JP2004174951A

JP2004174951A - Bright decorative board

Info

Publication number: JP2004174951A
Application number: JP2002344758A
Authority: JP
Inventors: Tomoko Osawa; 朋子大澤; Hideki Takahashi; 英樹高橋
Original assignee: Aica Kogyo Co Ltd
Current assignee: Aica Kogyo Co Ltd
Priority date: 2002-11-28
Filing date: 2002-11-28
Publication date: 2004-06-24
Anticipated expiration: 2022-11-28
Also published as: JP3923003B2

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a bright decorative board which has brightness different from that obtained by a dye or a pigment due to reflection and interference of light by applying a resin liquid with optical interference fibers scattered on resin-impregnated pattern paper and hot-press-molding it together with resin-impregnated core paper. <P>SOLUTION: The bright decorative board is formed by applying the optic fiber containing resin liquid with the optic interference fibers scattered in the resin liquid mainly containing a thermosetting resin on the resin-impregnated pattern paper, laminating with the resin-impregnated core paper and hot-press-molding. The ratio of mixing the optic interference fibers is 4 to 30 pts.wt. for a solid content of the resin liquid of 100 pts.wt. The optic interference fiber comprising two kinds of polymer layers with different refractive indexes which are alternately laminated in parallel to the longitudinal axis of a flat cross section is used. The combination of polymers includes polyester-aliphatic polyamide-based polymers or polyester-polymethyl methacrylate-based polymers. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【産業上の利用分野】
本発明は、光輝性化粧板に関する。
【０００２】
【特許文献１】特公昭６３−２２９８０号公報
【特許文献２】特開平３−１２１８４５号公報
【特許文献３】特公平５−７６４２６号公報
【０００３】
【従来の技術】
従来、光輝性を有する熱硬化性樹脂化粧板としては、パターン紙にアルミ粉、銅粉、マイカ粉等の無機質粉末を混抄したもの（特公昭６３−２２９８０号公報）や、表面保護層となるオーバーレイ紙中に偏光性を有する１ｍｍ角あるいは０．２〜２．５ｍｍの細長状小片の合成樹脂輝度物質を抄き込んだ化粧板（特開平３−１２１８４５号公報）や、オーバーレイ紙中にパール片又は雲母片微粒子状物表面に酸化チタンを溶融被覆した平均粒径が１０〜６０μｍの顔料を混入した化粧板（特公平５−７６４２６号公報）が知られている。
【０００４】
【発明が解決しようとする課題】
しかしながら、金属系の無機質粉末を用いた化粧板は、表面が斑点状になりやすく、光輝性にやや欠けるという欠点があった。
また、偏光性を有する合成樹脂輝度物を用いた化粧板は、偏光性は有するが、光輝性が弱く、雲母片の表面を酸化チタンで被覆した顔料を用いた化粧板は、光輝性が十分でなく、またパターン紙が濃い色（例えば黒色）の場合は光輝性を呈すが、薄く淡い色調のパターン紙の場合では十分な光輝性を呈すとは言い難いという欠点があった。
【０００５】
【課題を解決するための手段】
本発明はかかる状況に鑑み検討されたもので以下のことを特徴とする。すなわち、請求項１記載の発明は、熱硬化性樹脂を主な成分とする樹脂液に光学干渉繊維を分散させた光学繊維入り樹脂液を、樹脂含浸パターン紙上に塗布し、樹脂含浸コア紙とともに積層し、熱圧成形してなることを特徴とする光輝性化粧板である。
また、請求項２記載の発明は、該光学干渉繊維の配合割合が、該樹脂液の固形分１００重量部に対して、４〜３０重量部であることを特徴とする請求項１記載の光輝性化粧板である。
