JP6344612B2 - Manufacturing method of high gloss decorative board - Google Patents

Description

  The present invention relates to a method for producing a melamine-based resin decorative board in which a melamine resin-based coating layer is laminated on at least one surface of a substrate and hot-press molded.

As a conventional method for producing a high-gloss melamine decorative board, a decorative paper obtained by pattern printing is impregnated with a thermosetting resin, and a prepreg obtained by drying is superimposed on a kraft-impregnated paper to apply high pressure (for example, 50 A method is employed in which a laminate is formed by hot-press molding at ˜120 kg / cm ² ), and this laminate is further adhered to the substrate surface with an adhesive. The product obtained by this method is called a high-pressure melamine decorative board.

However, although this manufacturing method can provide a product with high gloss, it requires a long press process to laminate impregnated paper and kraft impregnated paper, and after sanding the adhesive surface, There is a drawback that the number of steps is large, such as bonding to a substrate.
Furthermore, when using a woody base material such as particle board, MDF, or plywood as the base material, there is a problem of thickness reduction due to pressing, and there is a base material on which high pressure cannot be applied.

  Therefore, a method is employed in which uncured impregnated decorative paper is directly superimposed on a base material and simultaneously press-molded without being laminated with kraft impregnated paper. This method enables mass production up to a decorative board in a short time, and the product obtained by this method is called a short cycle melamine decorative board or a low-pressure melamine decorative board.

However, the low-pressure melamine decorative board is limited to those having a low gloss and a matte product as compared with the high-pressure melamine decorative board. For example, the impregnated resin is cured in a short time, so the impregnated paper and the base material are molded at a high temperature and removed from the hot press. It is said that the desorption product produced by the condensation reaction of the functional resin tends to cause deterioration of the surface properties such as gloss reduction in the process of coming off on the surface of the molding material.
Therefore, a decorative board using a wooden base material that cannot be subjected to high pressure is stable and high, with a semi-glossy surface with a low surface gloss or uneven gloss with a mixture of high and low gloss. It is difficult to make a glossy decorative board. Currently, short-cycle melamine decorative boards using a wood-based base material on the market are limited to matte ones.

Means for solving the above-mentioned problems in the production of a short cycle melamine decorative board include a method of reducing the amount of volatile components of the base material and impregnated paper, and a method of increasing the amount of thermosetting resin and catalyst in the impregnated resin. But the effect is not enough. In particular, the latter causes pinholes and cracks at the time of molding and tends to deteriorate the surface properties of the product.
In addition, as a means for improving the gloss of a short cycle melamine decorative board, a method of blending a microgel emulsion containing diallyl phthalate as an essential component is described. The decorative board produced by this method exhibits excellent gloss, but the microgel emulsion is not readily available, is expensive in terms of cost, and has a problem that the amount of addition is limited (Patent Document 1). reference).

JP 09-53357

  Accordingly, an object of the present invention is to obtain a decorative board having gloss and sharpness comparable to that of a high-pressure melamine decorative board in a decorative board manufacturing method (short cycle method) in which an impregnated paper is directly bonded to a substrate and simultaneously molded. It is to provide a manufacturing method.

Gel time in a method for producing a decorative board in which a prepreg obtained by impregnating and drying a melamine resin on a decorative paper is superimposed on a base material, and pressure is applied under heating to cure the resin and bond the decorative paper to the base material. It has been found that the above-mentioned problems can be solved by impregnating decorative paper with different melamine resin compositions.
That is, the present invention can be described as follows.
Item 1 In a method for producing a decorative board in which a prepreg obtained by impregnating and drying a decorative paper with melamine resin is superimposed on a base material, and pressure is applied under heating to cure the resin and bond the decorative paper to the base material. ,
A step of impregnating decorative paper with a melamine resin composition having a gel time of 120 seconds or more and 250 seconds or less (inter-paper reinforcing impregnation step), and a melamine resin composition having a gel time of 150 seconds or more and 400 seconds or less, A method for producing a decorative board, wherein a decorative paper subjected to an impregnation step is impregnated with a melamine resin by a step of impregnating the decorative paper (main impregnation step), and the following formula is satisfied.
Gel time (seconds) of melamine resin composition in this impregnation step-Gel time (seconds) of melamine resin composition in inter-paper reinforced impregnation step ≧ 30 (seconds)
Item 2 Base material is particle board selected from particle board, MDF (medium density fiberboard), kenaf board, veneer plywood, metal plate base material selected from aluminum plate, stainless steel plate, magnesium oxide, aluminum hydroxide , Aluminum oxide, silicon oxide, titanium oxide, magnesium chloride, calcium silicate, volcanic glassy material, gypsum (calcium sulfate), limestone (calcium carbonate), hydraulic cement and pneumatic cement Item 2. The method for producing a decorative board according to Item 1, which is any one of inorganic base materials obtained by curing the material.
Item 3 The method for producing a decorative board according to Item 1 or 2, wherein the decorative board has a 20-degree gloss value of 100 or more measured by a method defined in JIS Z 8741.
Item 4 A step of impregnating a decorative paper with a melamine resin composition having a gel time of 120 seconds or more and 250 seconds or less (inter-paper reinforcing impregnation step), and a melamine resin composition having a gel time of 150 seconds or more and 400 seconds or less, A method for producing a prepreg characterized by impregnating decorative paper with melamine resin through a step of impregnating decorative paper that has undergone an intertempering impregnation step (this impregnation step) and satisfying the following formula.
Gel time (seconds) of melamine resin composition in this impregnation step-Gel time (seconds) of melamine resin composition in inter-paper reinforced impregnation step ≧ 30 (seconds)

