JP4282155B2 - Melamine resin decorative board - Google Patents
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- JP4282155B2 JP4282155B2 JP17133099A JP17133099A JP4282155B2 JP 4282155 B2 JP4282155 B2 JP 4282155B2 JP 17133099 A JP17133099 A JP 17133099A JP 17133099 A JP17133099 A JP 17133099A JP 4282155 B2 JP4282155 B2 JP 4282155B2
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Description
【０００１】
【発明の属する技術分野】
本発明は、メラミン樹脂を含浸させた基材に表面層を積層してなるメラミン樹脂化粧板に関する。
【０００２】
【従来の技術】
従来、この種のメラミン樹脂化粧板は、美観が良好であることで注目を集めている。ところが、この種のメラミン樹脂化粧板では、寸法変化が大きく耐クラック性に欠けるという問題点がある。そこで、これらを解消するためにメラミン樹脂の変成が試みられている。
【０００３】
例えば、特開昭５９−２９１５５号公報には、メラミン−パラトルエンスルホンアミド又はベンゾグアナミン−ホルムアルデヒドの反応物にグリシジルエーテル及び水溶性アクリル系共重合エマルジョンとを混合して得られる樹脂組成物をメラミン樹脂として用いることが、特開昭６２−８５９３８号公報にはメラミン−ホルムアルデヒドの反応物にアクリル酸エステル及び／またはメタアクリル酸エステルの重合物とメチロールメラミン樹脂及び／またはアルコール変成メラミン樹脂とを混合して得られる樹脂組成物をメラミン樹脂として用いることが開示されている。また、本出願人らは、特願昭６３−２９９３０６号にてメラミン−ホルムアルデヒドの反応物に熱可塑性樹脂エマルジョンを混合して得られる樹脂組成物を用いることを開示している。
【０００４】
【発明が解決しようとする課題】
しかしながら、上記の如く従来技術においては、変成剤に重合エマルジョン或いは重合物を用いている。このため、これらのエマルジョン或いは重合物が凝集したり、或いは紙の内部まで充分に浸透されない等により、得られたメラミン樹脂化粧板の寸法変化、耐クラック性は充分なものではなかった。
【０００５】
そこで本発明は、良好な半透明性を有し、かつ寸法変化率及び耐クラック性においても良好な特性を有するメラミン樹脂化粧板の提供を目的としてなされた。
【０００６】
【課題を解決するための手段及び発明の効果】
上記目的を達するためになされた請求項１記載の発明は、メラミン樹脂を含浸させた基材に表面層を積層してなるメラミン樹脂化粧板であって、上記基材が白色系繊維質基材であり、上記メラミン樹脂が、メラミンを縮合系変成剤によって変成し、続いて、メチルアルコールに溶解する分子量２０００以下のポリプロピレングリコールを添加してなるものであり、前記ポリプロピレングリコールの添加量は、前記変成後のメラミンの固形分１００重量部に対して、１５〜４０重量部であることを特徴とする。
【０００７】
本発明では、縮合系変成剤によって変成したメラミンに、メチルアルコールに溶解する分子量２０００以下のポリプロピレングリコールを添加している。そのポリプロピレングリコールの添加量は、前記変成後のメラミンの固形分１００重量部に対して、１５〜４０重量部である。また、そのポリプロピレングリコールは、請求項２記載の発明のように、含浸乾燥及び成型時の加熱によって、マトリックスとなる上記変成後のメラミンと相分離し均一にミクロ分散を起こすものとすることができる。このことは、得られるメラミン樹脂化粧板の寸法変化、耐クラック性、可撓性等の向上に寄与する。従って、本発明のメラミン樹脂化粧板は、良好な寸法変化率及び耐クラック性を有する。
【０００８】
また、請求項３記載の発明では、そのメラミン樹脂化粧板のＪＩＳＫ６９０２に準拠した寸法変化率を０．７０％以下としている。このため、寸法変化率を極めて良好に低減することができ、延いては、耐クラック性も一層向上させることができる。
【０００９】
なお、このような寸法変化率を実現する方法としては、例えば、低分子量体としてエーテル結合を有するものを使用する方法等が考えられる。また、白色系繊維質基材としては、漂白されたクラフトパルプ紙を始め、ガラス繊維，ビニロン繊維等の白色繊維を使用する紙、混抄紙、不織布、織布等、種々の基材を適用することができる。
【００１０】
