JP2007090534A - Decorative board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a decorative board having a smoothly finished appearance. <P>SOLUTION: The surface of a woody core material such as plywood, MDF, or a particle board is subjected to surface treatment, and a decorative thermoplastic resin sheet is adhered to the treated surface through a resin liquid containing a curable resin as a main component. In the surface treatment, a primer is applied, or paper is stuck. An unsaturated polyester resin, acrylic resin, vinyl ester resin, epoxy resin, urethane resin, silicone resin, or the like is used as the curable resin. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a decorative board in which a decorative sheet made of a thermoplastic resin is bonded to the outermost surface of a wood-based core material.

Conventionally, as a panel used for a floor or wall of a residential building, a cosmetic material in which a decorative sheet made of olefin resin, PET, or the like is bonded to the surface of a plywood, MDF, particle board or the like is known. When adhering, since it cannot adhere under heating conditions, it is common to cold press using an ethylene vinyl acetate resin adhesive or a polyurethane adhesive.
JP 2000-155991 A JP 2001-260109 A JP-A-9-187802

  However, depending on the pressure of the cold press, the formation of the base may appear on the surface. In addition, since water-based adhesive contains moisture, it shrinks when dried, and there is a problem that significant irregularities appear on the surface.When using polyurethane-based adhesive, it is necessary to shut off air as an adhesive application device, The workability was poor, bubbles were likely to accumulate in the adhesive layer, and the surface appearance after bonding appeared slight irregularities, which was expensive in terms of cost.

  The present invention has been studied in view of such a situation, and a decorative board comprising a thermoplastic resin decorative sheet bonded to the surface of a wooden core material via a curable resin, and the wooden core The invention is based on a decorative board characterized in that the surface of the material is ground-treated.

  By adhering decorative paper to the wood core and adhering the thermoplastic resin sheet with room temperature curable resin, it does not contain bubbles, and the appearance of the thermoplastic resin decorative sheet is clean and smooth with a deep mirror surface. A decorative board having a certain finished appearance is obtained. Moreover, no large equipment such as a press device is required. Hereinafter, the present invention will be described in detail.

  Examples of the wood-based core material that can be applied in the present invention include plywood, LDF (low density fiber board), MDF, HDF (high density fiber board), particle board, laminated material, strand board, LVL, and the like. Although it is not, it is preferable that the surface is smooth.

  Examples of the adhesive include epoxy resins, unsaturated polyester resins, urea-formaldehyde resins, urea-melamine-formaldehyde resins, curable resins such as melamine-phenol-formaldehyde resins, styrene-butadiene resin latex, polyacryl emulsion, Emulsion adhesives such as a polyvinyl acetate emulsion, an ethylene-vinyl acetate resin emulsion, and a butadiene-nitrile resin emulsion may be mentioned, and they may be applied by a flow coater, a roll coater, a brush or the like. There are no particular restrictions on the application method.

  The base treatment is performed as necessary to improve smoothness and prevent the infiltration of the resin liquid. The methods for the base treatment include primer application, paper application with Japanese paper, Western paper, decorative paper, etc. A sheet of resin-impregnated paper, impregnated with curable resin or thermoplastic resin, polyvinylidene chloride, polyethylene, aluminum-deposited polyethylene terephthalate, silica-deposited polyethylene terephthalate as a core layer on the front and back, fine paper, kraft paper, Japanese paper, Examples include paper pasting with moisture-proof paper in which paper such as thin paper is laminated, and in particular, a three-layer structure in which both sides of a primer coating and an inexpensive polyethylene sheet are sandwiched with kraft paper is preferable.

  For decorative paper, thin paper, titanium paper, mixed paper with synthetic resin mixed to enhance interlayer strength, linter paper, etc. as a base paper, printed with plain or arbitrary pattern, printed with monochromatic solid printing Etc. Among these, thin-leaf decorative paper having a thin paper thickness, hardly containing air therein, and high uniformity in paper density is preferable.

  The curable resin applied to the surface of paper such as decorative paper is, for example, an unsaturated polyester resin, an acrylic resin, a vinyl ester resin, an epoxy resin, a urethane resin, a silicone resin, and a resin liquid composed of a combination of these resins. Is mentioned. Among them, it is preferable to use an unsaturated polyester resin, an acrylic resin, or a vinyl ester resin that is quickly cured at room temperature.

  Unsaturated polyester resin, for example, by adding a reactive monomer such as styrene to unsaturated polyester made from dibasic acids such as maleic anhydride and phthalic anhydride and dihydric alcohols such as ethylene glycol and propylene glycol. Can be applied.

