JP2003237008A - Decorative material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that a conventional melamine resin decorative board has an excellent heat resistance, wear resistance, and stain resistance or the like and are widely applied for various applications but its surface cannot be imparted by characteristics such as water repellency, oil repellency, wipability and the like and it needs a preparation of various impregnated paper. <P>SOLUTION: A decorative material is obtained by integrally molding decorative sheet coated with a composition obtained by blending a resin with a wear resistance imparting material, an impregnated paper obtained by impregnating thin paper with the melamine resin and core paper obtained by impregnating with thermosetting resin. <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 and the like, and more specifically, it has excellent wear resistance, stain resistance, chemical resistance, and wear resistance. The present invention relates to a decorative material which is excellent in workability such as bending workability and cutability in addition to the properties, wiping property and 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. 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.

In addition, when it is used on a horizontal surface such as a table or a counter, articles or the like are constantly moved and rubbed, so that a decorative material excellent in abrasion resistance is required.

[0006]

DISCLOSURE OF THE INVENTION The present invention has been made as a result of studies in view of such a situation, and is a decorative sheet having excellent wear resistance, designability, and various surface performance and workability. Is intended to be provided.

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. 10 g / m 2 or more, preferably 10 or more, of a composition in which a resin such as urethane resin, urethane / silicon resin, unsaturated polyester resin, vinyl ester resin is mixed with a wear resistance imparting material.
The one coated at 50 g / m 2 is used.

Among these, it is preferable to use an acrylic resin when it is desired to secure weather resistance, and a silicone resin is selected in order to impart surface properties such as wiping property, water repellency and stain resistance. To be done. 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.

As a wear resistance imparting material for improving wear resistance, particles of high hardness having an average particle diameter of 5 to 100 μm, for example, α-alumina, silica, chromium oxide, iron oxide, diamond, corundum, silicon nitride. , Boron carbide, etc. Among them, α-alumina is suitable for use because of its high hardness and the remarkable effect of imparting wear resistance. In addition,
Treatment with a silane coupling agent or the like may be performed in order to improve the adhesion to the resin, the dispersibility, and the like. When the particle size is 5 μm or less, the viscosity of the blend tends to increase depending on the blending amount, which is not preferable. 100 μm
The above is not suitable because the sedimentation property in the compound is increased.

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 many problems such as cutting during resin impregnation and tearing 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.

As the material of the core layer, the material used in the conventional melamine resin decorative board can be used. 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 Gravure-printed thin paper having a basis weight of 30 g / m 2 was uniformly mixed in a roll mill with 5% by weight of α-alumina having an average particle size of 20 μm with respect to the solid content of the base silicon-modified acrylic resin. 60% composition 30g at application level
/ M2 Surface-coated printing paper, impregnated paper in which melamine resin is impregnated in 200% by weight of cellulose paper having a basis weight of 25 g / m2, unbleached kraft paper having a basis weight of 150 g / m2 and phenol resin in 60% of kraft paper. A laminate of five core papers impregnated by weight% was placed between 3 mm thick stainless steel plates, and hot pressed at 140 ° C. and 50 kg / cm 2 for 30 minutes to mold the decorative material of Example 1. The surface performance such as abrasion resistance and the bending performance are shown in Table 1.

Example 2 The same gravure-printed thin paper as in Example 1 was added with 5% by weight of α-alumina used in Example 1 relative to the solid content of the acrylic resin, and the mixture was uniformly mixed with a roll mill 60.
% Composition at 30 g / m2 coating level at coating level impregnated paper same as employed in Example 1, core paper 5
The sheets were laminated and thermocompression molded under the same conditions as in Example 1 to mold 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 30% melamine resin was added to cellulose paper having a basis weight of 30 g / m 2.
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 JISK6902 stain 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) ◯ indicates that θ is 71 ° or more, Δ is 60 to 70 °, and × is less than 60.

Cellotape resistance / cellophane tape for office use 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,
△ is gloss change, color change × is swelling, remarkable discoloration wiping property Draw 2 coils of coil (size about 2 cm * 3 cm) with an oil-based pen, 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, △
There is no stain soaking in, 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.

[0022]

The decorative material according to the present invention is a thermosetting resin for a decorative paper coated with a resin having an abrasion resistance-imparting agent on its surface, an impregnated paper obtained by impregnating a thin paper with a melamine resin, and a kraft paper. The core paper impregnated with is molded and integrated, and has excellent abrasion resistance. In addition, 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 is cured, and the surface of the decorative paper is present on the coated resin surface. Since it is integrally molded, the surface layer of the molded decorative material is reinforced in the state where the coat resin and the melamine resin are compounded, and there is no problem that the surface layer easily peels off.

Further, on the surface, the characteristics of the resin of the coated compound, that is, the surface performance such as water repellency, stain resistance, and oil repellency are secured, and the bending workability which is a drawback of the conventional melamine resin decorative board is greatly improved. I was able to improve. Moreover,
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. Since the preparation of is unnecessary, the production process can be rationalized, and the productivity can be significantly improved.

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 4F100 AA19A AJ04 AK01D AK25A                       AK33 AK36C AK52A AL08                       BA04 BA07 BA10A BA10D                       CA30A CC00A DG10B DG10C                       DG10D EH46A EJ82C EJ82D                       GB08 GB81 HB00B JB13D                       JK09A

Claims (3)

[Claims] 1. A decorative paper coated with a composition containing an abrasion resistance-imparting material, an impregnated paper obtained by impregnating a thin paper with a melamine resin, and a core paper impregnated with a thermosetting resin are integrally molded. A decorative board characterized by being. 2. The decorative material according to claim 1, wherein the resin used in the composition is a silicone resin. 3. The decorative material according to claim 1, wherein the resin used in the composition is an acrylic resin.