JP2009023244A - Metal decorative plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative plate having superior melamine resin property while maintaining metallic gloss and design. <P>SOLUTION: On a core substrate, a resin-applied metal foil is laminated to the reverse face of which a polyvinylacetal resin is applied and to the surface of which a melamine resin is applied. A sheet substrate is laminated on the surface thereof and thermocompression-integrated. After molding the sheet substrate is removed therefrom. The used melamine resin is a resin consisting of a water-soluble melamine resin and a polyvinylacetal resin. The core substrate uses MDF or resin impregnated core paper. Silane coupling agent is preferably added to adhesive to improve adhesion between the metal foil and the core substrate. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a metal decorative board using a metal foil.

A decorative board having a metal foil attached to its surface is known for a long time, and is widely used for housing equipment and interior materials because of its high design. In this decorative board, a surface coated with a metal foil such as an aluminum foil or a copper foil is used as a surface layer, and a resin impregnated paper obtained by impregnating a kraft paper with a phenol resin is used as a core layer. In addition, a metal-like melamine decorative board using a paper made by impregnating a melamine resin with a paper-like paper subjected to metal-like printing is known as a metal-like decorative material.
JP-A-2-116544 Japanese Patent Laid-Open No. 62-5846

  However, in the case of a decorative sheet with a metal foil attached to the surface, it is a coated metal foil, so scratches are easily attached in applications such as a top panel, and it has sufficient physical properties to withstand use in horizontal plane applications. There wasn't. In addition, in the case of a metal-like melamine decorative board, the excellent physical properties of melamine have enough physical properties to withstand horizontal surfaces such as a top board, but it has gloss, texture, depth compared to a decorative board using real metal foil. The design property was inferior in such aspects.

  The present invention has been studied in view of such a situation, and a core base material is laminated with a resin-coated metal foil coated with a polyvinyl acetal resin on the back surface and a melamine-based resin on the surface, and the surface is sheet-like. The metal decorative board is characterized in that it is coated with a base material and the sheet-like base material is removed after hot pressing.

  Resin is applied to the front and back of the metal foil, the surface is coated with a sheet-like base material, hot-pressed, and the sheet-like base material is removed after molding to maintain the gloss and design of the metal, and the melamine resin is excellent A decorative board having excellent physical properties can be obtained. Moreover, since no resin-impregnated overlay paper is used, the sharpness is improved.

  Hereinafter, the present invention will be described in detail. Examples of the core material according to the present invention include MDF and resin-impregnated core paper. As the core paper, a fibrous base material, for example, unbleached kraft paper, bleached kraft paper, etc., linter paper, woven fabric made of inorganic fibers such as glass fiber, rock wool, carbon fiber, non-woven fabric, polyethylene, polypropylene, Is it an organic fiber made of vinylon, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyamide, polyester, polyurethane, etc. or their modified products and various copolymers represented by ethylene-vinyl acetate copolymer, etc. Furthermore, composite fibers made of these polymers can be mentioned.

  Examples of the thermosetting resin include phenol resin, amino-formaldehyde resin, unsaturated polyester resin, epoxy resin, diallyl phthalate resin, or a mixture thereof. In particular, a phenol resin excellent in impact resistance, strength, and heat resistance is preferable. The impregnation rate may be set to 30 to 100% by the calculation method represented by Equation 1.

  Phenol resins are obtained by reacting phenols and aldehydes at a ratio of 1 to 3 moles of aldehydes with 1 mole of phenolic hydroxyl group under a basic catalyst or an acidic catalyst. Phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, bisphenol F and the like. Examples of aldehydes include formaldehyde, paraformaldehyde, glyoxal, trioxal and the like.

  In addition, those modified with a modifier that promotes plasticization such as paratoluene sulfonamide, tung oil, phosphoric esters, glycols, etc. can be applied as necessary. And oxides and hydroxides of alkaline earth metals such as magnesium and calcium, amines such as triethylamine and triethanolamine, and ammonia. Examples of acidic catalysts include paratoluenesulfonic acid and hydrochloric acid.