以下、本発明について、詳細に説明する。
【０００６】
樹脂含浸パターン紙は、化粧板用の化粧紙にジアリルフタレート樹脂、アミノーホルムアルデヒド樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂を主成分とする樹脂液を含浸し、乾燥したものが用いられる。中でもアミノ−ホルムアルデヒド樹脂が好適で、特に耐熱性に優れるメラミン−ホルムアルデヒド樹脂が好ましい。
【０００７】
樹脂含浸パターン紙上には、前記同様の熱硬化性樹脂を主な成分とする樹脂液に、光学干渉繊維を分散させた光学繊維入り樹脂液が塗布される。
光学干渉繊維の配合割合は樹脂液の固形分１００重量部に対して４〜３０重量部とするのが望ましく、配合割合が下限に満たないと仕上がった製品の光輝性が乏しく、上限を超えると樹脂液中で均一に分散しずらく、製品の光輝性がバラツクので好ましくない。
光学干渉繊維を分散させた光学干渉繊維入り樹脂液を塗布する手段としては、リバースコート、グラビアコート、バーコート、カーテンフローコート、ナイフコートなど公知のコーティング方法が採用される。
光学繊維入り樹脂の塗布量は、８０〜１２０ｇ／ｍ^２の範囲とするのが望ましく、塗布量が下限に満たないと仕上がった製品の光輝性が乏しく、上限を超えると均一な塗布が困難になりやすく、製品の光輝性がバラツクので好ましくない。生産方法としては、化粧紙を含浸処理した後、塗布するといった一連の作業で行うことが望ましいが、化粧紙を含浸処理し、裁断もしくは巻き取って、別の工程で塗布してもよい。
【０００８】
前記の光学干渉繊維は、屈折率の異なる２種類のポリマー層を扁平断面の長軸方向と平行に交互に薄膜積層して得られる光輝材で、長さは２０〜１０００μｍである。
屈折率が異なることで、高い光学干渉効果を得ることができ、また、扁平比が大きい程、光の干渉に有効な面積を大きく取ることができる。好ましい扁平比は３〜１２であり、扁平比が３未満では、高い光学干渉効果を得ることが困難で、一方１２を超えると折れ曲がりやすくなる。
【０００９】
ポリマーとしては、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート等の芳香族ポリエステル、ポリエチレン、ポリプロピレン等のポリオレフィン、ポリカーボネート、ポリスチレン、ポリメタクリレート、脂肪族ポリアミド、芳香族ポリアミド等のポリアミド等から、所望の屈折率に応じて適宜選択すればよく、好ましいの組み合わせとしては、例えば、ポリエチレンナフタレートを主成分とするポリエステル（高屈折率ポリマー）とナイロン６、ナイロン６，６、ナイロン６，１２、ナイロン１１、ナイロン１２などの脂肪族ポリアミド（低屈折率ポリマー）、また、ポリエチレンテレフタレートを主成分とするポリエステル（高屈折率ポリマー）とポリメチルメタクリレート（低屈折率ポリマー）が挙げられる。
【００１０】
層の厚みは０．０２〜０．３μｍであることが好ましく、厚みがこの範囲外では、期待する干渉効果を得ることはできない。交互積層数としては、とくに限定されないが、光の反射干渉性および透過性の面から、５層以上、とりわけ１０〜１５０層の範囲が望ましい。
【００１１】
樹脂含浸コア紙は、化粧板用のクラフト紙、不織布などのコア紙にフェノール樹脂、アミノ−ホルムアルデヒド樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂を主成分とする樹脂液を含浸した通常公知のものが用いられる。
【００１２】
フェノール樹脂は、フェノール類とアルデヒド類とをフェノール性水酸基１モルに対してアルデヒド類を１〜１．３モルの割合で塩基性触媒下にて反応させて得られるもので、フェノール類としては、フェノール、クレゾール、キシレノール、オクチルフェノール、フェニルフェノール、ビスフェノールＡ、ビスフェノールＳ、ビスフェノールＦなどが挙げられ、アルデヒド類としては、ホルムアルデヒド、パラホルムアルデヒド、グリオキザール、トリオキザールなどが挙げられる。
また、必要に応じてパラスルフォンアミド、桐油、燐酸エステル類、グリコール類などの可塑化を促す変性剤で変性されたものも適用でき、塩基性触媒としては、ナトリウム、カリウムなどのアルカリ金属、及びマグネシウム、カルシウムなどのアルカリ土類金属の酸化物や水酸化物、及びトリエチルアミン、トリエタノールアミンなどのアミン類、アンモニアが挙げられる。
【００１３】
アミノ−ホルムアルデヒド樹脂としてはアミノ化合物、例えばメラミン、尿素、ベンゾグアナミン、アセトグアナミンなどとホルムアルデヒドを反応させた初期縮合物のほか、メチルアルコール、ブチルアルコールなどの低級アルコ−ルによるエ−テル化、パラトルエンスルホンアミドなどの可塑化を促す反応性変性剤で変性されたものが適用でき、中でも耐熱性に優れるメラミン−ホルムアルデヒド樹脂が好ましい。
【００１４】
不飽和ポリエステル樹脂は、不飽和二塩基酸及び／又はその酸無水物と必要に応じて用いられるその他の飽和酸及び／又はその酸無水物とを含む酸成分と、多価アルコールとを窒素やアルゴンなどの不活性ガス雰囲気下で１６０〜２３０℃程度、好ましくは２１０〜２３０℃で常法に従い脱水縮合反応させ、重合性モノマー、例えばスチレンモノマーを加えたものである。
【００１５】
以下、本発明について、実施例、比較例を挙げて詳細に説明する。
【実施例】
実施例１
樹脂含浸コア紙
坪量１９８ｇ／ｍ^２のクラフト紙にフェノール樹脂を主成分とする樹脂液を、式１に示す含浸率が５０％となるように含浸してフェノール樹脂含浸コア紙を得た。
【式１】

