JP2006231769A - Internal embossed decorative laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an internal embossed decorative laminate having a smooth surface and a feeling of irregularity which solve the problem that the expression of design nature having a smooth surface is difficult and there is not a feeling of depth since the irregularity appears on the outermost surface of the decorative laminate of embossing finish, and that the cleaning takes more time and effort than those of a flat finish type because of irregularity of the surface when smudging adheres to the surface. <P>SOLUTION: The internal embossed decorative laminate comprises: using resin impregnated overlay paper in which overlay paper whose surface used as the rear surface is printed by an ink containing a brightness material is impregnated with a thermosetting resin, resin impregnated decorative paper, an embossed sheet 3, and a resin impregnated core material of one or more sheets; arranging and laminating an embossed sheet to either of layers from directly under the resin impregnated decorative paper to the lowest layer; and molding by hot pressing. When carrying out impregnation, a melamine-formaldehyde resin is used for the overlay paper and the decorative paper, and a resin liquid which makes a phenol resin as a principal component is used for the core material. When non-combustibility is needed, a thermosetting resin such as an inorganic fiber nonwoven fabric or the like is made to be a binder, and impregnated or coated with a slurry containing an inorganic filler. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an internal embossed decorative board.

  Hitherto, thermosetting resin decorative plates such as melamine resin decorative plates and diallyl phthalate resin decorative plates used for home interiors are known. There are two main types of finishes on the decorative board, flat finishes with smooth surfaces and embossed finishes with uneven surfaces.

  For the embossing finish, it uses a shaping material with irregularities and is called an embossed sheet, embossed plate, etc. The material is paper, film, metal foil, metal plate, plastic plate or a combination of these Things are used.

  However, in the embossed decorative board, unevenness appears on the outermost surface, so that it is difficult to develop a smooth design on the surface, which is a feeling of depth. Moreover, when dirt adheres due to the unevenness of the surface, it takes more time for cleaning than flat finishing.

As a means to solve such problems, a primer layer such as urethane resin type or epoxy resin type is applied on an embossed decorative decorative board, and after the primer layer is formed, clear coating is applied, and a thick film is laminated. However, since the former requires a polishing step, it is difficult to form uniform unevenness, and it is difficult to form large embosses for the latter.
JP-A-5-220916 JP 2003-136666 A JP2004-50777 JP-A-6-99563

  The present invention has been studied in view of such circumstances, a resin-impregnated overlay paper in which a thermoset resin is impregnated on an overlay paper on which the back surface is printed with a luminance substance-containing ink, a resin-impregnated decorative paper, A thermosetting resin decorative board formed by laminating an embossed sheet and one or more resin-impregnated core materials and hot-press molding, wherein the embossed sheet has a layer extending from directly under the resin-impregnated decorative paper to the lowest layer. It is an internal embossing decorative board characterized by being arranged in any layer.

  The internal embossed decorative board of the present invention expresses a design having an emboss in the interior while having a smooth and deep feeling on the surface. In addition, by printing on overlay paper, a variety of designs can be expressed with extremely ordinary decorative paper without the need for dedicated decorative paper with a sense of brightness.

  Hereinafter, the present invention will be described in detail.

  Examples of resin-impregnated decorative paper include resin-impregnated decorative paper in which decorative paper for decorative board is impregnated with a resin liquid containing a thermosetting resin as a main component. Examples of thermosetting resins include amino-formaldehyde resin and diallyl. Examples thereof include phthalate resins, unsaturated polyester resins, and mixtures thereof. In particular, amino-formaldehyde resins having excellent hardness and impact resistance are preferably used.

  The amino-formaldehyde resin is an etherification product of an amino compound such as melamine, urea, benzoguanamine, acetoguanamine and the like, as well as an initial condensate obtained by reacting formaldehyde with a lower alcohol such as methyl alcohol and butyl alcohol. Those modified with a modifying agent that promotes plasticization such as para-toluenesulfonamide can be applied. Among them, a melamine-formaldehyde resin excellent in various properties such as wear resistance, heat resistance, water resistance, dimensional stability and durability is preferable.

  The back side of the overlay paper is printed with a glittering ink containing a metallic powder pigment such as aluminum, silver, copper, nickel, titanium, or chromium, or a pearlescent pigment such as a titanium oxide-coated mica. The resin solution similar to the above is impregnated. Although it is conceivable to maintain a brightness feeling on the decorative paper, it is possible to develop a design with embossing inside even if using ordinary decorative paper by maintaining a brightness feeling on the back side of the overlay paper. Various embossed decorative boards can be developed without any special decorative paper.