請求項４記載の発明は、透過率が厚さ１．０ｍｍ相当で６．５％以上であることを特徴とする。
【００１２】
本発明のメラミン樹脂化粧板では、そのメラミン樹脂化粧板の透過率を、厚さ１．０ｍｍ相当で６．５％以上としている。このため、半透明性を一層向上させることができる。
【００１３】
なお、上記透過率は、例えば、厚さ１．３０ｍｍのガラス板を標準（透過率１００％）として測定することができる。また、このような透過率を実現する方法としては、例えば、低分子量体としてエーテル結合を有するものを使用する方法等が考えられる。
【００１４】
請求項５記載の発明は、請求項１〜４のいずれかに記載の構成に加え、上記基材に上記メラミン樹脂を５０〜１８０重量％含浸させたことを特徴とする。
メラミン樹脂化粧板におけるメラミン樹脂の重量％が増加すると、それに伴って木口の耐汚染性が向上する。また、樹脂の重量％が１８０重量％を超えると樹脂フローに伴う含浸基材の破損を招き好ましくない。本発明のメラミン樹脂化粧板は、基材にメラミン樹脂を５０〜１８０重量％含浸させているので、請求項１〜４のいずれかに記載の発明の効果に加えて、木口の耐汚染性が極めて良好であるといった効果が生じる。なお、更に好ましい樹脂の重量％（樹脂含浸率または樹脂率ともいう）は、５５〜１００重量％である。
【００１５】
請求項６記載の発明は、請求項１〜５のいずれかに記載の構成に加え、上記表面層が、パターン紙にメラミン樹脂を含浸させたものであることを特徴とする。
上記メラミン樹脂を含浸した白色系の基材は、前述のように良好な半透明性を有している。そこで、本発明のメラミン樹脂化粧板では、パターン紙にメラミン樹脂を含浸させたものを表面層としている。このため、上記半透明性を有する特性に起因して、パターン紙の色調が鮮明になったり、パターン紙の色調が基材（コア層ともいう）にうつったりする。従って、本発明では、請求項１〜５のいずれかに記載の発明の効果に加えて、表面層とコア層と芯材との間に外観上の極めて良好な一体感が生じるといった効果が生じる。
【００１６】
請求項７記載の発明は、請求項１〜５のいずれかに記載の構成に加え、上記表面層が、メラミン樹脂を含浸させたパターン紙に更にオーバーレイ紙を積層したものであることを特徴とする。
本発明では、メラミン樹脂を含浸させたパターン紙に更にオーバーレイ紙を積層したものを表面層としている。すなわち、請求項５記載の発明の構成に加え、上記パターン紙に更にオーバーレイ紙を積層して表面層としたことを特徴としている。オーバーレイ紙は、メラミン樹脂化粧板の耐摩耗性を向上させる作用がある。従って、本発明では、請求項５記載の発明の効果に加えて、耐摩耗性が一層良好であるといった効果が生じる。
【００１７】
【発明の実施の形態】
次に、本発明の具体的な実施の形態について説明する。前述のように、本発明では、縮合系変成剤として、例えば、アセトグアナミン、ベンゾグアナミン、シクロヘキサンカルボグアナミン、シクロヘキセンカルボグアナミン、ノルボルナンカルボグアナミン、ノルボルネンカルボグアナミン、グアニジン、ジシンジアミド、パラトルエンスルホン酸アミド、尿素、チオ尿素、イソプロパノールアミン、モノアミノブチレングリコール、イプシロンカプロラクタム、アクリル酸アミド等が使用でき、これらから選ばれた少なくとも１種がメラミン１モルに対して０．１〜１０モル添加され使用される。
【００１８】
通常、上記マトリックスを構成する樹脂を得るためにはホルムアルデヒドが添加されるが、メラミンと縮合系変成剤の混合物１モルに対して添加されるホルムアルデヒドは１．２〜４モルであり、樹脂保存性、反応性の面から好ましくは１．２〜３モルで反応が進められる。更に、樹脂保存性を良くするためにメチルアルコール、エチルアルコール、ブチルアルコール等の低級アルコール類によってエーテル化されてもよい。前述のマトリックス樹脂はメチルアルコール等の低級アルコール類、アセトン、ＭＥＫ等の低級ケトン類等の溶媒で所定の固形分に調整される。
【００１９】
次いで添加される低分子量体としては、上記マトリックス樹脂との相溶性が良好なものであって、メチルアルコールに溶解し、好ましくはエーテル結合を有するポリプロピレングリコールが使用される。その種類及び添加量は、上記エーテル化反応物中のメラミンと縮合系変成剤との混合比、その混合物とホルムアルデヒドとの配合比、該ポリプロピレングリコールの極性、分子量、及び成形条件等によって決定されるが、得られるメラミン樹脂化粧板の耐クラック性、寸法変化、耐水性、層間密着性などの観点から、該低分子量体はガラス転移点の低い柔軟なものが望ましく、添加量は上記マトリックス樹脂の固形分１００重量部に対して５〜９０重量部、好ましくは１５〜４０重量部とするとよい。
【００２０】
