape and pull it off at an angle of about 45 degrees within 15 minutes. If peeling is not recognized, it is judged as pass ◯, and if there is no abnormality in appearance, it is judged as pass ×. Abrasion resistance / Evaluated by an abrasion resistance test specified in JISK6902. ◎ means 790 times or more, ◯ means 500 ~
790 times, △ is 500 to 101 times × is 100 times or less

Heat resistance According to the heat resistance test specified in JIS K6902. ◎ is no abnormality, ◯ is a slight gloss loss,
△ indicates gloss change, color change × indicates swelling, and marked discoloration wiping property Draw 2 coils (size about 2 cm * 3 cm) with an oil-based pen and wipe off with Kimwipe after 5 seconds,
One time is when there is no color remaining. Repeatedly measure the number of passes. ◎ is passed more than once, ◯ is once passed,
△ There is no stain penetration, but it is difficult to wipe it off.

Bendability 150 mm long and 300 mm wide test pieces were coated with temperaque according to the heating temperature, placed on a heating support and melted with a sheath heater from above 60 mm. Heat up to (temperature 16
0-180 ° C). The heated test piece is separated from the sheath heater and externally bent. A convex die having a semi-cylindrical body having each bending radius at the top, and a plate body having the same thickness as the diameter of the semi-cylindrical body and the semi-cylindrical body connected, and a plate body of the convex die Using a bending tester consisting of a concave mold having a recess whose width is 10 mm wider than the width, the lateral direction of the test piece is inserted into both molds, and the test piece is subjected to a bending test. ◎ has a bending radius of 3
Passed at ~ 5 mm, ◯ passed at a bending radius of 6-8 mm, △ passed at a bending radius of 9-12 mm, × passed at a bending radius of 13 mm or more.

[0020]

The decorative material according to the present invention comprises a decorative paper whose surface is coated with a resin, an impregnated paper obtained by impregnating a thin paper with a melamine resin, and a core paper impregnated with a thermosetting resin such as kraft paper. The melamine resin impregnated in the impregnated paper penetrates from the back surface of the decorative paper toward the surface layer and is cured during molding, and the surface of the decorative paper is coated with a coating resin. Since they are present in the shape of and are integrally molded, the surface layer of the molded decorative material is finished in a state where the coat resin and the melamine resin are combined.

Therefore, the surface has the characteristics of the characteristics of the coating resin,
That is, surface properties such as water repellency, stain resistance, abrasion resistance, and oil repellency were ensured by the coating resin, and the bending workability, which was a drawback of the conventional melamine resin decorative board, could be greatly improved. Moreover, in the production of conventional melamine resin decorative boards, it was necessary to prepare overlay paper impregnated with melamine resin, pattern paper and core paper impregnated with phenol resin for molding, but with the decorative material of the present invention, Since it is not necessary to prepare overlay paper, the production process can be streamlined and productivity can be greatly improved.

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 2E110 AA14 AA26 AA41 AA65 AB17                       AB18 AB23 BA03 BA12 BB04                       DC21 EA06 GA03X GA08W                       GA17W GA32W GB44W GB49X                       GB52W GB53W GB63Z                 4F100 AK01A AK01D AK25A AK36C                       AK52A BA04 BA07 BA10A                       BA10D DG10B DG10C EJ82C                       HB00 JB01 JB06 JB13D                       JK16 JL06

Claims (3)

[Claims] 1. A decorative board comprising a resin-coated decorative paper, a thin paper impregnated with a melamine resin, and a core paper impregnated with a thermosetting resin, which are integrally molded. 2. The decorative material according to claim 1, wherein the resin used for the resin coating is a silicone resin. 3. The decorative material according to claim 1, wherein the resin used for the resin coat is an acrylic resin.