JP2838128B2 - Decorative sheet - Google Patents

Description

The present invention relates to a decorative sheet. What is called a decorative board is roughly divided into a surface material and a base material. As the base material, there are various materials such as wood materials such as plywood and board, gypsum board, asbestos board, cement board and steel plate. The surface material includes veneer overlay processing, plastic overlay processing, other overlay processing, painting processing, and the like. The plastic overlay processing includes a resin sheet overlay, a resin film overlay, and a resin coat overlay processing, and the present invention relates to a resin sheet overlay.

At present, the method of thermosetting resin sheet overlay processing is to immerse the synthetic resin liquid in the impregnated base paper, then volatilize the solvent by drying to make the impregnated paper, coat it on the surface of the base material, apply heat and pressure by hot press, and cure the resin. The formation of the surface coating and the adhesion to the substrate are performed simultaneously. Melamine resin, diallyl phthalate resin, unsaturated polyester resin and the like are used as the resin. The impregnation ratio of the resin to the impregnated base paper is determined, and the solvent evaporates to become porous.The air between the hot platen and the impregnated paper during hot press molding escapes from the perforations of the impregnated paper to the outside, causing air to collect. It is done in a way that does not come out. (If the impregnation rate is too high and it is not porous, it will accumulate and it will not become a decorative board.) With this method, air is released from the pores and the paper and resin are integrated with wood pulp. Yes, it requires considerable pressure to integrate because it is composed of entanglements. Currently 100kg / c with melamine decorative board
m ² , a diallyl phthalate resin requires a pressure of about 30 kg / cm ² . Further, in the impregnated paper, a hardening agent is almost polymerized, but if the amount of the hardening agent used is small, the hardening time is long and the productivity is very poor. On the other hand, if the amount used is large, the usable time during storage of the impregnated paper at room temperature is shortened, which makes inventory adjustment and export difficult.

The present invention solves the conventional drawbacks and has a long pot life during storage and cures very quickly during hot-press molding.In addition, without using impregnated paper that requires pressure during conventional molding, it is similarly porous at low pressure. It is a sheet for decorative board that can be molded at low pressure by excluding air.

The present invention will be described with reference to the drawings. FIG. 1 shows a state before hot pressing, wherein reference numeral 1 denotes a powder of a water-insoluble and hot-melt type curing agent, reference numeral 2 denotes a powder of a water-insoluble uncured thermosetting resin, and reference numeral 3 denotes an uncured resin. An emulsified product of the thermosetting resin in water, reference numeral 4 denotes shredded fibers, and reference numeral 5 denotes a filler, to which water is added and mixed, and before drying (when wet), the mixture is used as a release paper 7 , 8 to form a mixed resin sheet 16 by sinking the very open non-woven fabric 9 into the mixture, forming a core, and drying.
Use peeled from 7,8. This sheet requires considerable pressure to integrate the impregnated resin with the entangled wood pipe fiber as in the conventional hot-press molding with impregnated paper. Since a resin that melts and flows well due to heat is interposed therebetween, the whole is easily integrated at a low pressure when the temperature of the resin is melted. Also, in the action of releasing air to the outside with a porous material, voids are formed between the particles because the thermosetting resin 2 is a powder, and the air can similarly escape to the outside at the time of hot pressing from the voids so that there is no accumulation of air. The plate can be molded with low pressure.

Also, during the molding time, during storage, the curing agent is a solid powder that is insoluble in water, and the resin is also a solid powder that is insoluble in water,
Also, the resin becomes a solid resin when water is removed, so it is not dissolved with the hardener, so it is stable and has a long pot life, and it melts well when heat is applied once it is molded. If you do, the curing will be very fast. Conventional hot-press molding using impregnated paper requires considerable pressure, which is a drawback.For example, when using plywood, if there is a tunnel on the base plate, it cannot be used at high pressure and the choice of base material is limited. According to the present invention, a low pressure is sufficient and the selection of the base material is wide, and according to the present invention, the hot press molding time can be short, so that the number of presses per hour is greatly increased and the production quantity is increased. The cost of the press is very low.

 1 shows an embodiment of the present invention.

Example (1) In FIG. 1, a suspension 1 having a mean particle size of 10 μm was obtained by using a three-roll mill with a hardener powder 1 of 75% benzol peroxide solid powder and 25% water, using a surfactant. Produced by making in water.

The water-insoluble uncured thermosetting resin powder 2 has a melting point of 75
A solid unsaturated polyester resin having a melting point of 106.degree. C. and a solid monomer having a melting point of 106.degree. C. are melted at 120.degree.

The uncured thermosetting resin emulsion 3 is obtained by dissolving the same resin and monomer in toluene and emulsifying in water using an emulsifier to form an emulsion having an average particle diameter of 1 micron.

Reference numeral 4 is a broken glass fiber having a diameter of 10 microns and a length of 300 microns.