上記樹脂組成物は、含浸基材に含浸される直前に、マトリックス樹脂硬化に有効な有機または無機の酸、或いはアルカノールアミン塩などの潜伏性硬化触媒等が添加されて使用される。
本発明に用いられる含浸基材は、晒しクラフト等の白色系繊維質基材であり、これらの含浸基材に対して、上記樹脂組成物は重量比で含浸基材１００％に対して５０〜１８０％の樹脂含浸率で含浸乾燥される。該樹脂含浸率は５０％未満であると白化や層間剥離を招き、１８０％を超えると樹脂フローに伴う含浸基材の破損を招き好ましくない。更に好ましい樹脂含浸率は５５〜１００％である。
【００２１】
得られたメラミン樹脂含浸紙は所望の厚さとなるように複数枚積層され、パターン紙或いは更にオーバーレイ紙を使用した表面層を積層した上で常法に従って熱圧成形され、本実施の形態のメラミン樹脂化粧板が得られる。また、マトリックス樹脂に添加された上記ポリプロピレングリコールは、マトリックスとなるメラミン−縮合系変成剤−ホルムアルデヒド系反応物と相分離し均一にミクロ分散を起こして、得られるメラミン樹脂化粧板の寸法変化、耐クラック性、可撓性等の改善に寄与する。従って、本実施の形態のメラミン樹脂化粧板は、良好な寸法変化率及び耐クラック性を有する。また、本実施の形態のメラミン樹脂化粧板では、基材として白色系繊維質基材を使用しているので、メラミン樹脂が元々備えている半透明性が一層良好に反映され、良好な半透明性を呈する。このため、上記半透明性を有する特性に起因して、表面層のパターン紙の色調が鮮明になったり、パターン紙の色調が基材（コア層ともいう）にうつったりする。従って、表面層とコア層と芯材との間に外観上の極めて良好な一体感が生じる。
【００２２】
特に、前述のように、エーテル結合を有するポリプロピレングリコールを使用した場合、次に実施例を挙げて説明するように、メラミン樹脂化粧板のＪＩＳＫ６９０２に準拠した寸法変化率を０．７０％以下とすると共に、透過率を、厚さ１．０ｍｍ相当で６．５％以上とすることができる。従って、この場合、良好な半透明性を有し、かつ、寸法変化率及び耐クラック性においても極めて良好な特性を有するメラミン樹脂化粧板を提供することができる。
【００２３】
【実施例】
本願出願人は、本発明のメラミン樹脂化粧板を実施例として実際に製造し、従来と同様に製造した比較例との比較対照を行った。続いて、この実施例及び比較例について説明する。
【００２４】
実施例
メラミン１モルに対して１モルのグアニジンが添加された混合物１モルに対してホルムアルデヒドとして２．３モルの３７％ホルマリン水溶液を添加し、ＮａＯＨでｐＨ９．０に調整して昇温溶解させメチロール化反応を行った後、上記混合物１モルに対して２．５モルのメチルアルコールを加え、ギ酸にてｐＨ５．５に調整し、８０℃でエーテル化反応させ、８０％メチルアルコール水溶液に白濁した時点を反応終点とする。反応終了後ＮａＯＨでｐＨ７．０に中和し、固形分６０重量％となるように調整して、メチルアルコール溶性のマトリックス樹脂が得られた。次いで、上記マトリックス樹脂の固形分１００重量部に対してポリプロピレングリコール３０重量部、及び潜伏性硬化触媒のパラトルエンスルホン酸（ＰＴＳ）１重量部を添加して含浸用メラミン樹脂組成物が得られた。該含浸用メラミン樹脂組成物は非水溶性でメチルアルコール等には溶性であった。
【００２５】
上記含浸用メラミン樹脂組成物は灰分含有量０重量％、坪量２００ｇ／ｍ2 の晒しクラフトに樹脂含浸率６０％、揮発分７％で含浸乾燥された４枚のメラミン樹脂含浸紙（コア層）の上に、表面層として、坪量８０ｇ／ｍ2 のパターン紙に樹脂含浸率８０％でメラミン樹脂組成物を含浸させた含浸パターン紙１枚が積層され、１２０℃−８０ｋｇ／ｃｍ2 −２０分の熱圧条件で成形され、厚さ１．０ｍｍのメラミン樹脂化粧板が得られた。
【００２６】
比較例１
実施例において得られたメチルアルコール溶性マトリックス樹脂をそのまま含浸用メラミン樹脂組成物として用いる以外は実施例と全く同様。
比較例２
実施例において得られたメチルアルコール溶性マトリックス樹脂をそのまま含浸用メラミン樹脂組成物として用い、基材として灰分含有量０重量％、坪量２００ｇ／ｍ2 の未晒しクラフトを用いる以外は実施例と全く同様。
【００２７】
上記実施例及び比較例の物性を表１に示す。
【００２８】
【表１】
＊１ 化粧板裏面に接触させたもの（例えば、手・指）が蛍光灯にかざして見たとき、見えるか否か、また、その程度を相対的に官能的に評価する。但し、化粧板の厚さは同一にて評価する。
○：見える（半透明性に優れる）
×：見え難い（半透明性に乏しい）
＊２ ＪＩＳＫ６９０２準拠