樹脂含浸パターン紙
坪量１００ｇ／ｍ^２の黒色無柄の化粧紙に、メラミン−ホルムアルデヒド樹脂を主な成分とする樹脂液を、式１に示す含浸率が１００％となるように含浸し、乾燥し、メラミン樹脂含浸パターン紙を得た。
光輝性化粧板
メラミン樹脂含浸パターン紙を製造する際に用いた樹脂液に、ＰＥＴ−ナイロン６系、扁平比６．０の光学干渉繊維を樹脂液の固形分１００重量部に対して１０重量部分散し、メラミン樹脂含浸パターン紙上にバーコート法により、９５ｇ／ｍ^２塗布して乾燥させた後、フェノール樹脂含浸コア紙４枚とともに積層し、平板プレス機にて、温度１４０℃、圧力５０ｋｇ／ｍ^２、時間８０分で熱圧成形した。
【００１６】
比較例１
実施例１において、ＰＥＴ−ナイロン６系の光学干渉繊維を樹脂液の固形分に対して３重量部分散した以外は同様に実施し、比較例１の化粧板とした。
【００１７】
比較例２
実施例１において、ＰＥＴ−ナイロン６系の光学干渉繊維を樹脂液の固形分に対して３２重量部分散した以外は同様に実施し、比較例２の化粧板とした。
【００１８】
比較例３
実施例１において、塗布量を７５ｇ／ｍ^２とした以外は同様に実施し、比較例３の化粧板とした。
【００１９】
比較例４
実施例１において、塗布量を１３０ｇ／ｍ^２とした以外は同様に実施し、比較例４の化粧板とした。
【００２０】
比較例５
実施例１において、ナイロン６−ＰＥＴ系の光学干渉繊維を分散させた光学セに入り樹脂液を塗布しなかった以外は同様に実施して、比較例５の化粧板とした。
【００２１】
評価結果を表１に示す。
【表１】

