JP3049695B2 - Manufacturing method of thermosetting resin 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 method for producing a thermosetting resin decorative board and a shaping sheet used in the method. More specifically, this invention has a matte surface,
The present invention relates to a method for producing a thermosetting resin decorative plate having a smooth velvet-like or suede-like texture, and a shaping sheet used in the production method.

[0002]

2. Description of the Related Art Thermosetting resin decorative boards such as melamine resin decorative boards and diallyl phthalate resin decorative boards are used for architectural interior materials such as walls and ceilings, furniture such as desks, tables, cabinets, and kitchen stands. I have. In order to enhance the design effect of such a thermosetting resin decorative board, fine irregularities have been formed on the surface by various methods.

[0003] For example, when a thermosetting resin is heated and pressurized to be cured in the production of a thermosetting resin decorative board,
There has been known a method of using, as a template, a metal concavo-convex plate having a fine concavo-convex shape formed on the surface by a process such as etching, sand blasting, engraving, or the like, or a resin concavo-convex plate replicated from these metal concavo-convex plates.

[0004]

However, in the conventional method as described above, fine irregularities on the surface of a metal irregular plate or the like as a template are formed by etching, sandblasting, engraving or the like. The shape was limited to a sharp shape with an acute angle and could not be a smooth uneven shape.
Therefore, the surface of the thermosetting resin decorative plate formed with such a metal uneven plate as a template also has a sharp uneven shape with an acute angle as shown in FIG. 4, and has a smooth uneven shape as shown in FIG. Could not be. Therefore, the thermosetting resin decorative board cannot be made to have a smooth finger feel,
In addition, there is a problem that the design cannot have a velvet-like or suede-like texture.

[0005] Further, when a plate-shaped template such as a metal uneven plate or a resin uneven plate is used, the structure of the apparatus becomes complicated when a thermosetting resin decorative plate is continuously manufactured, and the mold plate is formed during hot press molding. However, there is a problem that the frequency of the damage is increased.

[0006] Further, since the metal uneven plate itself is very expensive, the production cost of the thermosetting resin decorative plate has been significantly increased. In addition, it is necessary to prepare a spare metal uneven plate in preparation for the damage of the metal uneven plate as described above, which has further increased the manufacturing cost of the thermosetting resin decorative plate.

In addition, since the resin uneven plate generally has poor releasability with respect to the thermosetting resin-impregnated sheet for transferring its surface shape, the separation between the resin uneven plate and the resin-impregnated sheet has good releasability. It was necessary to interpose a mold sheet or metal foil. For this reason, the manufacturing process of thermosetting resin decorative board increases,
Also, the configuration of the manufacturing apparatus has become more complicated.

SUMMARY OF THE INVENTION The present invention is to solve the above-mentioned problems of the prior art, and is intended to provide a thermosetting resin decorative board having a smooth finger touch and a velvet-like or suede-like texture. It is intended to be able to be manufactured at low cost.

[0009]

The above object has been achieved by the present invention described below. That is, the present invention, as a shaping sheet used as a template for the production of a thermosetting resin decorative board, a base sheet, and a coating layer having a smooth and fine irregular shape on the surface, the coating layer,
Disclosed is a shaped sheet for producing a thermosetting resin decorative board, comprising a resin bead, a silicone resin, and a resin binder.

[0010] Further, as a method for producing a thermosetting resin decorative board using such a shaping sheet, (a) the shaping sheet according to claim 1 and a thermosetting resin impregnated sheet are used. Placing the coating layer so as to sandwich it;
(B) The thermosetting resin is cured by heating and pressurizing the shaping sheet and the thermosetting resin-impregnated sheet integrally, and the surface shape of the shaping sheet is transferred to the surface of the thermosetting resin-impregnated sheet. And (c) peeling off the shaped sheet from the cured product of step (b). The method for producing a thermosetting resin decorative plate having a matte surface, smooth and fine irregularities. provide.

According to the method for producing a decorative thermosetting resin plate of the present invention, when forming fine irregularities on the surface of the thermosetting resin decorative plate, a sheet-like decorative plate can be formed without using a conventional plate-like template. The shaping sheet is used, and the shaping sheet is formed by coating a base sheet with a coating composed of resin beads having a smooth shape such as a sphere or a rugby ball, a silicone resin and a resin binder. It is characterized by using.

Hereinafter, the present invention will be described in detail with reference to the drawings. Note that, in each drawing, the same number indicates the same or equivalent component.

FIG. 1 is a sectional view of a shaping sheet 3 according to the present invention. The shaping sheet 3 includes a base sheet 1 and a coating layer 2 formed on the base sheet 1.

The coating layer 2 is formed by coating the base sheet 1 with a paint composed of spherical resin beads, silicone resin and a resin binder.

