JP2915950B2 - Manufacturing method of thermosetting resin decorative board - Google Patents

Description

Description: FIELD OF THE INVENTION The present invention relates to a method for producing a decorative board having an embossed surface, and more particularly, to a thermosetting resin decorative article having fine embossing, particularly precision lines. The present invention relates to an improvement in a method for manufacturing a plate.

[Conventional technology]

Conventionally, the production of a thermosetting resin decorative board having an embossed surface is performed by bringing a shaped film or the like having irregularities corresponding to the embossment of a desired pattern into contact with the surface of the thermosetting resin-impregnated paper and applying a hot press. This was done by molding.

[Problems to be solved by the invention]

However, the conventional method has a disadvantage that the gloss of the emboss is reduced particularly when the irregularities on the surface of the shaped film are formed on the thermoplastic resin layer. In order to avoid this drawback, a method has been proposed in which a thermosetting resin-impregnated paper and a shaped film are sandwiched between a thermosetting resin-impregnated paper and a shaped film at the time of hot-press molding to give a gloss to the embossing of the decorative board. However, in the case of a decorative board with fine embossing, especially precision lines, irregularities are easily crushed during hot press molding, the sharpness of the emboss is insufficient, and the gloss changes due to parallax. An effective manufacturing method capable of sufficiently exhibiting the effects has not yet been embodied.

In view of the necessity of a manufacturing method capable of forming a fine embossed line such as a precision line on the surface of a thermosetting resin decorative board in a glossy and sharp state, the present inventors have conducted intensive studies and as a result, The invention has been completed.

[Means for solving the problem]

The present invention has been made to solve the above problems, and by using a thermoplastic resin film having specific properties between a thermosetting resin-impregnated paper and a shaping film or an embossing plate, Compared to those obtained by the method of
The present invention relates to a manufacturing method that enables fine embossing with an extremely excellent appearance.

More specifically, the present invention relates to a thermosetting resin-impregnated paper, together with a base material to be laminated, if necessary, when hot-pressed at a temperature Tp sandwiched between hot plates. Then, the thermal deformation temperature Tt (JIS-K-7202, depending on 4.6kg load)
Lower than Tp and surface gloss after hot pressing (JIS-Z-874
1. A thermoplastic resin film with a 75 ° mirror gloss of 30 to 100.

 Shaped film or embossed plate.

And forming a fine emboss on the surface by releasing the thermoplastic resin film together with a shaping film or an embossing plate after hot-press molding together. About.

 Hereinafter, the present invention will be described in detail with reference to the drawings.

In general, a thermosetting resin decorative board is a core paper in which decorative base paper impregnated with a thermosetting resin is laminated together as necessary.
It is manufactured by being sandwiched between upper and lower hot plates together with an overlay paper, a base material, and the like, and then molded by heating and pressing.
Examples of the thermosetting resin include a melamine resin, a diallyl phthalate resin, a guanamine resin, a polyester resin, and a phenol resin. As the thermosetting resin decorative plate of the present invention, a melamine decorative plate and a diallyl phthalate decorative plate are preferable from the viewpoint of a design effect. Then, the thermosetting resin decorative plate in the present invention uses various presses such as a flat plate embossing machine or an embossing machine (however, a roll embossing machine is not included) at the time of the above-mentioned hot pressing, and forms a shaped film or an embossing plate together. Fine embossing is formed on the surface of the sandwiched thermosetting resin-impregnated paper.

The fine embossing to which the method according to the present invention is applied is, as a drawn shape having an interval of unevenness of about 1 to 100 μm, a line-shaped grain, a conduit groove of a wood grain, or the like. It is particularly effective in exhibiting the design effect of the above.

As shown in FIG. 1, a precision line is a set of patterns consisting of a group of irregularities or grooves forming parallel straight lines or curves and a closed boundary line surrounding the group. The direction of the group of parallel straight lines or curves of adjacent patterns is different, the depth and spacing of the lines are 0.1-100 μm, and the difference in direction of the adjacent lines through the boundary line makes the gloss difference clear Therefore, the angle is preferably 5 ° or more. The pattern of this tumor has a characteristic feature in that the gloss of each closed region changes depending on parallax. In order to make the directions of adjacent line groups all different, it is necessary and sufficient condition that there are four or more types of direction differences from the theorem of the four-color problem of the topology.