【００２２】
評価方法は以下の通りとした。
光輝性（目視にて確認）
○；均一な光輝感
△；不均一な光輝感
×；光輝感なし或いは光輝感に乏しい。
【００２３】
【発明の効果】
本発明で示したように、光学干渉繊維を分散させた樹脂液を樹脂含浸パターン紙上に塗布し、樹脂含浸コア紙とともに熱圧成形することにより、光の反射、干渉作用により、染料、顔料などによる輝きとは異なる光輝性化粧板を得ることができる。[0001]
[Industrial applications]
The present invention relates to a glittering decorative board.
[0002]
[Patent Document 1] JP-B-63-22980 [Patent Document 2] JP-A-3-121845 [Patent Document 3] JP-B-5-76426 [0003]
[Prior art]
Conventionally, as a thermosetting resin decorative board having brilliant properties, a pattern paper obtained by mixing an inorganic powder such as an aluminum powder, a copper powder, and a mica powder (Japanese Patent Publication No. 63-22980) or a surface protective layer is used. A decorative board (JP-A-3-121845) in which an elongated piece of synthetic resin luminance material of 1 mm square or 0.2 to 2.5 mm having a polarizing property is incorporated in overlay paper, or a pearl in overlay paper. There is known a decorative board (Japanese Patent Publication No. 5-76426) in which a pigment having an average particle diameter of 10 to 60 μm in which titanium oxide is melt-coated on the surface of fine particles or mica particles is mixed.
[0004]
[Problems to be solved by the invention]
However, a decorative board using a metal-based inorganic powder has a drawback that the surface tends to be spot-like and the glitter is slightly lacking.
In addition, a decorative plate using a synthetic resin luminance material having a polarizing property has a polarizing property, but has a weak glittering property, and a decorative board using a pigment in which the surface of a mica piece is coated with titanium oxide has a sufficient glittering property. However, when the pattern paper has a dark color (for example, black), it has a glitter, but when the pattern paper has a light and pale color tone, it is hard to say that it has sufficient glitter.
[0005]
[Means for Solving the Problems]
The present invention has been made in view of such circumstances, and has the following features. That is, the invention according to claim 1 is to apply a resin liquid containing an optical fiber in which an optical interference fiber is dispersed in a resin liquid containing a thermosetting resin as a main component on a resin-impregnated pattern paper, and together with the resin-impregnated core paper. It is a glittering decorative board characterized by being laminated and hot-pressed.
The invention according to claim 2 is characterized in that the blending ratio of the optical interference fiber is 4 to 30 parts by weight based on 100 parts by weight of the solid content of the resin liquid. It is a decorative veneer.
Hereinafter, the present invention will be described in detail.
[0006]
The resin-impregnated patterned paper is obtained by impregnating a decorative paper for a decorative board with a resin liquid containing a thermosetting resin such as a diallyl phthalate resin, an amino-formaldehyde resin, and an unsaturated polyester resin as a main component, and then drying. Among them, an amino-formaldehyde resin is preferable, and a melamine-formaldehyde resin particularly excellent in heat resistance is preferable.
[0007]
On the resin-impregnated pattern paper, a resin liquid containing optical fibers in which optical interference fibers are dispersed in a resin liquid mainly containing the same thermosetting resin as described above is applied.
The compounding ratio of the optical interference fiber is desirably 4 to 30 parts by weight with respect to 100 parts by weight of the solid content of the resin liquid, and if the compounding ratio is less than the lower limit, the finished product has poor glitter and exceeds the upper limit. It is difficult to uniformly disperse the resin in the resin solution, and the glitter of the product varies, which is not preferable.
As a means for applying the resin liquid containing the optical interference fiber in which the optical interference fiber is dispersed, a known coating method such as reverse coating, gravure coating, bar coating, curtain flow coating, and knife coating is adopted.
The coating amount of the resin containing an optical fiber is desirably in the range of 80 to 120 g / m ^{2. If} the coating amount is less than the lower limit, the glitter of the finished product is poor, and if it exceeds the upper limit, uniform application becomes difficult. It is not preferable because the luster of the product tends to vary. As a production method, it is desirable to perform a series of operations such as applying a decorative paper after impregnating, and then applying the decorative paper, impregnating the decorative paper, cutting or winding it, and applying it in another process.
[0008]
The optical interference fiber is a glittering material obtained by alternately laminating two types of polymer layers having different refractive indexes in parallel with the major axis direction of a flat cross section, and has a length of 20 to 1000 μm.
Since the refractive index is different, a high optical interference effect can be obtained, and the larger the aspect ratio, the larger the area effective for light interference. A preferable aspect ratio is 3 to 12. When the aspect ratio is less than 3, it is difficult to obtain a high optical interference effect, and when the aspect ratio is more than 12, it is easy to bend.
[0009]
As the polymer, desired refraction is obtained from aromatic polyesters such as polyethylene terephthalate, polybutylene terephthalate and polyethylene naphthalate, polyolefins such as polyethylene and polypropylene, polyamides such as polycarbonate, polystyrene, polymethacrylate, aliphatic polyamide and aromatic polyamide. The combination may be appropriately selected according to the refractive index. As a preferable combination, for example, polyester (high refractive index polymer) containing polyethylene naphthalate as a main component and nylon 6, nylon 6,6, nylon 6,12, nylon 11, Aliphatic polyamides such as nylon 12 (low-refractive index polymer), polyesters mainly composed of polyethylene terephthalate (high-refractive index polymer) and polymethyl methacrylate (low-refractive index polymer) And the like.
[0010]
The thickness of the layer is preferably from 0.02 to 0.3 μm, and if the thickness is out of this range, the expected interference effect cannot be obtained. The number of layers to be alternately stacked is not particularly limited, but is preferably 5 or more, particularly preferably 10 to 150 layers, from the viewpoint of light reflection interference and light transmission.
[0011]
Resin-impregnated core paper is generally known in which a kraft paper for decorative board, a core paper such as a non-woven fabric is impregnated with a resin liquid mainly containing a thermosetting resin such as a phenol resin, an amino-formaldehyde resin, and an unsaturated polyester resin. Things are used.
[0012]
Phenol resin is obtained by reacting phenols and aldehydes with aldehydes at a ratio of 1 to 1.3 mol per mol of phenolic hydroxyl group under a basic catalyst, and as phenols, Examples include phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, bisphenol F, and aldehydes include formaldehyde, paraformaldehyde, glyoxal, and trioxal.
If necessary, parasulfonamide, tung oil, phosphoric acid esters, those modified with a modifier that promotes plasticization such as glycols can also be applied.As the basic catalyst, sodium, alkali metals such as potassium, and Examples include alkaline earth metal oxides and hydroxides such as magnesium and calcium, amines such as triethylamine and triethanolamine, and ammonia.
[0013]
Examples of the amino-formaldehyde resin include an initial condensate obtained by reacting an amino compound such as melamine, urea, benzoguanamine, acetoguanamine and the like with formaldehyde, etherification with a lower alcohol such as methyl alcohol and butyl alcohol, and paratoluene. A resin modified with a reactive modifier such as sulfonamide which promotes plasticization can be used, and a melamine-formaldehyde resin having excellent heat resistance is preferable.
[0014]
The unsaturated polyester resin is obtained by converting an acid component containing an unsaturated dibasic acid and / or an acid anhydride thereof, and optionally another saturated acid and / or an acid anhydride thereof, and a polyhydric alcohol with nitrogen or the like. It is obtained by subjecting a dehydration condensation reaction to about 160 to 230 ° C., preferably 210 to 230 ° C. in a conventional manner in an atmosphere of an inert gas such as argon and adding a polymerizable monomer such as a styrene monomer.
[0015]
Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples.
【Example】
Example 1
Resin-impregnated core paper Kraft paper having a basis weight of 198 g / m ² was impregnated with a resin solution containing a phenol resin as a main component so that the impregnation rate shown in Formula 1 was 50%, to obtain a phenol resin-impregnated core paper.
(Equation 1)

