JP3980407B2 - Veneer - Google Patents

Description

【００４４】
表１から明らかなように、実施例１〜６は、乾燥処理時および吸湿処理時のいずれにおいても反り高さが低下しており、かつ化粧板に汚れ付着も無かった。
また、特に実施例２、４および６は、乾燥処理時および吸湿処理時の重量変化が大きく、化粧板の両面で吸湿性のバランスに優れていることが確認された。
また、特に実施例１〜３および５は、保護層の剥離強度にも優れており、安定した剥離作業が可能であることが確認された。
【００４５】
【発明の効果】
本発明によれば、使用段階（施工段階）における反りの発生を低減できる化粧板を提供することができる。これにより、切削加工、パネル化接着加工等の２次加工を容易にすることができる。
また、本発明によれば使用段階までの化粧板の寸法変化率、特に反りを低減することができる。
また、特にコア層に充填材を大量に添加している不燃化粧板においては、特に反りを大幅に改善することができる。
また、保護層の開口率を特定の値にする場合、剥離性と水蒸気透過性のバランスに優れた保護層を得ることができ、これを化粧板に用いると反りの改善と施工時の作業性を特に向上することができる。
【図面の簡単な説明】
【図１】本発明における化粧板の一例を示す断面図である。
【図２】本発明における保護層の一例を示す上面図である。
【符号の説明】
１ 化粧板
２ 保護層
２１ 小孔
３ 化粧層
４ コア層
４１ 基材層
４２ 補強層
５ バック層[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative board.
[0002]
[Prior art]
Generally, a decorative board is composed of a surface decorative layer and a core layer.
It is necessary to form a protective layer for the decorative board in order to prevent scratches on the surface and to prevent adhesion of dirt. As a method of forming a protective layer for protecting the design of the surface, a method of laminating a resin film on the surface of a decorative board and laminating the resin film, making a water-soluble resin such as polyvinyl alcohol into a liquid, Examples thereof include a method of forming a protective film by coating on the surface.
However, the decorative board formed with these protective layers has the problem that the occurrence of warpage of the decorative board becomes large at the use stage (construction stage), although the prevention of scratches on the surface and the prevention of dirt adhesion are maintained. Was.
[0003]
In order to improve the warp of the decorative board in such a use stage, methods for reducing the dimensional change rate of the decorative board itself, methods for improving storage conditions, and the like have been studied.
However, when the above method is used, even if the warpage can be reduced, there are problems such as an increase in the number of work steps and an increase in cost, and it has not been a practical improvement method.
[0004]
[Problems to be solved by the invention]
The objective of this invention is providing the decorative board which can reduce generation | occurrence | production of the curvature in a use stage (construction stage).
[0005]
[Means for Solving the Problems]
Such an object is achieved by the present invention described in the following (1) to ( 15 ).
(1) A decorative board having a core layer, a decorative layer provided on at least one side of the core layer, and a protective layer provided detachably on the surface of the decorative layer,
The protective layer has moisture permeability,
A decorative board having a back layer on the opposite side of the decorative layer .
( 2 ) The decorative plate according to ( 1 ), wherein the protective layer is a coating film.
( 3 ) The said protective layer is a decorative board as described in said ( 1 ) which is a resin film.
( 4 ) A decorative board having a core layer, a decorative layer provided on at least one side of the core layer, and a protective layer provided detachably on the surface of the decorative layer,
The decorative layer is characterized in that the protective layer has moisture permeability and is a coating film .
(5) The decorative layer according to any one of (1) to (4), wherein the decorative layer is made of a melamine resin.
( 6 ) A decorative board having a core layer, a decorative layer provided on at least one side of the core layer, and a protective layer provided detachably on the surface of the decorative layer,
The protective layer has moisture permeability,
The decorative layer is made of a melamine resin .
( 7 ) The decorative plate according to ( 6 ), wherein the protective layer is a resin film.
( 8 ) The decorative sheet according to any one of (1) to (7), wherein the protective layer has a water vapor permeability of 800 (g / m ² · 24h · atm · 25 ° C) or more.
( 9 ) The decorative board according to any one of (1) to ( 8 ), wherein the protective layer has a thickness of 30 to 200 μm.