Reference numeral 5 denotes a filler, which is calcium carbonate having an average particle size of 30 microns. Reference numeral 6 denotes an inorganic color pigment.

As shown in FIG. 2, a release paper 7 obtained by laminating a resin mixture obtained by twisting and mixing all of the above in water at a rate of 200 g / m ² and a polypropylene film 7 and a 23 g / m ² printing base paper 8 with a urethane adhesive. , 8 are coated on the film 7 side, open polyester non-woven fabric 9 (of 20 g / m ² ) is placed from above and is immersed in the mixture 16 to form a core material, and the resin mixture is dried. A mixed resin sheet 16 is formed.
After pressing for 40 seconds at a temperature of 120 ° C and a pressure of 5 kg / cm ² for 40 seconds using a 2 mm thick stainless steel plate with a wood grain pattern on the surface, peel off the release paper 7 and 8 to make a single color decorative board with wood grain pattern Was completed.

Example (2) 20 g / m ^{2 of} a mixture obtained by laminating a pigment 6 and calcium carbonate 5 from the resin mixture of Example (1) onto a film 7 on which a printing base paper 8 is bonded 20 g / m ²
And dried to form an overlay sheet 12.

Further, the composition of Example (1) is coated on the surface of a film (release paper) 7 at a rate of 100 g / m ² , and the open polyester non-woven fabric 9 is sunk into the resin mixture from above and the core material is removed. The film was dried and peeled off from the film 7 to form an adhesive sheet 13.

In FIG. 3, the adhesive sheet 13 is placed on the plywood 10, and the grain-printed 23 g / m ² printed paper 14 is placed thereon, and the overlay sheet 12 is placed thereon so that the resin surface is in contact with the grain print side. , Hang a 2 mil thick wood-plated stainless steel plate on a hot press
After hot-press molding at 120 ° C. and a pressure of 5 kg / cm ² for 40 seconds, the sheet was taken out of the press machine and the release papers 7 and 8 were peeled off to obtain a decorative board having a wood-grain pattern with wood grain patterns.

As shown in the examples, the conventional pressure (melamine decorative board 80 ~
(120kg / cm ² , dup decorative board 30kg / cm ² ) If you need a uniform base material that can withstand the pressure, you can also use a plywood with some tunnel because of low pressure. , Molding temperature is the same (150 ℃ of melamine decorative board)
Lower than about 170 ° C, about 140 ° C to 150 ° C for diallyl phthalate decorative board), and the molding time is 1 hour to 1.5 hours for melamine decorative board and 10 to 20 minutes for diallyl phthalate decorative board. What was required is only about 40 seconds, and it can be processed under significantly better molding conditions than before.

Therefore, when a decorative sheet is manufactured using the decorative sheet according to the present invention, the productivity is greatly improved and a thermosetting decorative sheet with low cost can be obtained.

[Brief description of the drawings]

FIG. 1 is an enlarged sectional view of the present invention, FIG. 2 is a configuration diagram of an embodiment (1), and FIG. 3 is a configuration diagram of an embodiment (2). 1 .... powder of a water-insoluble and hot-melt type curing agent, 2
... water-insoluble uncured thermosetting resin powder, 3 ... uncured thermosetting resin emulsion, 4 ... shredded fiber, 5 ...
Filler, 6 ... Pigment, 7 ... Film, 8 ... Paper, 9 ...
… Coarse nonwoven fabric, 12… Mixed resin sheet for overlay, 13… Mixed resin sheet for bonding, 16… Mixed resin sheet

Claims (8)

(57) [Claims] A release paper (7,8) and a mixed resin sheet (12,13,16) coated on the release paper (7,8), wherein the sheets (12,13,16) Is a method in which water is added to a mixed material containing a water-insoluble and hot-melt type curing agent powder (1) and a water-insoluble uncured thermosetting resin powder (2) and mixed to form a release paper. (7,8) A decorative sheet formed by coating on and drying. 2. The decorative sheet according to claim 1, wherein the mixed material constituting the mixed resin sheet contains cut fibers (4). 3. An uncured thermosetting resin emulsion (3) is contained in the mixed material constituting the mixed resin sheet (12, 13, 16). The decorative sheet according to claim 1. 4. The decorative sheet according to claim 1, wherein the mixed non-woven fabric is embedded in the mixed resin sheet. . 5. The decorative sheet according to any one of claims 1 to 4, wherein the mixed resin sheet is used for overlay. 6. The mixed material constituting the mixed resin sheet (13, 16) contains a pigment.
The decorative sheet according to any one of the above. 7. The decorative sheet according to any one of claims 1 to 4, wherein the mixed resin sheet is used for bonding. 8. The mixed resin constituting the mixed resin sheet (13, 16) contains calcium carbonate.
The sheet for decorative board according to any one of (1) to (4).