JP3057863B2 - Thermosetting decorative sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermosetting decorative sheet coated with a melamine resin and a method for manufacturing a decorative board using the decorative sheet.

[0002]

2. Description of the Related Art A melamine resin decorative board has excellent properties such as abrasion resistance, heat resistance, and water resistance.
It is widely used for horizontal surfaces such as counter tops, furniture materials such as storage furniture and cabinets, kitchen stands and the like.

By the way, the conventional melamine resin decorative board is
Backer paper and kraft paper impregnated with about 40 to 100% by weight of melamine resin in titanium paper and dried in 30 to 100%
Core paper impregnated with phenolic resin by weight and dried, decorative paper impregnated with 100-150% by weight of melamine resin on patterned titanium paper, and 40-300% by weight in rayon pulp or nonwoven fabric It is manufactured by sequentially laminating transparent overlay paper impregnated with melamine resin and dried, and then hot-pressing and curing the hot-cold method. The cured melamine resin decorative board is secondarily bonded to a board such as plywood or particle board, and is used for desks, horizontal surfaces such as countertops, furniture such as storage furniture and cabinets, kitchen stands, and the like. I have.

[0004]

However, since the conventional melamine resin decorative board is cured before being bonded to a substrate such as a particle board, it cannot be wound on a reel, and is not only stored and transported. It is necessary to perform single-sheet bonding also when bonding to a substrate, which is not suitable for mass production and has a problem that it is difficult to reduce production cost.

[0005] The present invention is to solve the above-mentioned problems of the prior art, in which a thermosetting decorative sheet which is cured to become a melamine resin decorative board is wound around a reel and can be stored and transported. Moreover, it is possible to produce a decorative board having a low cost and an inter-sheet strength not inferior to that of a conventional product by being able to be continuously performed instead of a sheet-fed type when bonding with a substrate such as a plywood or a particle board. It is intended to be.

[0006]

SUMMARY OF THE INVENTION The present inventor has set forth the above object by coating a printing paper with a melamine resin without impregnating the printing paper with the melamine resin, drying the coating paper so as not to block, and winding it on a reel. It has been found that the present invention can be achieved, and the present invention has been completed.

That is, the present invention provides a thermosetting decorative sheet in which a base paper, a sealer coat layer, a solid layer, a pattern layer and a melamine resin coat layer are sequentially laminated.

[0008] The present invention also provides a method for manufacturing a decorative board, characterized in that the thermosetting decorative sheet is bonded to a substrate via an adhesive and heated and pressed. In this case, it is preferable that the thermosetting decorative sheet be wound around a reel and continuously bonded to the substrate.

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 shows a thermosetting decorative sheet 1 according to the present invention.
0 shows a cross-sectional view. The decorative sheet 10 has a configuration in which a base paper 1, a sealer coat layer 2, a solid layer 3, a pattern layer 4, and a melamine resin coat layer 5 are sequentially formed.

It is important that the decorative sheet 10 can be entirely wound on a reel. Therefore, it is necessary to form a melamine resin coat layer 5 by coating the melamine resin, and to dry the melamine resin coat layer 5 without completely curing it while maintaining a certain degree of flexibility and not blocking. For this purpose, it varies depending on the type of melamine resin used, the layer thickness, etc., but is generally 90 to 120 ° C.
And dry for 120-240 seconds.

The melamine resin used for the melamine resin coating layer 5 can be appropriately selected from those conventionally used in thermosetting decorative boards. A so-called short cycle melamine resin which is hardened at the same time and which does not require cooling while being pressurized and which is compatible with a hot-hot method is preferable because it is suitable for mass production and the production cost can be reduced.

Further, regarding the amount of melamine resin to be applied, when impregnating a conventional base paper, the base paper is impregnated with 100 to 1%.
In contrast to the use of 50% by weight, this invention uses 100%.
%, Preferably 60 to 110% by weight.
If used excessively, it becomes too thick and hard to dry, so that it is difficult to take up on a reel.

The base paper 1 used in the present invention is a base material of the decorative sheet 10 of the present invention, and can be appropriately selected from those conventionally used in thermosetting decorative boards. For example, titanium paper containing a polyolefin-based resin having a basis weight of 30 to 50 g / m ² to improve inter-sheet strength is more preferable.

The sealer coat layer 2 is for improving the strength between base papers. For such a sealer coat layer 2, a synthetic resin such as a urethane resin or a melamine resin can be used. Generally, these resins are 5-1
Coated with 5 g (dry) / ^{m 2.}

The solid layer 3 is provided to conceal the underlying base paper 1 and the sealer coat layer 2 and to make the pattern layer 4 stand out clearly. Such a solid layer 3 can be formed by using an ink conventionally used in manufacturing a thermosetting decorative board, and preferably, an opaque ink is used.

The pattern layer 4 is provided to enhance the design of the decorative sheet, and can be formed by using an ink which has been conventionally used for producing a thermosetting decorative plate. The ink used may be transparent or opaque.