( 10 ) The decorative board according to any one of (1) to ( 9 ), wherein the protective layer is a porous layer.
( 11 ) The decorative plate according to ( 10 ), wherein the porous average pore diameter is 0.3 to 3.0 mm.
( 12 ) The decorative board according to ( 10 ) or ( 11 ), wherein the porous layer has an aperture ratio of 3 to 30%.
( 13 ) The decorative board according to any one of (1) to ( 12 ), wherein the protective layer is bonded to the decorative layer via an adhesive.
( 14 ) The decorative board according to ( 13 ), wherein the adhesive is provided in a lattice shape, a strip shape, or a dotted shape.
( 15 ) The decorative board according to any one of (1) to ( 14 ), wherein the core layer is formed by laminating a plurality of layers.
[0006]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the decorative board of the present invention will be described in detail based on preferred embodiments.
FIG. 1 is a cross-sectional view showing an example of a decorative board of the present invention.
The decorative board of the present invention is provided with a core layer 4, a decorative layer 3 provided on one side of the core layer 4, a back layer 5 on the opposite side of the decorative layer 3, and a peelable surface on the surface of the decorative layer 3. The decorative board 1 has a protective layer 2, and the protective layer 2 is moisture permeable.
[0007]
The core layer 4 has a function of improving the strength of the decorative board.
The core layer 4 may be a single layer or may be composed of a plurality of layers. In the present embodiment, the core layer 4 is composed of a three-layer laminate.
That is, the core layer 4 has the base material layer 41 on both surfaces of the reinforcing layer 42.
The reinforcing layer 42 is formed, for example, by impregnating a woven glass fabric with a melamine resin. Thereby, the intensity | strength of a decorative board can be improved.
[0008]
The method for impregnating the glass woven fabric with the melamine resin is not particularly limited, and a normal method can be used.
In the embodiment of the present invention, a melamine resin is used as the resin to be impregnated, but the present invention is not limited to this. Examples of the resin to be impregnated include thermosetting resins such as phenol resins and unsaturated polyester resins.
[0009]
The resin content of the reinforcing layer 42 is not particularly limited, but is preferably 30 to 40% by weight, and particularly preferably 34 to 38% by weight of the entire layer.
Although the thickness of the reinforcement layer 42 is not specifically limited, 0.1-0.5 mm is preferable and especially 0.2-0.3 mm is preferable.
[0010]
The base material layer 41 is obtained, for example, by impregnating a glass nonwoven fabric with a mixture of a phenol resin and aluminum hydroxide. Thereby, the flame retardance of a decorative board can be improved.
The content of aluminum hydroxide in the base material layer 41 is not particularly limited, but is preferably 70 to 90% by weight, and particularly preferably 75 to 85% by weight of the entire layer. If the content of aluminum hydroxide is less than the lower limit, the effect of improving flame retardancy may be reduced, and if the upper limit is exceeded, the fluidity of the mixture is reduced. It may be difficult to impregnate.
In the present embodiment, the base material layer 41 is impregnated with a glass nonwoven fabric with a phenol resin and aluminum hydroxide, but the present invention is not limited to this. Examples of the resin include other thermosetting resins such as melamine resin and unsaturated polyester resin. Examples of the filler include hydroxides such as magnesium hydroxide, talc, and clay.
[0011]
Although the thickness of the base material layer 41 is not specifically limited, 1.5 to 4.0 mm is preferable as a whole of both side layers, and 2.0 to 3.0 mm is particularly preferable.
The base material layer 41 is provided on both surfaces of the reinforcing layer 42 in the present embodiment, but may be provided on only one surface.
[0012]
When the core layer 4 is a single layer, for example, a known core layer for a thermosetting resin decorative board can be used. Specifically, a material such as kraft paper impregnated with another thermosetting resin such as phenol resin, diallyl phthalate resin, unsaturated polyester resin, or the like.
[0013]
Next, the decorative layer 3 will be described.
The decorative layer 3 has a function of improving the design of the decorative board, and is formed by impregnating a resin in decorative paper, for example.
Examples of the decorative paper include thin paper, bleached kraft paper, high-quality paper, pure white paper, paper-to-paper reinforced paper, mixed paper with synthetic resin mixed to enhance interlayer strength, and titanium paper.