＊３ ２５０ｍｍＷ×２５０ｍｍＬ×１８ｍｍＴの合板に同一大のメラミン樹脂化粧板をゴム系接着剤にて接着し、該メラミン樹脂化粧板の繊維方向と平行で両端の中央部に長さ２０ｍｍ、巾３ｍｍの切り込み加工したものを試験片とし、８０℃の恒温槽中に２時間放置後、更に−２０℃の恒温槽中に２時間放置することを１サイクルとし、クラック発生の有無及びクラック長さを測定する。クラックが発生し、その合計が２００ｍｍに達した時点を終点とする。
【００３０】
表１から判るように、白色系繊維質基材である晒しクラフトを使用した実施例及び比較例１では、いずれも半透明性及び木口の外観が良好であったが、低分子量体を添加しなかった比較例１，２では寸法変化率及び耐クラック性において充分な特性が得られなかった。これに対して、実施例では寸法変化率が０．６０％と極めて良好で、耐クラック性においても充分に満足のできる特性が得られた。
【００３１】
また、上記実施例のメラミン樹脂化粧板を試料として複数作成し、その透過率を測定したところ、１．０ｍｍ相当で、１０．３４，８．７６，９．５８，１２．０３，６．９９，１０．２７，１３．５７，１０．８５，１１．１１，１６．８６等（いずれも％）の値を示した。すなわち、上記実施例のメラミン樹脂化粧板は、パターン紙の色等によっても上記のように異なるが、その色に関わらず少なくとも６．５％以上の透過率（厚さ１．０ｍｍ相当）を呈し、良好な半透明性を有していた。これは、一般の化粧板が透過率５％以下であることを参照すれば、極めて優れた特性といえる。なお、上記透過率の測定は、厚さ１．３０ｍｍのガラス板を標準（透過率１００％）として、Ｕ−３２００形自記分光光度計（商品名：日立製作所製）を用いて波長３００〜８００ｎｍの光に対して行った。
【００３２】
次に、上記実施例のメラミン樹脂化粧板を、含浸用メラミン樹脂組成物の重量％（樹脂率）を種々に変化させて作成し、木口の耐汚染性を評価した。結果を表２に示す。
【００３３】
【表２】
但し、評価はＪＩＳＫ６９０２に準じ、木口をＣＣ８００番の耐水研磨紙を用いて湿潤摩擦により研磨して試験体とし、試験体木口に汚染材料（例えば、紅茶・コーヒー）を付着させた後１分程度で拭き取り比較して行った。
○：変化なし
△：軽微な変化
×：強い変化
このように、樹脂率を５５％以上とした場合、木口の耐汚染性が極めて良好になることが判った。なお、樹脂率が１８０％を超えると樹脂フローに伴う含浸基材の破損を招き好ましくない。従って、樹脂率は５０〜１８０％、更に好ましくは５５〜１００％とするとよい。
【００３５】
上記実施例のメラミン樹脂化粧板は、前述のように、寸法変化率が小さく、耐クラック性，木口の美観，及び耐汚染性が良好で、優れた半透明性を有するといった特性の他にも、柔軟性及びハンドリング性が良好で縁貼り機への適性に優れているといった特性を有している。上記特性の内、寸法変化率が小さいことから、加工品の反りや化粧板の割れが生じないといった効果が生じる。また、木口の美観が良好であることから、白色半透明でカット面が美しいとか、褐色コア層がなく加工品の仕上がりが良好であるとかいった効果が生じる。なお、柔軟性及びハンドリング性は、晒しクラフトの灰分が０％であることに起因する効果であるが、灰分が０〜５％の範囲内であれば同様の効果が生じる。
【００３６】
また、上記実施例のメラミン樹脂化粧板では、上記半透明性を有する特性に起因して、芯材の色調がコア層にうつるとか仕上がり外観がソフトであるとかいった効果が生じる。更に、メラミン樹脂化粧板はコア層の表面に表面層としてパターン紙或いはそのパターン紙に更にオーバーレイ紙を積層して使用される場合も多いが、この場合、上記半透明性を有する特性に起因して、パターン層の色調が鮮明になるとかパターン層の色調がコア層にうつるとかいった効果が生じる。このため、表面層とコア層と芯材との間に外観上の極めて良好な一体感が生じる。また、オーバーレイ紙を積層した場合は、メラミン樹脂化粧板の耐摩耗性が一層向上する。
【００３７】
ここで、オーバーレイ紙やパターン紙の一例を挙げておく。オーバーレイ紙としては、ホルムアルデヒド／メラミンのモル比１．５〜２．５程度で合成した一般のメラミン樹脂を坪量２０〜３０ｇ／ｍ2 のαセルロース紙に樹脂率２００〜３００％で含浸させたものを使用することが考えられ、パターン紙としては、同樹脂を坪量５０〜１５０ｇ／ｍ2 のαセルロース紙に樹脂率６０〜１６０％で含浸させたものを使用することが考えられる。なお、上記パターン紙としては、無地のものを使用しても柄物を使用してもよい。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a melamine resin decorative board formed by laminating a surface layer on a base material impregnated with melamine resin.
