JP3193795B2 - Cosmetic material and method for producing the same - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative material used as a surface material in, for example, furniture and building materials, and has a very high degree of mirror gloss, and furthermore, a decorative material base paper and a coating layer. The present invention provides a decorative material having high interlayer strength and excellent scratch resistance between the same and a method for producing the same.

[0002]

2. Description of the Related Art As a decorative material having a high degree of specular gloss, which is used as a surface material for furniture, building materials, etc., a base paper for decorative materials and an inorganic filler formed on the surface of the base paper for decorative materials An undercoat layer made of a resin layer containing, a solid printing coating layer made of a resin layer containing a pigment formed on the undercoat layer, and a printing coating layer formed on the printing coating layer. And a top coat layer made of a curable resin having a transparent film forming ability (Japanese Patent Application Laid-Open No. 4-89257).

[0003]

Although the decorative material described above has a sufficient specular gloss on the surface of the decorative material, the interlayer strength between the decorative material base and the coating layer is weak, and the decorative material base is poor. And the coating layer is peeled off, so that the scratch resistance is insufficient.

[0004] On the other hand, the present invention provides a decorative material having high specular gloss and excellent scratch resistance, and a method for producing the same.

[0005]

The above object can be attained by a decorative material of the present invention and a method of manufacturing the same according to the following constitutions. That is, the decorative material of the present invention comprises a base paper for decorative material made of non-size paper, an undercoat layer made of a resin layer containing an inorganic filler formed on the surface of the base paper for decorative material, and the undercoat layer. A nitrocellulose and / or alkyd resin formed on the vehicle is used as a vehicle, and a solid printing coating layer consisting of a resin layer containing a pigment, and a transparent printing layer formed on the printing coating layer. A top coat layer made of a curable resin having a film-forming ability, wherein the content of the binder resin in the undercoat layer is 20% by weight or less, and the transparent resin forming the top coat layer is A hardening resin having an excellent film-forming ability is impregnated in at least 1/2 of the thickness direction from the surface of the base paper for decorative material.

Further, according to the method for producing a decorative material of the present invention, the surface of a base paper for decorative material made of non-size paper contains an inorganic filler and the content of the binder resin is 20% by weight.
A step of forming an undercoat layer consisting of the following resin layer, and forming a solid printing coating layer on the entire surface of the undercoat layer using a nitrocellulose and / or alkyd resin as a vehicle and a pigment-containing coating agent. Forming a top coat layer by coating, impregnating, and curing a curable resin having a transparent film-forming ability on the surface of the print coating layer, and forming the top coat layer. Impregnating the curable resin having a transparent film-forming ability from the surface of the base paper for decorative material into １ ／ or more in the thickness direction.

In the decorative material of the present invention having the above-described structure and the method for producing the same, the base paper for the decorative material is, for example, non-sized paper containing no sizing agent such as rosin, wax emulsion, alkyl ketene dimer, ie, cellulose pulp. Paper is used as a papermaking component such as paper, paper strength agent, filler, and the like.

[0008] The Gurley-type air permeability is 100 seconds / 100 ml or less so that the hardening resin having a transparent film forming ability at the time of forming the top coat layer is sufficiently penetrated into the base paper for the decorative material. It is preferable to use one having a flow rate of 40 seconds / 100 ml or less.

[0009] The undercoat layer formed on the surface of the base paper for decorative material is composed of a resin layer containing an inorganic filler. The undercoat layer is formed by a coating agent comprising the inorganic filler, a resin constituting a binder component, and other additives. It is formed.

[0010] For example, a binder resin such as starch, casein, latex, polyvinyl alcohol, cellulose derivative, soybean protein, and a resin having a comparatively high brightness with kaolin, limestone clay, calcium carbonate, aluminum hydroxide, titanium oxide, satin white, etc. High mineral fillers and other auxiliaries such as dispersants, defoamers, lubricants, preservatives,
A coating agent having a viscosity of 10,000 cps or less and a solid component concentration of 80% or less containing an antifungal agent, a water-proofing agent, a dye, a flow modifier, etc. is applied to an air doctor coater, blade coater, transfer roll coater, bar coater, reverse roll coater. , A gravure roll coater, a die coater, etc., about 3 to 50 g (wet) / m ² ,
0.5 to 30 g (dry) / m ² , more preferably 5
It is formed by coating to about 20 g (dry) / m ² .