Examples of the resin include melamine resin, diallyl phthalate resin, unsaturated polyester resin, and acrylic resin.
Examples of the impregnation method include a method in which the resin is dissolved in water, methanol, acetone, toluene or the like and the above-mentioned decorative paper is immersed.
[0014]
Next, the back layer 5 will be described.
The back layer 5 has a function of balancing the hygroscopicity with the decorative layer 3 and suppressing the warping of the decorative board. For example, the back layer 5 is obtained by impregnating a back paper with a resin. As the backing paper, for example, thin paper, bleached kraft paper, high-quality paper, pure white paper and similar decorative paper can be used, but for economical reasons, lower cost unbleached kraft paper, Titanium-containing lightweight printing base paper is preferred.
[0015]
Examples of the resin include melamine resin, diallyl phthalate resin, unsaturated polyester resin, and acrylic resin. In order to balance the decorative layer, it is preferable to use a resin similar to the resin used in the decorative layer.
The back layer 5 is provided as necessary, and the back layer 5 may not be provided particularly when the warpage of the decorative plate is not a problem.
[0016]
Next, the protective layer 2 will be described.
The protective layer 2 has a function of preventing damage to the decorative layer and adhesion of dirt before and during use (construction).
In the present embodiment, the protective layer 2 is formed so as to cover the entire surface of the decorative layer 3 in order to protect the design of the decorative layer 3. Thereby, the prevention effect with respect to the damage | wound and dirt adhesion of the surface of a decorative board can be improved more.
The protective layer 2 can be peeled off. Thereby, it can peel easily after use.
[0017]
The protective layer 2 has moisture permeability. Thereby, the difference in the hygroscopicity in the front and back of a decorative board can be reduced, and the curvature of a decorative board can be reduced.
In conventional decorative boards (especially, decorative boards that maintain a balance between the layer structure of the decorative layer and the back layer), the decorative layer formed with a protective layer on the surface and the back layer or core layer make it hygroscopic. There was a difference, which caused a difference in dimensional change and warpage. On the other hand, in the present invention, since the protective layer on the surface has a certain level of moisture permeability, the difference in moisture absorption between the decorative layer and the back layer is reduced. As a result, the warpage that has occurred in the conventional decorative board can be reduced.
[0018]
The water vapor permeability of the protective layer 2 is not particularly limited, but is preferably 800 (g / m ² · 24 h · atm · 25 ° C.) or more, particularly 1,000 (g / m ² · 24 h · atm · 25 ° C.). The above is preferable. If the water vapor permeability is less than the lower limit, the effect of improving the warp of the decorative board may be reduced.
The water vapor permeability can be measured by, for example, JIS Z 7129 (Method A).
[0019]
Although the thickness of the said protective layer 2 is not specifically limited, 30-200 micrometers is preferable and 50-150 micrometers is especially preferable. If the thickness is less than the lower limit value, the strength of the protective layer may be reduced, and it may be difficult to peel and remove the protective layer. Even if the thickness exceeds the upper limit value, the protective function of the protective layer is improved. Absent.
[0020]
FIG. 2 is a top view of protective layer 2 in the embodiment of the present invention.
In the present embodiment, a large number of small holes 21 are formed in the protective layer 2. Thereby, the difference in hygroscopicity can be reduced on the front and back of the decorative board. Thereby, the curvature of the decorative board can be improved.
Since the conventional protective layer is intended to protect the decorative layer, it has not been possible to provide a hole in the protective layer. On the other hand, in the present invention, in order to improve warpage, a new function is imparted to the protective layer by providing a large number of small holes in the protective layer.
[0021]
The average pore diameter of the small holes is not particularly limited, but is preferably 0.3 to 3.0 mm, particularly preferably 0.5 to 2.5 mm, and most preferably 0.6 to 1.5 mm. If the average pore diameter is less than the lower limit value, the effect of improving the effect of improving the warp of the decorative board may be reduced, and if the upper limit value is exceeded, the function of preventing stains on the decorative board due to the inclusion of foreign matters or the like. May decrease. Further, when the average pore diameter is particularly within the above range, a protective layer in which the decorative board is less warped and the protective layer can be easily peeled can be obtained. That is, a protective layer having an excellent balance between the water vapor permeability of the protective layer and the tear strength of the protective layer can be obtained.