The decorative sheet 10 of the present invention can be manufactured according to a conventional method. For example, first, a base paper 1 is coated with a urethane resin or the like dissolved in an organic solvent using, for example, a roll coater and dried to form a sealer coat layer 2, on which a solid layer 3 and a pattern layer 4 are formed by gravure printing or the like. Provide. Further, a melamine resin for short cycle is applied thereon with a bar coater or the like, and dried to form a melamine resin coat layer 5, whereby the melamine resin can be manufactured.

FIG. 2 shows a thermosetting decorative sheet 1 of the present invention.
FIG. 2 is a diagram illustrating a preferred line mode for manufacturing a decorative board having a cured melamine resin layer on the surface by bonding No. 0 to a substrate such as a particle board.

In FIG. 1, first, a substrate 21 such as a particle board is put into a production line, and first, a surface stain is removed by a brush 22.

Next, an adhesive is applied to the particle board 21 by an adhesive applicator 24 to which an adhesive 23 such as a two-component urethane adhesive is supplied to form an adhesive layer 25.

Next, the thermosetting decorative sheet 10 of the present invention is laminated on the adhesive layer 25 such that the short cycle melamine resin coat layer is on the upper surface. At this time, the thermosetting decorative sheet 10 of the present invention is wound on a reel 26, and the substrate 21 is continuously bonded while preheating by a roller 27 and applying a desired tension.

Then, the melamine resin is cut into a desired size by a knife 28 and heated and pressed under a predetermined condition by a heat press 29 to cure the melamine resin coat layer. Thus,
It is possible to mass-produce decorative boards having a cured melamine resin layer on the surface at low cost.

In the embodiment shown in FIG. 2, the adhesive is applied to the substrate 21. However, the adhesive is not applied to the substrate 21 but may be applied to the decorative sheet 10 before the curable decorative sheet 10 is bonded to the substrate 21. Good.

[0025]

The thermosetting decorative sheet of the present invention is coated on the melamine resin without impregnating the base paper with the melamine resin and dried to the extent that it does not block, so that it can be wound on a reel. Therefore, when bonding the thermosetting decorative sheet of the present invention to a substrate, it is possible to perform the bonding continuously instead of in a single-wafer manner, and it is possible to cope with mass production and to manufacture a decorative plate at low cost. Become.

[0026]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below with reference to embodiments.

Example 1 Titanium oxide-containing paper with a basis weight of 45 g / m ² (HPT)
No. 45, manufactured by Tenma Specialty Paper Co., Ltd.), a urethane resin (manufactured by Dainichi Seika) was applied as a sealer using a gravure solid plate having a plate depth of 60 μm, and dried to form a sealer coat layer.

Then, solid printing and pattern printing were performed on the sealer coat layer using a butyral-based ink (D-2, manufactured by Dainichi Seika) by a gravure printing method to provide a solid layer and a pattern printing layer.

A melamine resin for short cycle (M-700, manufactured by Nissan Chemical Co., Ltd.) was applied on the pattern layer at a rate of 40 g / m ² (dry) at a line speed of 20 m / min. It was passed through a drying oven for 2 minutes and dried to produce a thermosetting decorative sheet. This sheet could be wound up without blocking on the reel after drying and could be stored stably.

Example 2 The thermosetting decorative sheet of Example 1 was put into the apparatus shown in FIG. 2 and bonded to a particle board having a thickness of 15 mm using a urea-vinyl acetate adhesive, at a temperature of 160 ° C. and a pressure of 160 ° C. A hardening treatment was performed at 30 kg / cm ² for 0.8 minutes to produce a decorative board.

The decorative board obtained was not inferior in physical properties as compared with the conventional decorative board having a cured melamine resin layer on the surface, and had a low production cost.

[0032]

According to the present invention, a thermosetting sheet which cures to become a melamine resin decorative board is wound around a reel and stored.
It can be transported, and can be continuously performed instead of a sheet-fed type when bonded to a substrate, so that it is possible to manufacture a decorative board that is low in cost and has a paper-to-paper strength that is not inferior to conventional products.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a thermosetting decorative sheet according to the present invention.

FIG. 2 is a diagram illustrating a preferred line mode for manufacturing a decorative board having a cured melamine resin layer on the surface by bonding the thermosetting decorative sheet of the present invention to a substrate.

[Explanation of symbols]

 Reference Signs List 1 substrate 2 sealer coat layer 3 solid layer 4 pattern layer 5 melamine resin layer 10 thermosetting decorative sheet 21 substrate 25 adhesive layer

Continuation of the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 D21H 19/24

Claims (3)

(57) [Claims] 1. A thermosetting decorative sheet in which a base paper, a sealer coat layer, a solid layer, a pattern layer and a melamine resin coat layer are sequentially laminated. 2. The thermosetting decorative sheet according to claim 1,
A method for manufacturing a decorative board, comprising: bonding a substrate via an adhesive; and applying heat and pressure. 3. The thermosetting decorative sheet is wound around a reel,
The method for producing a decorative board according to claim 2, wherein the decorative board is continuously bonded to a substrate.