JP2003225985A - Decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that a conventional melamine resin decorative plate has excellent heat resistance, wear resistance, stain resistance and the like and widely applied to various applications, but cannot impart water repellency, oil repellency, wipability and the like to the surface needs to prepare various impregnated sheets and needs fireproofness. <P>SOLUTION: The decorative material is obtained by integrally molding an impregnated sheet obtained by impregnating a decorative sheet or a thin sheet coated with a resin having a feature with the melamine resin and an incombustible base. <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 having excellent designability, surface performance, and fire resistance, and more specifically, excellent designability, stain resistance, chemical resistance, abrasion resistance, wiping property, The present invention relates to a novel fireproof decorative material having surface properties such as water repellency.

[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. In addition, there is a problem that the fire resistance, which is a requirement as a building material, is lacking.

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.

Further, when it is used on a horizontal surface such as a table top, articles are constantly moved and slid repeatedly, so that a wear-resistant decorative material has been demanded.

[0006]

DISCLOSURE OF THE INVENTION The present invention has been made as a result of studies in view of such a situation, and is excellent in designability, has various surface performances, and has a strong demand for fire protection in the construction field. It is intended to provide a new decorative board having properties.

The resin-coated decorative paper in the present invention means a resin such as a silicone resin, an acrylic resin, an acrylic / silicone resin, a urethane resin, an acrylic resin on the surface of a printing paper having a basis weight of 23 to 100 g / m 2. Resin such as urethane resin, urethane / silicon resin, unsaturated polyester resin, vinyl ester resin, etc.
/ M2 or more, preferably 10 to 50 g / m2 on a dry basis
The applied one is used. Among these, it is preferable to use an acrylic resin particularly when it is desired to ensure weather resistance, and a silicone resin is selected in order to impart surface properties such as wiping property, water repellency and 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 Urethane resin, unsaturated polyester resin,
Resins of the type such as vinyl ester resins are preferred.

Further, in order to improve wear resistance, as a wear resistance improving material, high hardness particles having an average particle diameter of 5 to 100 μm, for example, α-alumina, silica, corundum, silicon nitride, silicon carbide, etc. are used in the coating resin. Means for blending may be employed. If it is 5 μm or less, it is difficult to secure the dispersibility,
It is not preferable because the viscosity of the blend becomes too high. 10
When it is 0 μm or more, the sedimentation property increases, which is not preferable.

For the impregnated paper placed under the decorative paper, thin paper made of cellulose paper or the like 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.

The suitable 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.

Non-flammable substrates include thermosetting resins such as melamine resin precondensates, phenolic resin precondensates,
Porous mat-like sheet made by processing a mixture of unsaturated polyester resin, vinyl ester resin, etc. and inorganic powder such as aluminum hydroxide, calcium carbonate, silica sand powder, etc. from inorganic fibers such as glass fiber, rock wool, etc. It can be used as a composite with the body.

As a compounding method, if the thermosetting resin is a water-soluble resin such as a melamine resin precondensate or a phenol resin precondensate, a liquid material prepared by mixing an inorganic powder with a resin solution is applied to the sheet body. When the thermosetting resin lacks water solubility, the thermosetting resin is emulsified to make it water-based, and then a liquid substance mixed with inorganic powder is applied to form a composite. can do. Further, a treatment liquid prepared by mixing an inorganic powder or the like with an aqueous solution or emulsion of a thermosetting resin can be formed into a sheet with a paper machine such as a wet machine together with inorganic fibers such as glass fiber and rock wool.

The fiber material used for the sheet body is not easily crushed and is excellent in reinforcing property. Therefore, a glass fiber non-woven fabric processed from glass fiber, particularly a basis weight of 25 to 120 is used.
A g / m 2 glass fiber non-woven fabric is suitable. 25 g / m
If it is 2 or less, the strength is insufficient, and the proportion of breakage is high in the handling step during processing or molding, which is not preferable. When it is 120 g / m 2 or more, the impregnating property and penetrability of the composition are deteriorated, which is not suitable.

In order to realize the fireproof performance of the molded decorative material, it is preferable that the sheet body has an organic content having flammability and exothermicity suppressed to 10% by weight or less of the weight of the base material. The presence of an organic component in an amount of 10% by weight or more of the weight of the base material tends to impair the fire resistance, and is not suitable for the decorative material of the present invention.

In order to ensure the fireproof performance, the thermosetting resin as the organic component is preferably 10% by weight or less, and aluminum hydroxide is mainly used as the inorganic powder in the proportion of 60 to 70 in order to ensure the fireproof performance. A 90% by weight formulation is suitable. In addition to aluminum hydroxide, appropriately as an inorganic powder,
Calcium carbonate, silica sand powder, etc. may be blended in consideration of fire resistance.