The average pore diameter described above varies greatly depending on the resin constituting the resin layer.
Examples of the method of forming the porous material include a method of passing a resin layer film through a heating roll provided with a needle-like member.
[0022]
The opening ratio of the protective layer is not particularly limited, but is preferably 3 to 30%, particularly preferably 5 to 25%. When the aperture ratio is less than the lower limit, the effect of improving the warp of the decorative board may be reduced, and when the upper limit is exceeded, the strength of the resin layer is reduced and it is difficult to peel off the protective layer There is.
The opening ratio means the ratio of the opening area of the small holes to the area of the protective layer.
[0023]
Although the protective layer 2 is comprised with the resin film in this Embodiment, a coating film can be used. Further, the protective layer in the present invention may be, for example, a mesh body such as a mesh or a net, or a laminate of such a network body with another layer.
As said resin film, resin films, such as a polyethylene film, a polypropylene, polyester, a polyvinyl chloride, can be used, for example.
As the coating film, for example, a water-soluble resin having excellent film forming properties such as polyvinyl alcohol is used as a liquid, and a coating coating film or the like can be used on the surface of the decorative layer.
[0024]
The method for joining the protective layer and the decorative layer is not particularly limited, but the protective layer and the decorative layer are preferably joined via an adhesive.
The method for applying the adhesive is not particularly limited, but is preferably a method of applying partially rather than a method of applying to the entire protective layer. Thereby, water vapor permeability can be maintained. Examples of the coating method include a method of coating in a lattice shape, a strip shape, or a dotted shape. Thereby, the curvature improvement effect of the decorative board by formation of the small hole 21 can be improved more.
The relationship between the adhesive strength of the protective layer and the tear strength of the protective layer is not particularly limited, but the tear strength is preferably 3 times or more of the adhesive strength, and a particularly stable peeling operation can be performed. It is preferable that there is more than twice. Within the above range, in the operation of removing the protective layer, the protective layer removal workability is particularly excellent without causing the protective layer to tear or break the film.
[0025]
As the adhesive, for example, a commonly used acrylic, vinyl acetate, or hot melt adhesive can be used.
Alternatively, a self-adhesive film that is laminated with a base film and extruded by two layers may be applied.
[0026]
【Example】
EXAMPLES Hereinafter, although this invention is demonstrated in detail based on an Example and a comparative example, this invention is not limited to this.
Example 1
<Manufacture of protective layer>
An acrylic adhesive (manufactured by Nitto Denko Corporation) 1.2 g / m ² (thickness 10 μm) was applied to one side of a polyethylene film (Asahi Kasei Corporation thickness 70 μm) by roll coating. Next, this polyethylene film was subjected to hot needle hole processing to provide holes with an average hole diameter of 0.8 mm and an aperture ratio of 20%.
[0027]
<Manufacture of decorative panels>
(1) Manufacture of decorative layer Resin liquid for melamine decorative board (aldehyde (F) / melamine (M) ratio) on white paper (made by Kojin Co., Ltd.) and gravure-printed decorative paper (80 tsubo / m ² ) 1.7 and a viscosity of 30 Pa · sec) was impregnated so that the resin adhesion amount was 50% in terms of nonvolatile content. Next, this resin-impregnated paper was dried at 120 ° C. for 1.5 minutes to obtain a decorative paper.
[0028]
(2) Production of core layer / Reinforcing layer A glass woven fabric (WEA-7628 manufactured by Nittobo Co., Ltd.) was impregnated with the resin solution for melamine decorative board so that the resin adhesion amount was 40% in terms of nonvolatile content. Next, this resin-impregnated base material was dried at 120 ° C. for 2 minutes to obtain one reinforcing layer having a thickness of about 0.2 mm.
[0029]
A mixed solution of a base layer glass nonwoven fabric (EPM-4050 manufactured by Nippon Vilene Co., Ltd.), a phenol resin solution (aldehyde (F) / phenol (P) ratio = 1.8, viscosity 50 Pa · sec) and aluminum hydroxide. The solid content was applied so that the non-volatile content was 90%. Next, this resin-impregnated base material was dried at 160 ° C. for 4 minutes to obtain a single base material layer having a thickness of about 0.7 mm.