By using the spherical resin beads as the coating material for forming the coating layer 2 as described above, it is possible to impart a matte smooth and fine irregular shape to the surface of the coating layer 2 based on the spherical shape of the beads. Becomes possible. In this case, the particle size of the beads can be appropriately determined according to a desired design to be provided to the thermosetting resin decorative board,
Generally, the thickness is preferably 20 to 70 μm.

Further, as such spherical resin beads, those formed from, for example, an acrylic resin, a polyethylene resin, a rubber resin or the like can be used.
By using a resin-made bead as described above, it is possible to improve the coating property of a paint to which the bead is added. Further, since the coating layer 2 can be given elasticity, it is possible to prevent breakage of a layer placed above or below the shaping sheet 3 when the shaping sheet 3 is heated and pressed as a template. Becomes possible. On the other hand, if glass or metal beads are used, the coating properties are reduced, and the layer placed above or below the shaping sheet 3 is more likely to be damaged when heated and pressed.

In the present invention, the coating material for forming the coating layer 2 is obtained by adding a silicone resin in addition to the spherical resin beads. In this case, the addition amount of the silicone resin is generally preferably 0.3 to 5 parts by weight based on the paint. Thereby, the shaping sheet 3 can be easily separated from the thermosetting resin after the heat and pressure molding.

As the resin binder used for the paint,
For example, a polyurethane-based or acrylic-based resin binder can be used. As such a resin binder, those commercially available as a matting paint can also be used. For example, a brand name “RAVI” manufactured by Ohashi Chemical Co., Ltd. and a brand name “Bell” manufactured by NOF Corporation Soft ", trade name" Velbex "manufactured by Fujikura Kasei Co., Ltd. and the like can be used.

In addition, the paint contains a solvent for dispersing the above-mentioned spherical resin beads, silicone resin and resin binder, and may further contain various additives as necessary.

The amount of the coating material for forming the coating layer 2 to be applied to the base sheet 1 needs to be sufficient to fix the spherical resin beads to the base sheet 1, and is generally applied after drying. Is preferably 10 g / m ² or more. As a coating method, a comma coater, a reverse roll coater, a curtain flow coater or the like may be used in accordance with a conventional method.

As the base sheet 1, a sheet (film) material which has excellent smoothness and which can withstand the heat and pressure molding of a thermosetting resin decorative board is used. As such a sheet material, a resin film such as a polyester film, an acrylic film, or a polypropylene film, or a composite sheet of these and paper can be used. Above all, a polyester film is excellent in heat resistance and can withstand heat and pressure molding of a thermosetting resin decorative board, so that it can be preferably used. The thickness of the base sheet 1 is preferably 25 to 125 μm in consideration of its mechanical strength and the like.

FIG. 2 is an explanatory view in the case of manufacturing a thermosetting resin decorative board using the shaping sheet 3 of the present invention shown in FIG.

As shown in the figure, in the method for manufacturing a decorative board according to the present invention, a thermosetting resin is made of paper or cloth according to a conventional method except that the shaping sheet 3 of the present invention is used as a template. What is necessary is just to use a thermosetting resin-impregnated sheet impregnated with the resin and heat-press it. That is, as a thermosetting impregnated sheet between the upper and lower heating plates 10, the heat-resistant cushion sheet 9, the metal plate 8 such as a mirror surface plate, etc. Core paper 6, which mainly determines the thickness of the decorative board, colored titanium paper or titanium paper on which a pattern is printed, impregnated with a thermosetting resin 5, and overlay paper 4 are sequentially laminated, and the imprint sheet of the present invention is further laminated. 3 is placed on the overlay paper 4 so as to sandwich the coating layer 2. Here, generally, the backer paper 7 has a basis weight of about 55 to 160 g / m.
Melamine resin-impregnated paper obtained by impregnating about 40 to 100% by weight of melamine resin into the titanium paper of No. ² and drying is preferably used. The core paper 6 has a basis weight of about 140 to 180 g.
/ M ² paper, impregnated with 30 to 100 wt% of phenolic resin, it can be used after drying, it is preferred to use overlapping about 4-8 sheets of this. As the colored titanium paper or the patterned titanium paper 5 impregnated with the thermosetting resin,
Melamine resin-impregnated titanium paper impregnated with 40 to 100% by weight of melamine resin and dried is preferably used. Overlay paper 4, the rayon pulp or nonwoven fabric having a basis weight of about 25 to 45 g / ^{m 2,} impregnated with 40-300 wt% of a melamine resin, a transparent resin impregnated paper drying can be preferably used.

As the thermosetting resin used for the decorative board of the present invention, in addition to such melamine resin and phenol resin, those including those requiring heat and pressure for molding such as diallyl phthalate resin may be used. Well-known resins can be widely used.