The non-combustible base material is an existing non-combustible base material such as a flexible board which is a ceramic base material, and can withstand the molding conditions of the decorative material according to the present invention. Any material can be used without problems.

The organic content of the surface layer is 300 g / m ^{2 in} order to obtain the performance that passes the nonflammability test stipulated in the Building Standards Law.
In the following, the organic content contained in the core layer or the base material layer is preferably 10% or less as described above. The cosmetic material according to the present invention is configured to pass the nonflammability test in consideration of the above points.

Hereinafter, the present invention will be further described with reference to Examples and Comparative Examples, but the present invention is not limited thereto.

Examples Example 1 Gravure-printed thin paper having a basis weight of 30 g / m 2 and a silicone-modified acrylic resin surface-coated at 15 g / m 2 on a dry basis were used as a printing paper. Cellulose paper having a basis weight of 25 g / m 2 and 200 weights of melamine resin were used. % Impregnated paper, a blend of 5 parts by weight of a phenol resin initial condensate and 95 parts by weight of aluminum hydroxide was used as a base material, and a basis weight of 80 g /
After being applied to a m2 glass fiber non-woven fabric and laminated with three sheet bodies having a treatment rate of 10 times the weight of the glass fiber non-woven fabric, thermocompression molding at 140 ° C. and 50 kg / m ² was performed. Molded cosmetic material. Table 1 shows the surface properties and other properties of the decorative material.

Example 2 A coating material prepared by adding 5% by weight of α-alumina having an average particle diameter of 25 μm to the solid content of acrylic resin was added to the same gravure-printed thin paper as in Example 1 at a dry conversion of 15 g / m 2.
On the coated printing paper, the same impregnated paper used in Example 1 and three sheets were laminated, and thermocompression molding was performed under the same conditions as in Example 1 to form the decorative material of Example 2. The performances such as surface 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 performances such as surface 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.
Impregnated paper with 0% impregnation, printing paper mixed with titanium oxide with a basis weight of 80 g / m2 impregnated with 100% by weight of melamine resin, unexposed kraft paper with a basis weight of 150 g / m2 and phenol resin with a weight resistance ratio of 60 Five core papers impregnated with each other by weight were laminated and thermocompression-molded under the same conditions as in Example 1 to obtain a decorative board of Comparative Example 2. The performances such as surface performance are shown in Table 1.

The performances of the examples and comparative examples are shown in the table below.

[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 / cellophane tape for office work is attached 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 passed once, △
Is not soaked with dirt, but difficult to wipe, × is soaked with dirt.

Nonflammability test The fireproofness is judged by the surface test and the base material test of the fireproof material specified in the Ministry of Construction Notification No. 1828 "Matters for Specifying Nonflammable Material". Pass 〇 Fail ×

[0027]

The decorative material according to the present invention comprises a decorative paper having a surface coated with a resin, an impregnated paper obtained by impregnating a thin paper with a melamine resin, and a non-combustible substrate, which are integrally formed. Since the melamine resin impregnated in the impregnated paper at the time of molding penetrates from the back surface of the decorative paper toward the surface layer and hardens, and the coat resin exists on the surface of the decorative paper and is integrally molded. Since the surface layer of the molded decorative material is reinforced in the state where the coat resin and the melamine resin are compounded, the surface layer does not peel off.

Since the base layer is integrally molded with a non-flammable base material, it can be safely used as a non-flammable decorative material effective for fire prevention in various construction fields. Further, since the characteristics of the coating resin, that is, the surface properties such as water repellency, stain resistance, and oil repellency, can be utilized as they are, the decorative material of the present invention can be used for various purposes. A decorative material in which the abrasion resistance-imparting material is contained in the coating resin can be used for a long period of time even on a horizontal surface such as a table top under severe operating conditions.

As a merit in the production process, in the conventional production of 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. ,
In the decorative material of the present invention, the preparation of the overlay paper is not necessary, so that the production process can be rationalized and the productivity can be greatly improved.

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 2E110 AA02 AA57 AA65 AB04 AB23                       BA02 BA12 BB03 GA32W                       GA33X GA42X GB42X GB63W                 4F100 AA19D AA19H AG00D AK01A                       AK25A AK33D AK36C AK52A                       AR00A AR00H AT00D BA04                       BA07 BA10A BA10D CC00A                       DG10B DG10C DG15D DH00D                       EJ82C GB08 HB00A JB01                       JB06 JJ07D JK09A JK09H                       JL06

Claims (4)

[Claims] 1. A decorative material comprising a resin-coated decorative paper, an impregnated paper obtained by impregnating a thin paper with a melamine resin, and a non-combustible substrate, 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. 4. The decorative material according to claim 1, wherein the resin coat contains a wear resistance imparting material.