The undercoat layer made of a resin layer containing an inorganic filler is used as a binder in the undercoat layer in order to improve the permeability of the coating agent for forming the topcoat layer with the curable resin. It is necessary that the content of the resin be 20% by weight or less.

Further, the undercoat layer made of a resin layer containing the above-mentioned inorganic filler is used in the undercoat layer so that the undercoat layer has a hiding property.
It is preferred that about 80% by weight be titanium oxide.

When an undercoat layer is formed by a transfer roll coater, an undercoat layer having excellent surface smoothness can be obtained, so that a decorative material having higher mirror gloss can be obtained.

The solid printing coating layer on the entire surface is made of nitrocellulose and / or alkyd resin as a vehicle and uses a printing ink containing a pigment, preferably a printing ink containing a low-brightness pigment. It is formed by solid printing on the entire surface by a known means such as an offset printing method, a letterpress printing method, and a screen printing method.

As described above, the pigment in the printing ink used to form the solid printing coating layer is preferably a pigment having a low lightness, such as black to gray achromatic pigments, green such as dark green, and sepia. And other pigments of various hues such as red, blue, and tan.

Further, since the printing coating layer on the entire surface is formed of a printing coating layer containing nitrocellulose or an alkyd resin as a vehicle and containing a pigment, it is used for forming a top coating layer of a curable resin. It has good properties for the permeability of the coating agent.

After a printing pattern is formed on the solid printing coating layer as required, a transparent top coat layer of a curable resin is formed. As the curable resin at this time, a thermosetting resin or an ionizing radiation-curable resin is used.

The top coat layer made of a thermosetting resin is made of, for example, a composition comprising an unsaturated polyester resin, styrene, benzoyl peroxide, and cobalt naphthenate, or a melamine resin or a urea resin or an alkyd resin alone or as a mixture of paratoluene. Composition containing a catalyst such as sulfonic acid, epoxy resin and polyamide resin, thermosetting composition composed of polyamine or acid anhydride, polyester polyol, polyether polyol, alkyd polyol, acrylic polyol, or epoxy polyol and polyisocyanate If necessary, a plasticizer, a stabilizer, a filler, a dispersant, a dye, a pigment, a diluent, etc. are added to the composition and the like, and the mixture is kneaded to form a coating agent.

The top coat layer made of the ionizing radiation-curable resin is, for example, a composition comprising a monomer or a prepolymer having a polymerizable unsaturated bond in a molecule, specifically, urethane acrylate, polyester acrylate, This is based on acrylates such as epoxy acrylate, unsaturated polyester, polythiol, and the like. In the case of curing with ultraviolet light or visible light, a photosensitizer such as benzophenone or acetophenone or a photoreaction initiator is added. As the ionizing radiation to be applied, visible light, ultraviolet light, electron beam, or the like is used.

As a coating agent for forming a top coat layer, the coating agent penetrates a solid printing coating layer composed of a resin layer containing a pigment and an undercoat layer composed of a resin layer containing an inorganic filler. And then,
A low-viscosity material having a viscosity of 1000 cps or less, preferably 100 cps or less is used so as to penetrate 1/2 or more in the thickness direction of a base material for decorative material made of non-size paper.

[0021]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The concrete structure of the decorative material of the present invention and the method for producing the same will be described below based on examples.

Example 1 10 g of a coating agent having the following composition [b] was applied to the surface of a decorative base paper made of non-size paper having a basis weight of 30 g / m ^{2 and} having the following composition [a] by air doctor coating.
(Dry) / m ² was applied and dried to form an undercoat layer.