[0002]
[Prior art]
Conventionally, this type of melamine resin decorative board has attracted attention because of its good appearance. However, this type of melamine resin decorative board has a problem that the dimensional change is large and the crack resistance is insufficient. In order to solve these problems, attempts have been made to modify the melamine resin.
[0003]
For example, JP-A-59-29155 discloses a resin composition obtained by mixing a reaction product of melamine-paratoluenesulfonamide or benzoguanamine-formaldehyde with glycidyl ether and a water-soluble acrylic copolymer emulsion. In JP-A-62-85938, a melamine-formaldehyde reaction product is mixed with an acrylic ester and / or methacrylic ester polymer and a methylol melamine resin and / or an alcohol-modified melamine resin. It is disclosed that the resin composition obtained in this way is used as a melamine resin. In addition, the present applicants disclose in Japanese Patent Application No. 63-299306 that a resin composition obtained by mixing a thermoplastic resin emulsion with a reaction product of melamine-formaldehyde is used.
[0004]
[Problems to be solved by the invention]
However, as described above, in the prior art, a polymer emulsion or polymer is used as the modifying agent. For this reason, dimensional change and crack resistance of the resulting melamine resin decorative board were not sufficient due to aggregation of these emulsions or polymers, or insufficient penetration into the paper.
[0005]
Then, this invention was made | formed for the purpose of provision of the melamine resin decorative board which has favorable translucency and has a favorable characteristic also in a dimensional change rate and crack resistance.
[0006]
[Means for Solving the Problems and Effects of the Invention]
In order to achieve the above object, the invention according to claim 1 is a melamine resin decorative board obtained by laminating a surface layer on a base material impregnated with a melamine resin, wherein the base material is a white fibrous base material. , and the above-mentioned melamine resin, a melamine denatured by condensation modifier, followed by state, and are made by adding a molecular weight of 2,000 or less of polypropylene glycol is dissolved in methyl alcohol, the addition amount of the polypropylene glycol, It is 15-40 weight part with respect to 100 weight part of solid content of the melamine after the said modification | denaturation, It is characterized by the above-mentioned.
[0007]
In the present invention, polypropylene glycol having a molecular weight of 2000 or less that is dissolved in methyl alcohol is added to melamine that has been modified with a condensation-type modifying agent. The addition amount of the polypropylene glycol is for the previous SL 100 parts by weight of the solid content of the melamine after the shift, from 15 to 40 parts by weight. In addition, as in the invention described in claim 2 , the polypropylene glycol can be phase-separated from the melamine after the transformation, which becomes the matrix, by heating during impregnation drying and molding, and can be uniformly microdispersed. . This contributes to improvement in dimensional change, crack resistance, flexibility and the like of the resulting melamine resin decorative board. Therefore, the melamine resin decorative board of the present invention has a good dimensional change rate and crack resistance.
[0008]
Moreover, in the invention of Claim 3 , the dimensional change rate based on JISK6902 of the melamine resin decorative board is 0.70% or less. For this reason, the rate of dimensional change can be reduced very well, and crack resistance can be further improved.
[0009]
In addition, as a method of realizing such a dimensional change rate, for example, a method using a low molecular weight substance having an ether bond can be considered. In addition, as the white fiber base material, various base materials such as bleached kraft pulp paper, paper using white fiber such as glass fiber and vinylon fiber, mixed paper, non-woven fabric, woven fabric, etc. are applied. be able to.
[0010]
The invention according to claim 4 is characterized in that the transmittance corresponds to 1.0 mm or more and is 6.5% or more.
[0012]
In the melamine resin decorative board of the present invention, the transmittance of the melamine resin decorative board is set to 6.5% or more at a thickness equivalent to 1.0 mm. For this reason, translucency can be improved further.
[0013]
The transmittance can be measured using, for example, a glass plate having a thickness of 1.30 mm as a standard (transmittance of 100%). In addition, as a method for realizing such transmittance, for example, a method using a low molecular weight substance having an ether bond may be considered .
[0014]
The invention according to claim 5 is characterized in that, in addition to the constitution according to any one of claims 1 to 4 , the base material is impregnated with 50 to 180% by weight of the melamine resin.
When the weight percentage of the melamine resin in the melamine resin decorative board increases, the contamination resistance of the lip improves accordingly. On the other hand, if the weight percent of the resin exceeds 180 weight percent, the impregnated base material is damaged due to the resin flow, which is not preferable. In the melamine resin decorative board of the present invention, the base material is impregnated with 50 to 180% by weight of melamine resin, so that in addition to the effect of the invention according to any one of claims 1 to 4 , the stain resistance of the lip is The effect of being extremely good is produced. In addition, the more preferable weight% (it is also called the resin impregnation rate or resin rate) of resin is 55 to 100 weight%.