  The acrylic resin is made of a polymer of acrylic acid, methacrylic acid or a derivative thereof, and examples thereof include acrylic acid esters such as methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, methacrylic acid. Examples thereof include a polymer mainly composed of a methacrylic acid ester such as butyl acid.

  Vinyl ester resins, also called epoxy acrylate resins, are generally polymerizable by a ring-opening reaction between a compound having a glycidyl group (epoxy group) and a carboxyl group of a carboxyl compound having a polymerizable unsaturated bond such as acrylic acid. A compound obtained by adding a reactive monomer such as styrene to a vinyl ester which is a compound having an unsaturated bond can be used.

  The epoxy resin is composed of a compound having two or more hydroxyl groups, a glycidyl ether type compound synthesized from epichlorohydrin or methyl epichlorohydrin, a compound having two or more carboxyl groups or an acid anhydride thereof, and epichlorohydrin or methyl epichlorohydrin. A synthesized glycidyl ester type compound can be applied.

  The polyurethane resin is a copolymer obtained by reacting a polyisocyanate and a polyol. As the isocyanate component, aromatic diisocyanate, aliphatic diisocyanate, and alicyclic diisocyanate are used. For example, tolylene 2,4-diisocyanate, 4 4,4'-diphenylmethane diisocyanate, 1,6-hexane diisocyanate, 1,4-cyclohexane diisocyanate, and the like. As the polyol component, polyether polyol and polyester polyol are used, and examples of the polyether polyol include polyethylene glycol, polypropylene glycol, and polytetramethylene glycol.

  Silicone resin is mainly composed of methylhydrogenpolysiloxane, dimethylorganosilanol, methylpolysiloxane and alkoxysilane, and catalysts such as dibutyltin dilaurate and fatty acid organic metal salts such as zinc octoate and toluene, benzene, tetrahydrofuran and methylethyl. Those dissolved in an organic solvent such as Kenton can be used.

  The viscosity of the curable resin is preferably about 0.2 to 1.5 Pa · s. If the lower limit is not reached, the adhesion tends to be inferior, and if the upper limit is exceeded, uneven coating tends to occur.

The coating amount is preferably 100 to 400 g / m ² in terms of solid content, and if it is less than the lower limit, the adhesion with the thermoplastic resin decorative sheet tends to be inferior, and slight irregularities are likely to appear on the surface. , Warping easily occurs.

  Examples of the resin used for the outermost thermoplastic resin decorative sheet include low density polyethylene (including linear low density polyethylene), medium density polyethylene, high density polyethylene, ethylene α-olefin copolymer, homopolypropylene, polymethylpentene, Olefin-based thermoplastic resins such as polybutene, ethylene-propylene copolymer, propylene-butene copolymer, ethylene-vinyl acetate copolymer, saponified ethylene-vinyl acetate copolymer, or mixtures thereof, polyethylene terephthalate, Thermoplastic ester resins such as polybutylene terephthalate, polyethylene naphthalate, polyethylene naphthalate-isophthalate copolymer, polycarbonate, polyarylate, polymethyl methacrylate, polyethyl methacrylate, polyacryl Acrylic thermoplastic resins such as ethyl and polybutyl acrylate, polyamide thermoplastic resins such as nylon-6 and nylon-66, or polyimide, polyurethane, polystyrene, acrylonitrile-butadiene-styrene resin, etc. These thermoplastic resins may be used alone or as a mixture of two or more.

  If necessary, a corona discharge treatment or a plasma discharge treatment, or a primer may be applied to the back surface of the thermoplastic resin decorative sheet, and an ionizing radiation curable resin that is cured by an electron beam, ultraviolet rays, or the like is applied to the surface. It may be cured to improve wear resistance, kill resistance, and the like. Examples of the material for forming the primer layer include polyester resin, polyurethane resin, acrylic resin, polycarbonate resin, vinyl chloride / vinyl acetate copolymer, polyvinyl butyral resin, and nitrocellulose resin.

  When bonding the thermoplastic resin decorative sheet, first, apply a resin liquid mainly composed of a room temperature curable resin to the surface of the decorative paper, place the thermoplastic resin decorative sheet, and extend the resin liquid with a roll. . Repeat this several times to remove bubbles and leave at room temperature.