An important component in the method of the present invention, the thermoplastic resin film used between the surface of the thermosetting resin-impregnated paper and the imprinted film, on the other hand, the unevenness of the imprinted film surface is a thermosetting resin It is necessary to easily deform by the heat at the time of hot pressing so as not to impede the formation of the desired emboss by biting into the thermosetting resin on the surface of the impregnated paper,
On the other hand, the surface of the embossed thermosetting resin layer to be formed must have a gloss that can withstand hot pressing in order to provide gloss.

That is, the thermoplastic resin film used in the present invention is a thermoplastic polyester generally used in the market, polyformaldehyde, polytetrafluoroethylene, polyethylene, polypropylene, polybutadiene,
Polycarbonate, polyamide, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyvinyl acetal, polyacryl, polystyrene, polyvinyl acetate, etc., a film or sheet of resin alone or a thermoplastic film containing several types of these resins Among them, the heat deformation temperature Tt of JIS-K-7202 with a load of 4.6 kg / cm ² is lower than the temperature Tp during hot pressing (Tt <Tp), and the surface gloss after hot pressing (JIS- Z-8741, 75 ° specular gloss) 30-100
Are selected and used.

When the thermal deformation temperature Tt is Tt ≧ Tp, the thermoplastic resin film does not sufficiently follow the shape of the shaped film at the time of hot pressing, and the sharpness of the embossed shape cannot be obtained. If the gloss is not in the above range, the gloss of the fine emboss of the product is reduced, and the design effect peculiar to the precision line, particularly the change in gloss due to parallax, cannot be sufficiently exhibited.

 The heat deformation temperature Tt is preferably Tt ≦ Tp−40 ° C.

The temperature Tp at the time of hot pressing is usually 130 to 150 ° C. Specifically, the type of the thermoplastic resin having the irregularities on the surface of the shaped film and the heat of the thermosetting resin decorative plate to be shaped are specifically described. It depends on the type of the curable resin.

The thickness of the thermoplastic resin film is preferably 12 to 25 μm
It is. If it is too thick, embossing is difficult, and if it is too thin, workability is difficult.

As the thermoplastic resin film used in the present invention, a uniaxially stretched polypropylene film or a biaxially stretched polypropylene film is preferable from the viewpoint of forming a fine emboss and forming temperature. The heat deformation temperature Tt of the uniaxially stretched polypropylene film and the biaxially stretched polypropylene film is preferably 90 to 110 ° C., and when the temperature Tp during hot pressing is 130 ° C., the glossiness after hot pressing (JIS-Z -8741, 7
5 ° specular gloss) is 30 to 100, and the thickness is 16 to 20 μm.

These stretched polypropylene films are, for example, generally commercially available uniaxially stretched polypropylene films and biaxially stretched polypropylene films, and have been subjected to a desired matting process as required.

The shaping film used in the method of the present invention is for a thermosetting resin decorative board, and is a resin sheet of a polyolefin-based or ethylene-vinyl alcohol copolymer having thermoplasticity on a base sheet that is strong in heat pressure or tension. The layers are laminated to form a sheet, and the resin layer of the polyolefin or ethylene vinyl alcohol copolymer is provided with an embossed pattern.

Since the base sheet is used for a thermosetting resin decorative board, the polyolefin or ethylene vinyl alcohol copolymer resin is used to prevent deformation of the resin layer of the polyolefin or ethylene vinyl alcohol copolymer due to heat and pressure. Plastic sheets with high heat distortion temperature, such as polyethylene terephthalate, polyimide, polyacrylate, polyetheretherketone, triacetylcellulose, etc., art paper, coated paper, glassine paper, parchment paper, etc. Paper with high smoothness can be used. The thickness is 3 ~ 250μ
m is preferable, and more preferably 12 to 100 μm.

Particularly, in the case of paper, a paint having releasability (including silicone, wax, fluorine-based resin, etc.) may be applied to a thermosetting resin decorative plate or the like to be processed.

As the polyolefin-based resin layer, polymethylpentene, polypropylene, polyethylene, or the like can be used. The thickness of the resin layer is set according to the depth of the emboss to be processed.

Further, as a method of laminating the base sheet and a polyolefin-based resin layer, commonly used dry lamination, wet lamination, extrusion coating of a polyolefin-based resin, so-called doubling in which heat and pressure are simultaneously fused and hot-pressed. Embossing or the like can be used.

Further, as an embossing method applied to the polyolefin resin side of the shaped film formed by lamination, a known embossing method can be used. That is, a hot-press embossing method using a flat plate or a roll plate, a method for transferring irregularities on a cooling roll used at the time of extrusion coating, a method for casting a molten resin, and the like can be used.