[0030]
(3) Production of Back Layer As a backing paper, low-titanium-containing lightweight printing base paper (PM-801, manufactured by Kojin Co., Ltd.) was impregnated with the resin solution for melamine decorative board so that the resin adhesion amount was 52% in terms of nonvolatile content. . Next, this resin-impregnated paper was dried at 120 ° C. for 1.5 minutes to obtain a back layer.
[0031]
(4) Manufacture of decorative plate One decorative layer, four base layers, one reinforcing layer, four base layers and one back layer are stacked in this order at 160 ° C., 10 MPa. And heated and pressurized for 60 minutes to obtain a decorative board.
The above-mentioned protective layer was bonded to the obtained decorative plate to obtain a decorative plate having a protective layer. The water vapor permeability of the protective layer was 800 (g / m ² · 24 h · atm · 25 ° C.) or higher.
[0032]
(Example 2)
Example 1 was repeated except that the protective layer was as follows.
The condition of the hot needle hole processing was changed to an average hole diameter of 1.0 mm and an aperture ratio of 18%.
The water vapor permeability of the protective layer was 800 (g / m ² · 24 h · atm · 25 ° C.) or higher.
[0033]
(Example 3)
Example 1 was repeated except that the protective layer was as follows.
The condition of the hot needle hole processing was changed to an average hole diameter of 0.5 mm and an aperture ratio of 8%. The water vapor permeability of the protective layer was 800 (g / m ² · 24 h · atm · 25 ° C.) or higher.
[0034]
(Example 4)
Example 1 was repeated except that the protective layer was as follows.
The condition of the hot needle hole processing was changed to an average hole diameter of 0.8 mm and an aperture ratio of 30%.
The water vapor permeability of the protective layer was 800 (g / m ² · 24 h · atm · 25 ° C.) or higher.
[0035]
(Example 5)
The same procedure as in Example 1 was conducted except that the resin film of the protective layer was changed as follows.
A polypropylene film (thickness 75 μm, manufactured by Asahi Kasei Co., Ltd.) was used instead of the protective layer resin film. The water vapor permeability of the protective layer was 800 (g / m ² · 24 h · atm · 25 ° C.) or higher.
[0036]
(Example 6)
The procedure was the same as Example 1 except that the adhesive was applied as follows.
Instead of applying the adhesive to the entire surface, it was applied in the form of dots. The water vapor permeability of the protective layer was 800 (g / m ² · 24 h · atm · 25 ° C.) or higher.
[0037]
(Comparative Example 1)
The protective layer was the same as Example 1 except that a polyethylene film not subjected to hot needle processing was used as it was. The water vapor permeability of the protective layer was less than 100 (g / m ² · 24 h · atm · 25 ° C.).
[0038]
The following evaluation was performed about the decorative board obtained by the Example and the comparative example. The evaluation items are shown together with the contents. The obtained results are shown in Table 1.
In addition, each evaluation used the test piece which made the decorative board the size of 50 mm x 200 mm.
(1) Warpage and change in weight The two test pieces described above were subjected to the following treatment in a nitrogen atmosphere.
The moisture absorption treatment was performed at 25 ± 2 ° C. and 92 ± 3% RH for 24 hours, and the drying treatment was performed at 40 ± 3 ° C. and 20 ± 3% RH for 24 hours.
[0039]
-Change in warpage In the above-described moisture absorption and drying treatment, the warpage of the test piece after 1 hour, 2 hours, 4 hours, 8 hours, 12 hours, and 24 hours was measured.
The warp was measured by measuring the arrow height warp (S0) at the center in the width direction (200 mm length) side of the test piece before processing to a unit of 0.01 mm with a taper-type gap gauge. , S2... Sn) were measured to the nearest 0.01 mm.
[0040]
-Change in weight In the above-described moisture absorption and drying treatment, the weight of the test piece was measured after 1 hour, 2 hours, 4 hours, 8 hours, 12 hours, and 24 hours.
For the weight, the weight of the test piece before the test (W0) is weighed to the unit of 0.1 mg, and after each time, the weight of the test piece (W1, W2,... Wn) is weighed to the unit of 0.1 mg, The amount of change relative to the pre-test weight was determined.