Composition [a] Chemical pulp 91.5 parts by weight Anionic acrylamide 1.0 parts by weight Cationic acrylamide 0.5 Parts by weight Cationic starch 2.0 parts by weight Titanium oxide 5.0 parts by weight

Composition [b] Kaolin 15.0 parts by weight Aluminum hydroxide 10.0 parts by weight Part Titanium oxide 17.5 parts by weight Modified starch 2 5 parts by weight Latex 5.0 parts by weight Water .... 50.0 parts by weight

Subsequently, 3 g (dry) of a coating agent having the following composition [c] containing a pigment having a low brightness is coated on the surface of the undercoat layer by a gravure printing method.
/ M ² to form a uniform printing coating layer over the entire surface.

Composition [c] Nitrocellulose 7.0 parts by weight Alkyd resin 3.0 parts by weight Carbon 10.0 parts by weight Ethyl acetate 80.0 parts by weight

Further, a coating agent of a curable resin having a transparent film-forming ability having the following composition component [d] was diluted with a solvent to a viscosity of 20 cps on the surface of the above-mentioned solid printing coating layer on the entire surface. The base material is coated by a gravure coating method, and the solid printing coating layer and the undercoat layer are permeated through the gravure coating method.
/ 2 or more, followed by drying at 150 ° C. for 20 seconds to form a top coat layer of 15 g (dry) / m ² , thereby obtaining a cosmetic material as an example product of the present invention. .

Composition [c] Polyester polyol: 80.0 parts by weight Silicone: 1.0 part by weight Isocyanate prepolymer 20 0.0 parts by weight methyl ethyl ketone

The top coat layer surface of the decorative material obtained by the above process has a 75-degree specular gloss of 95 or more, and the decorative material has a high interlayer strength between the base paper for decorative material and the coating layer. It had characteristics excellent in scratch resistance.

[0030]

The decorative material of the present invention comprises a base paper for decorative material made of non-size paper and an undercoat layer composed of a resin layer containing an inorganic filler formed on the surface of the base paper for decorative material. A nitrocellulose and / or alkyd resin formed on the undercoat layer as a vehicle, and a solid print coating layer composed of a resin layer containing a pigment; and A top coat layer made of a curable resin having a transparent film-forming ability, wherein the content of the binder resin in the undercoat layer is 20% by weight or less; The hardening resin having the ability to form a transparent film is impregnated into the base paper for decorative material at least 1/2 of the thickness direction from the surface, and has extremely high specular gloss. Since it has excellent interlayer strength between the base paper for decorative material and the coating layer, it also has a high degree of scratch resistance, and becomes a decorative material that exhibits high quality properties as a surface material in furniture and building materials, for example. .

According to the method for producing a decorative material of the present invention, a decorative material having the above-mentioned extremely high specular gloss and excellent scratch resistance can be easily and reliably produced.
Moreover, it can be obtained efficiently.

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-89257 (JP, A) JP-A-62-191143 (JP, A) JP-A-57-137158 (JP, A) 339644 (JP, A) JP-A-3-169545 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (2)

(57) [Claims] 1. A base paper for decorative material made of non-size paper,
An undercoat layer made of a resin layer containing an inorganic filler formed on the surface of the base paper for decorative material, and a nitrocellulose and / or alkyd resin formed on the undercoat layer as a vehicle; and A solid print coating layer consisting of a resin layer containing a pigment, and a top coat layer of a curable resin having a transparent film-forming ability formed on the print coating layer, In addition, the content of the binder resin in the undercoat layer is 20% by weight or less, and the curable resin having a transparent film-forming ability forming the topcoat layer has a thickness from the surface of the base paper for decorative material. A decorative material characterized by being impregnated in at least half of the direction. 2. A step of forming an undercoat layer comprising a resin layer containing an inorganic filler and having a binder resin content of 20% by weight or less on the surface of a decorative base paper made of non-size paper. Forming a solid print coating layer on the undercoat layer surface with a coating agent containing nitrocellulose and / or alkyd resin as a vehicle, and containing a pigment; and forming a transparent print coating layer on the surface of the print coating layer. Coating with a curable resin with excellent film forming ability
The top coat layer is formed by impregnating and curing, and a curable resin having a transparent film forming ability at the time of forming the top coat layer is 以上 or more in the thickness direction from the surface of the base paper for decorative material. Impregnating the cosmetic material.