  The metal foil according to the present invention has a thickness of about 10 to 50 μm, and may be uneven by using a coloring process, an embossing mold, or an embossing roll. Examples of the irregularities include a grained shape or a satin-like shape, and a hairline finish. Examples of the metal foil include gold foil, silver foil, copper foil, zinc foil, indium foil, aluminum foil, and stainless steel foil. If the thickness is thin, it is easy to break during handling, and if it is thick, the finished product tends to warp. In particular, aluminum foil is preferable from the viewpoint of easy handling, moisture-proof effect, and glossy color that can be visually recognized in a metallic style.

  An adhesive is applied to the surface of the metal foil in contact with the core substrate in order to improve the adhesion between the core substrate and the metal foil. The type of the adhesive is not particularly limited, but it is preferable to use an adhesive having excellent heat resistance. For example, epoxy, phenol, chloroprene rubber, polyvinyl acetal, modified polyvinyl acetal, silicone, polyimide, Examples include polybenzimidazole adhesives. In particular, when a phenol resin-impregnated core paper is used, the adhesiveness is good when a modified polyvinyl acetal adhesive, specifically, a phenol-butyral adhesive is used.

  As a sheet-like base material, a plastic film and metal foil are mainly mentioned. As plastic film, polyester film, polyethylene film, polypropylene film, cellophane, diacetyl cellulose film, triacetyl cellulose film, acetyl cellulose butyrate film, polyvinyl chloride film, polyvinylidene chloride film, polyvinyl alcohol film, ethylene vinyl alcohol film, Coating using a polystyrene film, a polycarbonate film, a polymethylpentene film, a polysulfone film, a polyether ketone film, a polyether sulfone film, a polyetherimide film, a polyimide film, a fluororesin film, a nylon film, an acrylic film, or the like can be performed. As the metal foil, those described above can be applied. Furthermore, the base material may be a glossy type or a matte type with a change in gloss, or may be embossed.

  Melamine resins include amino compounds such as melamine, urea, benzoguanamine, acetoguanamine, etc., initial condensates, etherification with lower alcohols such as methyl alcohol and butyl alcohol, and paratoluenesulfonamide. Those modified with a reactive modifier that promotes plasticization can be applied, and among them, those adopting melamine and formaldehyde are preferable because of excellent durability.

  In the present invention, a melamine resin in which a polyvinyl acetal resin is blended with the melamine resin is used as the resin applied to the surface in contact with the metal foil sheet substrate. The polyvinyl acetal resin can be obtained by a condensation reaction of polyvinyl alcohol and an aldehyde and acetalization. Examples of the aldehyde include formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, amylaldehyde, hexylaldehyde, heptylaldehyde, 2-ethylhexylaldehyde, cyclohexylaldehyde, benzaldehyde, 2-methylbenzaldehyde, 3-methylbenzaldehyde, 4-methylbenzaldehyde, p -Hydroxybenzaldehyde, m-hydroxybenzaldehyde, phenylacetaldehyde, etc. are mentioned, These aldehydes are used individually or in combination of 2 or more types. When a polyvinyl acetal resin using an aromatic aldehyde such as benzaldehyde is used, the water resistance is good and preferable.

  Examples of commercially available products include: ESREC BM-1, BM-2, BM-5, BX-1, BX-2, BX-5, BL-10, BL-1, BX- L, KS-1, KS-3, KS-5, KS-10, KX-1, KX-5 (above Sekisui Chemical Co., Ltd. product name), Denkabutyral # 5000D, 6000C, There are 6000EP (named above, product name of Electrochemical Industry Co., Ltd.). These may be used alone or in combination.

  The blending ratio of the melamine resin and the polyvinyl acetal resin is preferably 1: 0.1 to 0.8 in terms of solid content, and if the lower limit is not reached, the leveling to the film is not good and the adhesion to the metal foil is poor. On the other hand, if the upper limit is exceeded, the excellent properties of the melamine resin, specifically, wear resistance, heat resistance, impact resistance, etc., tend to be inferior.

  Furthermore, in order to improve the adhesion between the metal foil and the core substrate, it is preferable to add a silane coupling agent to the adhesive, and among the various silane coupling agents, the epoxy silane coupling agent is particularly preferable from the viewpoint of adhesion. Specifically, β- (3,4-epoxycyclohexyl) ethyltrimethoxysilane, γ-glycidyloxypropyltrimethoxysilane, γ-glycidyloxypropylmethyldiethoxysilane, glycidoxypropyltrimethoxysilane and the like are preferable. Can be mentioned. The addition amount is preferably 0.5 to 10 parts by weight with respect to 100 parts by weight of the solid content of the melamine resin.