Next, the thermosetting resin-impregnated papers 4 to 7 thus laminated and the shaping sheet 3 are integrally heated and pressed. The heating and pressing conditions depend on the thermosetting resin used, but in the case of a melamine resin, the maximum temperature is about 140 to 15.
0 ° C., pressure about 60-100 kg / cm ² , about 15-30
Heat and pressure mold for minutes. Then, the thermosetting resin-impregnated papers 4 to 7 are integrally cured by cooling with cold water for about 15 to 60 minutes while pressurizing.

Next, when the shaping sheet 3 is peeled off from the decorative board, a thermosetting resin decorative board 11 shown in FIG. 3 is obtained.
The surface of the decorative sheet 11 has a matte shape, smooth and fine irregularities are transferred to the decorative sheet 11, so that the surface of the decorative sheet 11 has a smooth finger feel,
It has a velvet-like or suede-like texture.

[0027]

In the shaping sheet of the present invention, since the smooth resin beads are fixed in the coating layer on the base sheet, the surface thereof has a matte, smooth and fine uneven shape.

Therefore, when the shaping sheet of the present invention is used as a template in the production of a thermosetting resin decorative board by heating and press molding, the surface of the thermosetting resin decorative board can be smoothened. Since the fine uneven shape is transferred, the thermosetting resin decorative board has a smooth finger touch and has a velvet-like or suede-like texture.

Further, since a silicone resin is added to the coating layer on the surface of the shaped sheet of the present invention,
The releasability of the thermosetting resin decorative board after such heat-press molding and the shaping sheet is good.

Furthermore, the imprinting sheet of the present invention is made of a sheet material, and does not require an expensive metal template.
The apparatus configuration for manufacturing a decorative board is simplified, and a thermosetting resin decorative board can be manufactured at low cost.

[0031]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to embodiments. Example 1 A silicone resin was added to a resin composition (Bellsoft (trade name), manufactured by NOF CORPORATION) containing a urethane-based transparent resin, a spherical bead made of a urethane-based resin having a particle size of 20 to 70 μm, and a diluent. A coating material was prepared by adding 0.5 part to all of them. Using a comma coater, this paint
The thickness is 50 so that the coating amount after drying is 40 g / m ^2.
It was applied to a μm polyester film to produce a shaped sheet. The surface of the imprinted sheet had a matte, smooth, fine irregular shape.

Next, as shown in FIG. 2, a basis weight of 100 is sequentially placed from the bottom between the upper and lower hot plates, the heat-resistant cushion sheet, and the mirror surface plate.
g / m ² titanium paper impregnated with 80% by weight of melamine resin, backer paper impregnated with 150 g / m ² paper with 60% by weight of phenolic resin, and four core papers impregnated with 80% by weight.
melamine resin impregnated titanium paper impregnated with 80% by weight of melamine resin in g / m ² grained titanium paper and a basis weight of 25
g / ^{m 2} rayon pulp melamine resin 300 wt%
The impregnated overlay paper was laminated, and the above-mentioned shaped sheet was further laminated thereon. The laminate was heated and pressed at a maximum temperature of 145 ° C. and a pressure of 80 kg / cm ² for 30 minutes. Then, while pressurizing, 40
After cooling for one minute, the pressure was released, and the shaped sheet was peeled off to produce a melamine resin decorative board.

The obtained melamine resin decorative board has a matte, smooth, fine uneven shape on the surface,
It had a velvet-like or suede-like texture, and had a smooth finger feel.

[0034]

According to the present invention, a thermosetting resin decorative board having a smooth finger feel and a velvet-like or suede-like texture can be easily manufactured at low cost.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a shaping sheet of the present invention.

FIG. 2 is an explanatory view of a method for producing a thermosetting resin decorative board according to the present invention.

FIG. 3 is a cross-sectional view of a thermosetting resin decorative board obtained by the method for producing a thermosetting resin decorative board of the present invention.

FIG. 4 is a cross-sectional view of a conventional thermosetting resin decorative board.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base sheet 2 Coating layer 3 Forming sheet 11 Thermosetting resin decorative board

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification code FI B44C 1/165 B44C 1/165 F

Claims (2)

(57) [Claims] 1. A thermosetting resin comprising a base sheet and a coating layer having a smooth and fine irregular shape on the surface, wherein the coating layer contains resin beads, a silicone resin and a resin binder. Shaped sheet for decorative board production. 2. (a) placing the shaped sheet according to claim 1 and a thermosetting resin-impregnated sheet so as to sandwich a coating layer of the shaped sheet; (b) the shaping sheet and thermosetting Curing the thermosetting resin by integrally heating and pressing the thermosetting resin-impregnated sheet, and transferring the surface shape of the shaping sheet to the surface of the thermosetting resin-impregnated sheet; and (c) the shaping A method for producing a thermosetting resin decorative board having a matte surface, smooth and fine irregularities, including a step of peeling a sheet from a cured product in step (b).