JP2804441B2 - Metal core decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a melamine resin metal core decorative board used for interior parts of vehicles and the like,
The present invention relates to a metal core decorative plate used for applications involving bending with the decorative surface facing outward (hereinafter referred to as “outer bending”), which was impossible in the past.

[0002]

2. Description of the Related Art In addition to excellent heat resistance, a melamine resin metal core decorative board has been used for railway vehicles as an interior material that has a surface property of the melamine decorative board and a high mechanical strength characteristic by being combined with a metal plate. Used in

[0003] A conventional melamine metal decorative board usually comprises a surface layer 1, a melamine resin decorative layer 2, a shielding layer 3, a phenol resin core material layer 4 and a metal plate 5, as shown in FIG. 1. The surface layer 1 is made of thin translucent paper impregnated with melamine resin impregnated and dried, and becomes transparent after molding, and is required to have good abrasion resistance. Melamine resin decorative layer 2
Is impregnated paper obtained by impregnating and drying a predetermined amount of melamine resin on printed decorative paper or pigmented paper. The phenol resin core material layer 4 is an impregnated paper obtained by impregnating a kraft paper with a phenol resin and drying. Between the decorative melamine resin layer 2 and the phenolic resin core layer 4, a shielding layer 3 made of a paper impregnated with a phenolic resin or a melamine resin and impregnated with a phenolic resin or a melamine resin is usually provided. As the metal plate 6, an aluminum plate is generally used, but a rust-proof iron plate is also used. If these impregnated papers and metal plates are set and heated and pressed by a conventional method, a melamine decorative metal plate can be obtained.
The thickness of the layer excluding the metal plate is in the range of 0.5 to 0.7 mm. In the case of a thin melamine decorative board made by thinning this, it is about 0.3 mm.

As described above, the conventional decorative melamine metal plate has a resin layer only on one side, and is composed of only a phenol resin layer and a melamine resin layer. In such a configuration, when performing curved surface processing (inward bending) with the decorative surface inside, processing of 50 mmR in the horizontal direction and 75 mmR in the vertical direction is the limit, and curved surface processing with the decorative surface outside (outward bending) Was virtually impossible.

On the other hand, as for the interior of a railway vehicle, a melamine resin decorative plate is abutted to a corner portion and stopped with an aluminum presser. However, there is a demand in the market for integrating the same. However, since the conventional single-sided metal decorative board cannot be bent outward, it cannot be applied to the above-mentioned applications.

[0006]

As described above, the conventional metal core decorative plate cannot be bent outwardly, but the metal core decorative plate of the present invention allows this outward bending.

[0007]

SUMMARY OF THE INVENTION The present invention provides a paper base material in which one side of a metal plate is impregnated with a thermosetting resin and has a heat deformation temperature of 60%.
With respect to a metal core decorative board, characterized in that a thermoplastic film and a melamine resin-impregnated paper base material at a temperature of about 120 ° C. to 120 ° C. are sequentially laminated and formed by heating and pressing, more preferably, on one side of the metal plate, Paper base material impregnated with thermosetting resin,
A thermoplastic film having a heat deformation temperature of 60 ° C. to 120 ° C., a paper base material impregnated with a thermosetting resin, and a melamine resin impregnated paper base material are sequentially laminated and molded by heating and pressing. Metal core decorative board.

[0008] That is, at least one thermosetting resin-impregnated paper base material for bonding is laminated on a metal plate, and the heat deformation temperature is 6
After laminating a thermoplastic film of 0 to 120 ° C., laminating a thermosetting resin-impregnated paper substrate, and finally laminating a melamine resin-impregnated paper substrate, and heating and pressing to form a metal capable of outer bending A core decorative plate is obtained.