The embossing plate used in the method of the present invention has a plate surface uneven shape with fine embossment, the interval between the unevenness is 1 to 100 μm, the depth of the unevenness is about 10 to 100 μm, and the shape is a hairline, a line, a grain, Wood grain conduit and the like.

Hereinafter, the present invention will be described more specifically with reference to Examples, but the present invention is not limited thereto.

〔Example〕

As shown in FIG. 2, a, dry lamination of coated paper 1 (manufactured by Sanyo Kokusaku Pulp Co., Ltd., SK coated paper; 73.3 g / m ² ) with OPP2 (manufactured by Nimura Chemical Co., Ltd., FOR-20; 20 μm) And PP
A precision line was formed on the surface to produce a shaped film 3. Here, OPP represents biaxially oriented polypropylene.

Next, a balance sheet 8, a core paper 7, a melamine resin-impregnated titanium paper 6 (black, 80 g / m ² manufactured by Kojin Co., Ltd.), an overlay paper 5 impregnated with melamine resin (manufactured by Daifuku Paper Co., Ltd.),
A CPP film 4 (manufactured by Nimura Chemical Co., Ltd., FHK-20; 20 μm) having a glossiness (JIS-Z-8741, 75 ° specular gloss 97.5) and the above-described shaped film 3 are sequentially stacked, and a hot-press machine is used. Used, 13
After performing hot pressing under the conditions of 0 ° C and 100kg for 20 minutes,
As shown in FIG. 2B, the CPP film 4 was released together with the shaping film 3 to produce a melamine decorative board 9 containing a precision line emboss. However, CPP represents glossy uniaxially oriented polypropylene.

The glossiness (JIS-Z-8741, 75 ° specular gloss) of the released CPP film was 35.

The obtained thermosetting resin decorative board had a three-dimensional appearance on the embossed surface, sharply changed the gloss by parallax, and was excellent in design as a precision line.

In addition, the gloss of the embossed surface is
The gloss was the same as that of the CPP film.

〔The invention's effect〕

As is clear from the above, according to the present invention, by using a thermoplastic resin film having specific properties between the thermosetting resin-impregnated paper and the shaped film, etc., the unevenness of the shaped film is faithfully reproduced. In addition, the surface gloss can reflect the glossiness of the thermoplastic resin film surface, and is not affected by the gloss of the imprinted film. It is possible to provide a method for producing an excellent thermosetting resin decorative board.

[Brief description of the drawings]

Fig. 1, a is an enlarged view of a precision line, and Figs.
FIG. 2 is a cross-sectional view taken along the line A ′, and FIG. 2 is a schematic cross-sectional view showing steps of the method of the present invention. DESCRIPTION OF SYMBOLS 1 ... Coated paper, 2 ... OPP 3 ... Forming film, 4 ... Polypropylene film 5 ... Melamine resin impregnated overlay paper 6 ... Melamine resin impregnated titanium paper, 7 ... Core paper 8 ... Balance sheet, 9 ... Melamine decorative board

Claims (5)

(57) [Claims] 1. A thermosetting resin-impregnated paper, together with a base material to be laminated as necessary, is sandwiched between hot plates and hot-pressed at a temperature Tp. Deformation temperature Tt (JIS-K-7202, under 4.6kg / cm ² load) is lower than Tp, and surface gloss after hot pressing (JI
SZ-8741, a thermoplastic resin film with a 75 ° specular gloss of 30 to 100. Shaped film or embossed plate. And forming a fine emboss on the surface by releasing the thermoplastic resin film together with a shaping film or an embossing plate after hot-press molding together. . 2. The heat according to claim 1, wherein irregularities corresponding to a desired fine emboss pattern of the shaping film or the embossing plate are provided on the thermoplastic resin layer on the surface of the shaping film or the embossing plate. A method for producing a curable resin decorative board. 3. The method for producing a thermosetting resin decorative board according to claim 1, wherein the fine emboss is a precision line. 4. A thermoplastic resin film comprising a polyester,
One or more selected from polyformaldehyde, polytetrafluoroethylene, polyethylene, polypropylene, polybutadiene, polycarbonate, polyamide, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyvinyl acetal, polyacryl, polystyrene, polyvinyl acetate The method for producing a thermosetting resin decorative plate according to any one of claims 1 to 3, wherein the resin film is a resin film. 5. The method for producing a decorative thermosetting resin sheet according to claim 1, wherein the thermoplastic resin film is a stretched polypropylene film.