[0015]
The invention according to claim 6 is characterized in that, in addition to the structure according to any one of claims 1 to 5 , the surface layer is obtained by impregnating a patterned paper with a melamine resin.
The white base material impregnated with the melamine resin has good translucency as described above. Therefore, in the melamine resin decorative board of the present invention, the surface layer is obtained by impregnating the pattern paper with the melamine resin. For this reason, the color tone of the pattern paper becomes clear or the color tone of the pattern paper is transferred to the substrate (also referred to as a core layer) due to the above-described translucency characteristic. Therefore, in the present invention, in addition to the effects of the invention according to any one of claims 1 to 5 , there is an effect that a very good sense of unity in appearance occurs between the surface layer, the core layer, and the core material. .
[0016]
The invention according to claim 7 is characterized in that, in addition to the structure according to any one of claims 1 to 5 , the surface layer is obtained by further laminating an overlay paper on a pattern paper impregnated with a melamine resin. To do.
In the present invention, the surface layer is obtained by further laminating overlay paper on pattern paper impregnated with melamine resin. In other words, in addition to the structure of the invention described in claim 5 , overlay paper is further laminated on the pattern paper to form a surface layer. The overlay paper has the effect of improving the abrasion resistance of the melamine resin decorative board. Therefore, in the present invention, in addition to the effect of the invention according to the fifth aspect , the effect that the wear resistance is further improved.
[0017]
DETAILED DESCRIPTION OF THE INVENTION
Next, specific embodiments of the present invention will be described. As described above, in the present invention, examples of the condensation modifier include acetoguanamine, benzoguanamine, cyclohexanecarboguanamine, cyclohexenecarboguanamine, norbornanecarboguanamine, norbornenecarboguanamine, guanidine, dicindiamide, p-toluenesulfonic acid amide, urea, Thiourea, isopropanolamine, monoaminobutylene glycol, epsilon caprolactam, acrylic amide, and the like can be used, and at least one selected from these is added in an amount of 0.1 to 10 mol per mol of melamine.
[0018]
Usually, formaldehyde is added in order to obtain the resin constituting the matrix, but the formaldehyde added is 1 to 4 mol per 1 mol of the mixture of melamine and the condensation modifier, and the resin storage stability is increased. From the viewpoint of reactivity, the reaction is preferably carried out at 1.2 to 3 mol. Furthermore, it may be etherified with lower alcohols such as methyl alcohol, ethyl alcohol, and butyl alcohol in order to improve the resin storage stability. The aforementioned matrix resin is adjusted to a predetermined solid content with a solvent such as lower alcohols such as methyl alcohol and lower ketones such as acetone and MEK.
[0019]
Then a low molecular weight material is added, the compatibility with the matrix resin is not more favorable, dissolved in methylation alcohol, preferably used is polypropylene glycol having an ether bond. The type and amount of addition are determined by the mixing ratio of melamine and condensation modifier in the etherification reaction product, the blending ratio of the mixture and formaldehyde, the polarity, molecular weight, and molding conditions of the polypropylene glycol. However, from the viewpoint of crack resistance, dimensional change, water resistance, interlayer adhesion, and the like of the resulting melamine resin decorative board, the low molecular weight material is desirably a flexible one having a low glass transition point, and the amount added is that of the matrix resin. It is good to set it as 5-90 weight part with respect to 100 weight part of solid content, Preferably it is 15-40 weight part.
[0020]
The resin composition is used by adding a latent curing catalyst such as an organic or inorganic acid effective for matrix resin curing or an alkanolamine salt immediately before impregnating the impregnated substrate.
The impregnated substrate used in the present invention is a white fibrous substrate such as bleached craft, and the resin composition is 50 to 100% by weight of the impregnated substrate with respect to these impregnated substrates. It is impregnated and dried at a resin impregnation rate of 180%. If the resin impregnation ratio is less than 50%, whitening and delamination are caused, and if it exceeds 180%, the impregnated base material is damaged due to the resin flow. A more preferable resin impregnation rate is 55 to 100%.
[0021]
The obtained melamine resin-impregnated paper is laminated in plural sheets so as to have a desired thickness, and after being laminated with a surface layer using pattern paper or further overlay paper, it is hot-pressed in accordance with a conventional method, and the melamine of this embodiment A resin decorative board is obtained. In addition, the polypropylene glycol added to the matrix resin phase-separates with the melamine-condensation modifier-formaldehyde reactant to be a matrix and causes uniform micro-dispersion. Contributes to improvements in cracking and flexibility. Therefore, the melamine resin decorative board of the present embodiment has a good dimensional change rate and crack resistance. Moreover, in the melamine resin decorative board of the present embodiment, since the white fiber base material is used as the base material, the translucency originally provided by the melamine resin is reflected more favorably, and the good translucency is achieved. Exhibits sex. For this reason, the color tone of the pattern paper on the surface layer becomes clear or the color tone of the pattern paper is transferred to the base material (also referred to as a core layer) due to the above-described translucency characteristic. Therefore, a very good sense of unity in appearance occurs between the surface layer, the core layer, and the core material.