FIG. 2 is a schematic cross-sectional view of a metal core single-sided decorative plate of the present invention, in which a thermosetting resin-impregnated paper base material 10 is laminated on one side of a metal plate 11 and a thermoplastic film 9 is further laminated. A melamine resin-impregnated paper base material (decorative layer) 7 is superposed on this, and if necessary, a thin melamine resin-impregnated paper base material (surface layer) 6 is superposed, and the whole is integrated by heat and pressure molding. Preferably, the adhesiveness between the thermoplastic film and the melamine resin-impregnated paper substrate is improved by inserting the thermosetting resin-impregnated paper substrate 8 between the thermoplastic film 9 and the melamine resin-impregnated paper substrate 7. be able to. In the present invention, the metal plate 10 is not particularly limited, but is preferably an aluminum plate because it is lightweight and hardly generates rust. Its thickness is usually 0.8-1.6
mm. This surface is usually roughened for better adhesion.

A thermosetting resin-impregnated paper substrate 9 to be superimposed on one side of a metal plate 10 acts as an adhesive between the metal plate and the thermoplastic film 8, and is used for a commonly used paper substrate such as kraft paper. Impregnated with a thermosetting resin and dried.
The thermosetting resin is preferably a phenol resin and / or an epoxy resin having good adhesion to a metal plate and excellent in impregnating the paper base material. Usually, a phenol resin or a mixture of a phenol resin and an epoxy resin is used to make the decorative board nonflammable. A phenol resin is preferably used because a water-soluble phenol resin is particularly excellent in impregnation into a paper substrate. The paper substrate is not particularly limited as long as such a thermosetting resin varnish is well impregnated.
0 g / m ² kraft paper is used. In order to further improve the nonflammability of the decorative board, preferably the basis weight is 30 to 40 g.
/ M ² kraft paper can be used, but the cost increases. When a plurality of thermosetting resin-impregnated paper base materials 9 are used, a plasticizer can be added to the phenol resin to improve the bending workability. The outermost layer of the thermosetting resin-impregnated paper substrate 9 may be a shielding layer composed of a shielding-impregnated paper substrate in which a phenol resin or a melamine resin is impregnated into a paper substrate into which a pigment has been incorporated.

In the present invention, the thermoplastic film 8 laminated for imparting the outer bending process is a polyester sheet, an AS sheet, an ABS sheet, a polycarbonate sheet, or the like. An ABS resin sheet is preferable as the film having good adhesiveness with the curable resin-impregnated paper substrate. The thickness of the film is usually 100 to 250 μm, but when it is thicker than 150 μm, there is a high possibility that a problem occurs in water resistance due to moisture absorption from the end face of the film. Therefore, the film thickness is preferably 100 to 150 μm. If it is less than 100 μm, it is difficult to obtain a sufficiently small curvature in outer bending.

The melamine resin impregnated in the melamine resin-impregnated paper substrate 7 may be one used for a normal melamine resin decorative plate, but is preferably of a flexible type when bent with a small curvature. In order to obtain a flexible melamine resin, modification with p-toluenesulfonamide, guanamines, gliogizole, etc., modification or mixing with a thermoplastic resin such as polyacrylonitrile, polymethyl acrylate, polyvinyl butyral, polyamide, etc., formaldehyde to melamine And a decrease in the molar ratio.

In order to eliminate the surface layer 6 of the decorative board, it is preferable to incorporate alumina in the melamine resin varnish from the viewpoint of improving abrasion resistance. The amount of alumina is suitably 2 to 5% by weight based on the resin solid content in the melamine resin varnish.

[0014]

【Example】

Example 1 One surface of an aluminum plate having a thickness of 1.0 mm was roughened by sanding. Basis weight 3 on sanding surface
One impregnated paper (A) having a resin content of 70% obtained by impregnating and drying a water-soluble phenol resin on 0 g / m ² kraft paper was overlaid, and an ABS sheet having a thickness of 150 μm was overlaid thereon. Next, a phenol resin-impregnated paper base material (B) with a resin content of 35% on a kraft paper having a basis weight of 195 g / m ² and a melamine resin on a decorative paper having a basis weight of 120 g / m ² were prepared. A decorative layer having a resin content of 50% obtained by impregnation and drying, and a surface layer having a resin content of 50% obtained by impregnating and drying the melamine resin on a kraft paper having a basis weight of 30 g / m ² were sequentially superimposed on each other.
It was heated and pressed under the conditions of 100 ° C. and 100 kg / cm ² to obtain a 1.6 mm-thick aluminum core melamine resin decorative board (FIG. 2).