  In the present invention, a moisture-proof layer may be formed on the back surface of the wood-based core material in order to prevent warping and improve the moisture-proof effect. For the moisture-proof layer, polyethylene, polypropylene, polyvinyl chloride, Synthetic resin sheets such as polyvinylidene chloride, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polytetrafluoroethylene, metal foil such as aluminum and stainless steel, resin-impregnated paper impregnated with phenol resin, melamine resin, etc., resin-impregnated cloth, etc. A material with low humidity is suitable. Alternatively, a moisture-proofing agent such as paraffin wax or urethane sealer may be applied. Examples of the application method include spraying with a spray and application with a roll coater.

  The present invention will be specifically described below by showing examples and comparative examples. In addition, this invention is not limited only to the following Example.

A 40 g / m ² thin paper was bonded to the surface of a 3 mm thick MDF using a vinyl acetate adhesive. Next, after applying a resin solution (viscosity 0.8 Pa · s / 25 ° C.) having the following composition to the surface of the thin paper with a flow coater at a solid content conversion value of 200 g / m ² , the coated surface is UV-curable. Covered with a polypyropylene-based resin sheet with a cured layer formed of resin and coated with a two-component urethane primer on the back side, spread the resin solution uniformly from the surface with a rubber roller, remove bubbles, and let stand for 2 hours, The decorative board of Example 1 was obtained.
70 parts by weight of unsaturated polyester resin blended with resin liquid (including monomer and curing accelerator. Aika Resin HR-200, manufactured by Aika Industry Co., Ltd.)
Curing agent (methyl ethyl ketone peroxide) 1 part by weight polymerization inhibitor (t-butylcatechol) 200 ppm

  In Example 1, it carried out similarly except having adhered the moisture-proof paper of thickness 0.12mm which sandwiched both sides of the polyethylene sheet with the kraft paper as a moisture-proof layer on the back of MDF, and obtained the decorative board of Example 3 .

Comparative Example 1
A 40 g / m ² thin paper was bonded to the surface of a 3 mm thick MDF using a vinyl acetate adhesive. Next, an ethylene-vinyl acetate emulsion was applied to the surface of the thin paper, and the same polypyropylene-based resin sheet as in Example 1 was laminated and molded by a cold press to obtain a cosmetic material.

Comparative Example 2
A moisture curable polyurethane resin was applied to the surface of a 3 mm thick MDF, and the surface was coated with a polypyropylene resin sheet having a cured layer formed of an ultraviolet curable resin on the surface and a two-component urethane primer applied to the back surface.

Comparative Example 3
In Example 1, it implemented similarly except having apply | coated 80 g / m < ² > by solid content conversion value.

Comparative Example 4
In Example 1, it implemented similarly except having apply | coated 450 g / m < ² > by the solid content conversion value.

The evaluation results are shown in Table 1.

The evaluation method was as follows.
Appearance: Visually confirmed from a distance of 30 cm, a smooth surface was indicated by ◎, a surface having slight unevenness was indicated by ○, and a surface having clear unevenness was indicated by ×.
Maximum height roughness (Rz): Measured according to JIS B 0601: 2001 with a surface roughness measuring instrument (TOKYO SEIMITSU SURFACE TEXTURE MEASURING INSTRUMENT model F_ST_852B). The lower the value, the smoother and the lower substrate unevenness appear.
Warpage: The product was laid flat in a room at 40 ° C.-30% RH for 7 days, and the heights at which the four corners were lifted were measured. A value of 0.5 or more and less than 3 mm was marked with ◎, a value of 3 or more and less than 6 mm was marked with ○, and a value of 6 mm or more and 10 mm was marked with ×.
Adhesiveness: Adhesiveness was evaluated by a cross cut test according to JIS K5400.
Specifically, make 100 grids of 1 mm square on the surface, paste cellophane tape on it, peel it off at an angle of 90 degrees, count the remaining grids, and mark 95/100 to 100/100 ○ Less than 95/100 was set as x.

1 is a cross-sectional configuration diagram of a decorative board of Example 1. FIG. FIG. 5 is a structural cross-sectional view of a decorative board of Example 2.

Explanation of symbols

1 Polypropylene-based resin sheet 2 Unsaturated polyester resin layer 3 Thin paper 6 Moisture-proof layer 8 Adhesive layer 9 MDF
20 Decorative board 21 Decorative board

Claims (5)

A decorative board comprising a thermoplastic resin decorative sheet bonded to a surface of a wooden core material through a curable resin. 2. The decorative board according to claim 1, wherein the curable resin is an unsaturated polyester resin or an acrylic resin. The decorative board according to claim 1 or 2, wherein the surface of the wood-based core material is subjected to a ground treatment. 4. The decorative board according to claim 3, wherein the base treatment is performed by paper pasting. 5. The decorative board according to claim 1, wherein a moisture-proof layer is formed on the back surface of the wooden core material.