[0022]
In particular, as described above, when using a polypropylene glycol having a d ether bond, as will now be described by way of example, 0.70 percent dimensional change rate in conformity to JISK6902 melamine resin decorative plate and In addition, the transmittance can be 6.5% or more when the thickness is equivalent to 1.0 mm. Therefore, in this case, it is possible to provide a decorative melamine resin board having good translucency and having very good characteristics in terms of dimensional change rate and crack resistance.
[0023]
【Example】
The applicant of the present application actually manufactured the decorative melamine resin board of the present invention as an example, and compared it with a comparative example manufactured in the same manner as before. Subsequently, the examples and comparative examples will be described.
[0024]
Example 2.3 mol of 37% formalin aqueous solution as formaldehyde is added to 1 mol of a mixture in which 1 mol of guanidine is added to 1 mol of melamine, and the mixture is adjusted to pH 9.0 with NaOH and dissolved at elevated temperature. After methylolation reaction, 2.5 mol of methyl alcohol was added to 1 mol of the above mixture, adjusted to pH 5.5 with formic acid, etherified at 80 ° C., and white turbid in 80% aqueous methyl alcohol solution. The reaction end point is taken as the reaction end point. After completion of the reaction, the mixture was neutralized with NaOH to pH 7.0 and adjusted to a solid content of 60% by weight to obtain a methyl alcohol-soluble matrix resin. Next, 30 parts by weight of polypropylene glycol and 1 part by weight of paratoluenesulfonic acid (PTS) as a latent curing catalyst were added to 100 parts by weight of the solid content of the matrix resin to obtain a melamine resin composition for impregnation. . The impregnating melamine resin composition was insoluble in water and soluble in methyl alcohol and the like.
[0025]
The melamine resin composition for impregnation is composed of four sheets of melamine resin impregnated paper (core layer) impregnated and dried in bleached kraft having an ash content of 0% by weight and a basis weight of 200 g / m 2 at a resin impregnation rate of 60% and a volatile content of 7%. ), A sheet of impregnated pattern paper impregnated with a melamine resin composition at a resin impregnation ratio of 80% is laminated on a pattern paper having a basis weight of 80 g / m 2 as a surface layer, and 120 ° C.-80 kg / cm 2 − A melamine resin decorative board having a thickness of 1.0 mm was obtained by molding under hot pressure conditions for 20 minutes.
[0026]
Comparative Example 1
Except for using the methyl alcohol-soluble matrix resin obtained in the examples as the melamine resin composition for impregnation as it is, the same as the examples.
Comparative Example 2
The methyl alcohol-soluble matrix resin obtained in the examples is used as it is as a melamine resin composition for impregnation, and is completely the same as the examples except that an unbleached craft having an ash content of 0% by weight and a basis weight of 200 g / m 2 is used. Same.
[0027]
The physical properties of the above Examples and Comparative Examples are shown in Table 1.
[0028]
[Table 1]
* 1 Relative sensory evaluation of whether or not an object (for example, hand / finger) that is in contact with the back of the decorative board is visible over a fluorescent lamp and whether it is visible. However, the thickness of the decorative board is evaluated as the same.
○: Visible (excellent translucency)
×: difficult to see (poor translucency)
* 2 Conforms to JISK6902 * 3 Adheres a melamine resin decorative board of the same size to a 250 mmW x 250 mmL x 18 mmT plywood with a rubber adhesive and is 20 mm in length at the center of both ends parallel to the fiber direction of the melamine resin decorative board The test piece is 3 mm wide cut and left in a thermostatic bath at 80 ° C. for 2 hours, and then in a thermostatic bath at −20 ° C. for 2 hours. Measure the length. The time when a crack occurs and the total reaches 200 mm is taken as the end point.
[0030]
As can be seen from Table 1, in Examples and Comparative Example 1 using bleached craft which is a white fiber base material, both the translucency and the appearance of the mouth were good, but a low molecular weight substance was added. In Comparative Examples 1 and 2 that were not present, sufficient characteristics in terms of dimensional change rate and crack resistance were not obtained. On the other hand, in the examples, the dimensional change rate was as extremely good as 0.60%, and a sufficiently satisfactory characteristic in crack resistance was obtained.