Example 2 An aluminum core melamine resin decorative board having a thickness of 1.5 mm was obtained in the same manner as in Example 1 except that the impregnated paper base material (B) was not used. .

Example 3 In Example 1, the point that the impregnated paper base material (A) and the impregnated paper base material (B) between the ABS sheet and the decorative layer were not used, and the resin content of the decorative layer was 60 % In the same manner as in Example 1 except that the thickness was 1.45 m
m aluminum core melamine resin decorative board was obtained.

Comparative Example 1 One piece of impregnated paper (C) having a resin content of 50% obtained by impregnating a kraft paper having a basis weight of 190 g / m ^{2 with} a water-soluble phenol resin and drying the same aluminum plate as in the above example. The phenol resin-impregnated paper base material (B) was overlaid thereon, and a decorative layer of 50% resin content obtained by impregnating and drying a melamine resin on decorative paper of 120 g / m ² and a basis weight of 3
0 g / m ² kraft paper was immersed in a melamine resin and dried to obtain a 50% resin surface layer.
Heat-press molding under the condition of 100 kg / cm ² , thickness 1.
A 6 mm aluminum core melamine resin single-sided decorative board was obtained (FIG. 1).

<< Comparative Example 2 >> AB in Example 1
Using a polycarbonate sheet (thickness 0.25 mm) having a heat deformation temperature of 140 ° C. instead of the S sheet,
It was heated and pressed under the conditions of ² ° C. and 100 kg / c to obtain a 1.6 mm-thick aluminum core melamine resin decorative board.

<< Comparative Example 3 >> AB in Example 1
A polyester sheet (thickness: 0.2 mm) having a heat deformation temperature of 60 ° C. was used in place of the S sheet.
It was heated and pressed under the conditions of kg / cm ² to obtain a 1.5 mm thick aluminum melamine resin decorative board.

The obtained decorative boards were evaluated for bending workability (flexibility) and appearance under heating and pressing. The results shown in Table 1 were obtained. Note that a white part number was applied to the surface layer.

[0021]

[Table 1]

The bending conditions are as follows.
After heating at 40 ° C. for 40 seconds, external bending was performed, and the minimum radius of curvature that did not cause cracks in the decorative surface was determined.

[0023]

The metal core decorative board of the present invention enables the outer bending work which was impossible with the conventional metal core decorative board. Therefore, since the corner portion of the vehicle interior can be processed with one decorative board, it is useful as a vehicle interior material in the future.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a conventional metal core decorative plate.

FIG. 2 is a schematic cross-sectional view of an example of a decorative metal core plate of the present invention.

[Explanation of symbols]

 Reference Signs List 1 surface layer 2 melamine resin decorative layer 3 shielding layer 4 phenol resin core material layer 5 metal plate 6 melamine resin impregnated paper substrate (surface layer) 7 melamine resin impregnated paper substrate (decorative layer) 8 thermosetting resin impregnated paper base Material 9 Thermoplastic film 10 Thermosetting resin-impregnated paper base material 11 Metal plate

Claims (2)

(57) [Claims] 1. A paper base material impregnated with a thermosetting resin, a thermoplastic film having a heat deformation temperature of 60 ° C. to 120 ° C., and a melamine resin impregnated paper base material are sequentially laminated on one surface of a metal plate and heated. A metal core decorative plate that can be bent without the decorative surface, characterized by being pressed. 2. A paper substrate impregnated with a thermosetting resin on one side of a metal plate, a thermoplastic film having a heat deformation temperature of 60 ° C. to 120 ° C., a paper substrate impregnated with a thermosetting resin, and melamine. A decorative metal core decorative board which is formed by sequentially laminating resin-impregnated paper bases and molding by heating and pressurizing.