  Resin-impregnated core paper is impregnated with core components and resin liquid for core paper for decorative board, for example, kraft paper with thermosetting resin such as amino-formaldehyde resin, diallyl phthalate resin, unsaturated polyester resin, phenol resin Resin impregnated core paper is used.

  Moreover, when imparting incombustibility, inorganic base materials, such as a calcium silicate board and a gypsum board, and the prepreg which made the inorganic fiber base material impregnate the slurry which consists of a resin component and an inorganic filler can be used.

Examples of the inorganic fiber substrate include nonwoven fabrics and woven fabrics made of inorganic fibers such as glass fiber, rock wool, and carbon fiber. The basis weight of the inorganic fiber substrate is in the range of 10 to ²⁰⁰ g / m ² . In particular, it is preferable to use glass fibers that are excellent in heat resistance and flame resistance and excellent in impregnation of slurry.

  As the embossed sheet disposed in any one of the layers from directly under the resin-impregnated decorative paper to the lowest layer, one or more of the above-mentioned resin-impregnated core materials are used to give unevenness with an embossing shaping material. .

When the internal embossed decorative board of the present invention is obtained, a resin-impregnated core material, an embossed sheet, a resin-impregnated decorative paper, and a resin-impregnated overlay paper are laminated, and the heating temperature is 110 to 180 ° C. and the pressing condition is 50. It can be obtained by molding under molding conditions of ˜100 kg / cm ² .

  Hereinafter, although an Example is given and it demonstrates in detail, a specific example is shown and it does not limit to this.

Example 1
Melamine resin impregnated overlay paper Melamine resin is impregnated with a melamine-formaldehyde resin resin liquid so that the impregnation ratio is 240% on an overlay paper having a basis weight of 40 g / m ² and solidly printed with pearl ink. A resin-impregnated overlay paper was obtained.

Melamine resin-impregnated decorative paper A decorative paper with a basis weight of 80 g / m ² was impregnated with the same resin solution as described above so that the impregnation ratio represented by Equation 1 was 100% to obtain a melamine resin-impregnated decorative paper.
Phenol resin impregnated paper core paper A 198 g / m ² kraft paper is impregnated with a resin solution containing phenol resin as a main component so that the impregnation ratio shown in Formula 1 is 100%, thereby obtaining a phenol resin impregnated paper core paper. It was.
Embossed sheet One phenol resin impregnated paper core paper, inserted between a flat metal plate and an embossed molding material with irregularities in a lattice shape, and at a temperature of 140 ° C. and a pressure of 60 kg / m ² with a flat plate press. The embossed sheet was obtained by hot pressing under conditions of 60 minutes.
Production of internal embossed decorative board In order from the bottom, four phenol resin impregnated paper core papers, one embossed sheet, one melamine resin impregnated decorative paper, and one melamine resin impregnated overlay paper are laminated, A flat stainless steel plate was placed and hot pressed with a flat plate press at a temperature of 140 ° C., a pressure of 60 kg / cm ² , and a time of 90 minutes to obtain an internal embossed decorative plate of Example 1.

Example 2
A slurry in which 4 parts of amino-formaldehyde resin and 91 parts of aluminum hydroxide are blended with 5 parts of phenol resin in a prepreg 50 g / m ² glass fiber nonwoven fabric has a slurry solid content of 1600% shown in Equation 2. A prepreg was obtained by impregnation.

  In Example 1, it carried out similarly except having used a prepreg instead of the phenol resin impregnation paper core paper, and obtained the internal embossing decorative board of Example 2. The internal embossed decorative board of Example 2 was nonflammable.

Example 3
In Example 1, it implemented similarly except having used an embossing sheet for the lowest layer, and obtained the internal embossing decorative board of Example 3. FIG.

FIG. 3 is an exploded configuration cross-sectional view of the internal embossed decorative board of Example 1.

Explanation of symbols

1 Melamine resin impregnated overlay paper 2 Melamine resin impregnated decorative paper 3 Embossed sheet 5 Phenol resin impregnated core paper 6 Core layer 7 Internal embossed decorative board

Claims (1)

A resin-impregnated overlay paper in which a thermosetting resin is impregnated on an overlay paper printed with a luminance substance-containing ink on the back surface; a resin-impregnated decorative paper; an embossed sheet; and one or more resin-impregnated core materials; Is a thermosetting resin decorative board obtained by laminating and hot pressing, wherein the embossed sheet is disposed in any one of the layers from directly under the resin-impregnated decorative paper to the lowest layer. Internal embossed decorative board.