Resin-impregnated pattern paper A black non-patterned decorative paper having a basis weight of 100 g / m ² is impregnated with a resin solution containing a melamine-formaldehyde resin as a main component so that the impregnation ratio shown in Formula 1 becomes 100%, and dried. Thus, a melamine resin-impregnated patterned paper was obtained.
10 parts by weight of a PET-nylon 6 type optical interference fiber having an aspect ratio of 6.0 was added to the resin liquid used for producing the glitter decorative board melamine resin impregnated pattern paper with respect to 100 parts by weight of the solid content of the resin liquid. After dispersing, applying 95 g / m ² on a melamine resin-impregnated pattern paper by a bar coating method and drying, the resultant was laminated with four phenol resin-impregnated core papers, and a flat plate press was used at a temperature of 140 ° C. and a pressure of 50 kg / m ^2. It was hot pressed at m ² for 80 minutes.
[0016]
Comparative Example 1
A decorative plate of Comparative Example 1 was obtained in the same manner as in Example 1, except that the PET-nylon 6-based optical interference fiber was dispersed in 3 parts by weight with respect to the solid content of the resin liquid.
[0017]
Comparative Example 2
A decorative plate of Comparative Example 2 was prepared in the same manner as in Example 1, except that PET-nylon 6-based optical interference fibers were dispersed in an amount of 32 parts by weight with respect to the solid content of the resin solution.
[0018]
Comparative Example 3
A decorative board of Comparative Example 3 was obtained in the same manner as in Example 1, except that the coating amount was 75 g / m ² .
[0019]
Comparative Example 4
A decorative board of Comparative Example 4 was obtained in the same manner as in Example 1, except that the application amount was changed to 130 g / m ² .
[0020]
Comparative Example 5
A decorative plate of Comparative Example 5 was obtained in the same manner as in Example 1, except that the resin solution was not applied to the optical cell in which the nylon 6-PET optical interference fiber was dispersed.
[0021]
Table 1 shows the evaluation results.
[Table 1]

[0022]
The evaluation method was as follows.
Brightness (confirmed visually)
；: Uniform glitter △; non-uniform glitter x: no glitter or poor glitter.
[0023]
【The invention's effect】
As shown in the present invention, a resin liquid in which optical interference fibers are dispersed is coated on a resin-impregnated pattern paper, and hot-pressed together with the resin-impregnated core paper to reflect light, interfere with the action of dyes, pigments, etc. Glittering decorative board different from the luster caused by the above can be obtained.

Claims

An optical fiber-containing resin liquid in which optical interference fibers are dispersed in a resin liquid containing a thermosetting resin as a main component is coated on a resin-impregnated pattern paper, laminated with a resin-impregnated core paper, and hot-pressed. A glittering decorative board characterized by the following.

The glittering decorative board according to claim 1, wherein the blending ratio of the optical interference fiber is 4 to 30 parts by weight based on 100 parts by weight of the solid content of the resin liquid.