[0031]
Moreover, when a plurality of melamine resin decorative plates of the above examples were prepared as samples and the transmittances thereof were measured, it was equivalent to 1.0 mm, and was 10.34, 8.76, 9.58, 12.03, 6.99. , 10.27, 13.57, 10.85, 11.11, 16.86, etc. (all are%). That is, the melamine resin decorative board of the above example exhibits a transmittance (corresponding to a thickness of 1.0 mm) of at least 6.5% regardless of the color, although it varies as described above depending on the color of the pattern paper. And had good translucency. This can be said to be an extremely excellent characteristic when referring to a general decorative board having a transmittance of 5% or less. The transmittance is measured with a glass plate having a thickness of 1.30 mm as a standard (transmittance of 100%) using a U-3200 self-recording spectrophotometer (trade name: manufactured by Hitachi, Ltd.) with a wavelength of 300 to 800 nm. Went against the light.
[0032]
Next, melamine resin decorative boards of the above examples were prepared by changing the weight percentage (resin ratio) of the impregnating melamine resin composition in various ways, and the stain resistance of the lip was evaluated. The results are shown in Table 2.
[0033]
[Table 2]
However, the evaluation is in accordance with JISK6902, and the end is polished by wet friction using CC800 water resistant abrasive paper to make a test piece, and about 1 minute after a contaminated material (for example, tea or coffee) is attached to the end of the test piece. It was done by wiping and comparing.
○: No change Δ: Minor change ×: Strong change Thus, it was found that when the resin ratio was 55% or more, the contamination resistance of the lip was extremely good. In addition, when the resin ratio exceeds 180%, the impregnated base material is damaged due to the resin flow, which is not preferable. Therefore, the resin ratio is 50 to 180%, more preferably 55 to 100%.
[0035]
As described above, the decorative melamine resin board of the above embodiment has a small dimensional change rate, crack resistance, aesthetic appearance of the mouth, and good anti-contamination property, and has excellent translucency. It has the characteristics that it has good flexibility and handling properties and is excellent in suitability for edge pasting machines. Among the above characteristics, since the dimensional change rate is small, there is an effect that warpage of the processed product and cracking of the decorative board do not occur. Moreover, since the aesthetics of Kiguchi is good, effects such as white translucency and a beautiful cut surface, and a good finished product without a brown core layer are produced. In addition, although a softness | flexibility and handling property are the effects resulting from the ash content of bleaching craft being 0%, if the ash content is in the range of 0 to 5%, the same effect will arise.
[0036]
Moreover, in the melamine resin decorative board of the said Example, due to the characteristic which has the said semi-transparency, the effect that the color tone of a core material passes on a core layer or the finished external appearance is soft arises. In addition, melamine resin decorative boards are often used by laminating patterned paper as a surface layer on the surface of the core layer or overlay paper on the patterned paper. In this case, the melamine resin decorative board is attributed to the above-mentioned translucency. Thus, effects such as a clear color tone of the pattern layer and a color tone of the pattern layer passing on the core layer are produced. For this reason, a very good sense of unity in appearance occurs between the surface layer, the core layer, and the core material. Moreover, when overlay paper is laminated | stacked, the abrasion resistance of a melamine resin decorative board improves further.
[0037]
Here, examples of overlay paper and pattern paper are given. As the overlay paper, a general melamine resin synthesized with a formaldehyde / melamine molar ratio of about 1.5 to 2.5 was impregnated with α cellulose paper having a basis weight of 20 to 30 g / m 2 at a resin ratio of 200 to 300%. It is conceivable to use a pattern paper, and it is conceivable to use the same resin impregnated with α cellulose paper having a basis weight of 50 to 150 g / m 2 at a resin ratio of 60 to 160%. In addition, as said pattern paper, you may use a plain thing or a patterned thing.
Claims (7)
上記基材が白色系繊維質基材であり、
上記メラミン樹脂が、メラミンを縮合系変成剤によって変成し、続いて、メチルアルコールに溶解する分子量２０００以下のポリプロピレングリコールを添加してなるものであり、
前記ポリプロピレングリコールの添加量は、前記変成後のメラミンの固形分１００重量部に対して、１５〜４０重量部であることを特徴とするメラミン樹脂化粧板。It is a melamine resin decorative board formed by laminating a surface layer on a base material impregnated with melamine resin,
The substrate is a white fibrous substrate;
The melamine resin, a melamine denatured by condensation modifier, followed by state, and are made by adding a molecular weight of 2,000 or less of polypropylene glycol is dissolved in methyl alcohol,
The addition amount of the polypropylene glycol is 15 to 40 parts by weight with respect to 100 parts by weight of the solid content of the melamine after the modification .
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| WO2007020900A1 (en) * | 2005-08-12 | 2007-02-22 | Dai Nippon Printing Co., Ltd. | Decorative plate and method for manufacture thereof |
| JP4758851B2 (en) * | 2006-08-29 | 2011-08-31 | アイカ工業株式会社 | Thermosetting resin decorative board |
| AU2011230894B2 (en) * | 2010-03-23 | 2014-11-27 | Aica Kogyo Co., Ltd. | Decorative melamine board |
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