[0041]
(2) Peel strength of protective film The strength when peeling the protective film was visually evaluated. Each symbol is as follows: ◎: Protective film is not cut or cracked, and can be peeled ○: Protective film is cracked, but peelable △: Protective film is cracked, partly difficult to peel × : Protection film is cut and cannot be peeled. [0042]
(3) Surface dirt adhesion The presence or absence of dirt adhesion on the surface of the decorative board was visually evaluated after peeling off the protective layer. Each code is as follows.
◎: No dirt on the surface ○: Some dirt on the surface, but no problem in practical use △: Some dirt on the surface, impractical ×: There is dirt on the surface [0043]
[Table 1]

[0044]
As is clear from Table 1, in Examples 1 to 6, the warp height was reduced both during the drying process and during the moisture absorption process, and there was no contamination on the decorative board.
In particular, in Examples 2, 4 and 6, the weight change during the drying treatment and the moisture absorption treatment was large, and it was confirmed that the moisture absorption balance was excellent on both sides of the decorative board.
Moreover, especially Examples 1-3 and 5 were excellent also in the peeling strength of a protective layer, and it was confirmed that the stable peeling operation | work is possible.
[0045]
【The invention's effect】
ADVANTAGE OF THE INVENTION According to this invention, the decorative board which can reduce generation | occurrence | production of the curvature in a use stage (construction stage) can be provided. Thereby, secondary processes, such as a cutting process and panel-ized adhesion process, can be made easy.
Moreover, according to this invention, the dimensional change rate of the decorative board up to a use stage, especially curvature can be reduced.
In particular, in a non-combustible decorative board in which a large amount of filler is added to the core layer, warpage can be greatly improved.
In addition, when the opening ratio of the protective layer is set to a specific value, it is possible to obtain a protective layer with an excellent balance between peelability and water vapor permeability, and when this is used for a decorative board, the warp is improved and the workability during construction is improved. Can be particularly improved.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view showing an example of a decorative board according to the present invention.
FIG. 2 is a top view showing an example of a protective layer in the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Decorative board 2 Protective layer 21 Small hole 3 Decorative layer 4 Core layer 41 Base material layer 42 Reinforcing layer 5 Back layer

Claims (15)

A decorative board having a core layer, a decorative layer provided on at least one side of the core layer, and a protective layer provided detachably on the surface of the decorative layer,
The protective layer has moisture permeability,
A decorative board having a back layer on the opposite side of the decorative layer . The protective layer, decorative plate according to claim 1 is a coating film. The protective layer, decorative plate according to claim 1 is a resin film. A decorative board having a core layer, a decorative layer provided on at least one side of the core layer, and a protective layer provided detachably on the surface of the decorative layer,
The decorative layer is characterized in that the protective layer has moisture permeability and is a coating film .   The said decorative layer is a decorative board in any one of Claim 1 thru | or 4 comprised by the melamine resin. A decorative board having a core layer, a decorative layer provided on at least one side of the core layer, and a protective layer provided detachably on the surface of the decorative layer,
The protective layer has moisture permeability,
The decorative layer is made of a melamine resin . The decorative board according to claim 6 , wherein the protective layer is a resin film. The decorative sheet according to any one of claims 1 to 7, wherein the protective layer has a water vapor permeability of 800 (g / m ² · 24h · atm · 25 ° C) or more. The decorative board according to any one of claims 1 to 8 , wherein the protective layer has a thickness of 30 to 200 µm. The decorative board according to any one of claims 1 to 9 , wherein the protective layer is a porous layer. The decorative board according to claim 10 , wherein the porous average pore diameter is 0.3 to 3.0 mm. The decorative board according to claim 10 or 11 , wherein an opening ratio of the porous layer is 3 to 30%. The decorative board according to any one of claims 1 to 12 , wherein the protective layer is bonded to the decorative layer via an adhesive. The decorative board according to claim 13 , wherein the adhesive is provided in a lattice shape, a strip shape, or a dotted shape. The decorative sheet according to any one of claims 1 to 14 , wherein the core layer is formed by laminating a plurality of layers.

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