  When applying the melamine resin to the substrate, a known method such as spray coating, gravure coating, bar coating, knife coating, roll coating, blade coating, die coating, curtain coating, reverse coating, comma coating, etc. is used. be able to.

  The metal decorative board of the present invention is formed by laminating a core base material with a resin-coated metal foil coated with a polyvinyl acetal resin on the back surface and a melamine resin on the surface, and a sheet-like base material on the surface. After laminating, it can be obtained by integrating with heat and pressure using a heat and pressure press and removing the sheet-like substrate after molding. The hot pressing conditions may be a heating temperature of 110 to 180 ° C. and a pressing condition of 5 to 10 MPa.

Preparation of phenol resin impregnated paper Resol type phenol resin with a molar ratio of formaldehyde to phenol of 1.3 is reacted with sodium hydroxide catalyst, and methanol is added to obtain an unmodified phenol resin solution with a resin content of 50% by weight. Obtained, and then impregnated with a phenol-impregnated resin liquid so that the impregnation ratio shown in Equation 1 is 50% on a kraft paper having a basis weight of 200 g / m ² and dried to prepare a phenol resin-impregnated paper.

Production of resin-coated aluminum foil On the back side of a hard aluminum foil having a thickness of 40 μm, a phenol-butyral resin (butyral resin, Denka Butyral # 5000-D, trade name, manufactured by Denki Kagaku Kogyo Co., Ltd.) having a solid content of 10% is applied. The weight after drying was 5 g / m ² . Next, a polyvinyl acetal resin (ESREC K "KX-5" Sekisui Chemical Co., Ltd.) obtained by using a water-soluble melamine-formaldehyde resin part and benzaldehyde on the surface side is blended in a solid content ratio of 1: 0.6. The resin solution obtained by adding 1 part by weight of glycidoxypropyltrimethoxysilane (SH-6040: manufactured by Toray Dow Corning Co., Ltd.) to 100 parts by weight of the resin solid content is applied to the melamine resin and dried. The latter weight was obtained to be 10 g / m ² .

Manufacture of metal decorative board In order from the bottom, 5 sheets of phenol resin-impregnated paper, 1 sheet of resin-coated aluminum foil, and 1 sheet of matte polypropylene film with a thickness of 25 μm were laminated as a sheet-like base material. Hot pressure molding was performed under conditions of a pressure of 6 MPa and a time of 60 minutes, and the film was peeled off to obtain a metal decorative board of Example 1.

  In Example 1, it implemented similarly except having used the embossed polypropylene film as a sheet-like base material.

  In Example 1, it implemented similarly except having used 40-micrometer-thick copper foil for metal foil.

Comparative Example 1
In Example 1, it implemented similarly except having set the compounding ratio of the melamine resin and the polyvinyl acetal resin to 1: 0.01.

Comparative Example 2
In Example 1, it implemented similarly except having set the mixture ratio of melamine resin and polyvinyl acetal resin to 1: 1.

  The evaluation results are shown in Table 1.

The evaluation method was as follows.
Adhesiveness (surface side): Cut the cut layer with a cutter knife (100 mm in 2 mm x 2 mm) into the decorative layer until it reaches the aluminum foil, affix the cellophane tape, remove it rapidly, and check for the presence of peeling And the remaining squares were counted.
Scratch property: Place a commercially available ordinary gold sardine with a load of 1 kg on the surface of the decorative material,
The gold sardine was moved back and forth 15 times on the surface of the decorative plate and scratched. A scratch test was made on the surface of the decorative plate.

1 is an exploded configuration cross-sectional view of a metal decorative board of Example 1. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Sheet-like base material 2 Melamine resin 3 Phenol-butyral resin 4 Metal foil 5 Metal foil coated with resin 6 Phenol resin impregnated core paper 9 Metal decorative board

Claims (2)

The core base material is coated with a resin-coated metal foil coated with a polyvinyl acetal resin on the back surface, and coated with a melamine resin on the surface, and the surface is further coated with a sheet-shaped base material. A metal decorative board, wherein the substrate is removed. 2. The metal decorative board according to claim 1, wherein the melamine resin comprises a water-soluble melamine resin and a polyvinyl acetal resin.