  According to the production method of the present invention, a general short-cycle melamine decorative board can be produced with a high gloss, high sharpness and good smoothness comparable to those of a high-pressure melamine decorative board under molding conditions and molding conditions. Manufacturing becomes possible.

Hereinafter, the production method of the present invention will be described in detail.
The present invention relates to a method for producing a decorative board in which a prepreg obtained by impregnating and drying decorative paper with melamine resin is laminated on a base material, and pressure is applied under heating to cure the resin and bond the decorative paper to the base material. (Short cycle method).

Prepreg The prepreg of the present invention is obtained by impregnating decorative paper with melamine resin and drying, and is characterized by impregnating decorative paper with melamine resin compositions having different gel times. That is, the melamine resin used in the inter-paper strengthening impregnation step on the decorative paper that has previously been impregnated with the melamine resin composition having a short gel time into the back of the paper (also referred to as inter-paper strengthening impregnation step). Impregnation is performed using a melamine resin composition having a longer gel time than the composition (also referred to as this impregnation step).

  The melamine resin used in the melamine resin composition of the present invention may be a melamine resin for high pressure molding, but a melamine resin for low pressure molding is preferred. As the melamine resin, a known resin can be adopted as long as it is a resin having melamine and its derivatives as monomers, and it may be a resin composed of a single monomer or a copolymer composed of a plurality of monomers. Also good. Examples of the melamine derivative include derivatives having a functional group such as an alkoxymethyl group such as an imino group, a methylol group, a methoxymethyl group, or a butoxymethyl group. A compound obtained by reacting a lower alcohol with a melamine derivative having a methylol group and partially or completely etherified can also be used as a monomer.

  In the melamine resin composition of the present invention, a resin other than the melamine resin may be contained, and examples thereof include alkylene glycoside resins such as methylene glycoside and butylene glycoside, acrylic resins, and the like.

  In the melamine resin composition of the present invention, when a resin other than the melamine resin is contained, the ratio of the melamine resin in the resin component is preferably 50% by weight or more, and more preferably 70% by weight or more. .

  In the melamine resin composition of the present invention, a solvent may be used, and examples thereof include water-soluble organic solvents such as water, methanol, ethanol, and isopropanol. A mixture of water and a water-soluble organic solvent may be used.

  A curable catalyst may be used in the melamine resin composition of the present invention, and is not particularly limited. However, ammonium chloride, p-toluenesulfonic acid, ammonium p-toluenesulfonate, diammonium imidodisulfonate, 2-amino-2 -Methyl-1-propanol etc. can be illustrated.

  If necessary, the melamine resin composition of the present invention includes crystalline cellulose, a curing accelerator, a release agent, an inorganic or organic filler, a plasticizer, a dispersant, a thickener, a viscosity modifier, and an antifoaming agent. Ordinarily used additives such as preservatives, ultraviolet absorbers, depleting agents, antibacterial agents, and leveling agents may be included.

  Although the gel time of the melamine resin composition of the present invention is greatly affected by the type and amount of the curable catalyst, and if necessary, the type and amount of the curable accelerator, the formulation and formulation of the entire resin composition Determined by quantity. The gel time of the melamine resin composition was 5 ml of melamine resin composition sampled into a glass test tube having a diameter of 16.5 mm and a length of 165 mm, and the surface was about 3 cm below the surface of boiling water having a capacity of about 3 L. And measure the time (seconds) until the resin liquid turns from transparent to cloudy.

  Examples of the decorative paper of the present invention include impregnated paper cloth such as titanium paper, thin paper, reinforced paper, kraft paper, and cellulose paper, and nonwoven fabric such as polyester, rayon, acrylic, and vinylon.

Inter-paper reinforcing impregnation step In the inter-paper reinforcing impregnation step of the present invention, a decorative paper is impregnated with a melamine resin composition having a gel time of 120 seconds or more and 250 seconds or less. The melamine resin composition is preferably a melamine resin composition having a gel time of 120 seconds to 200 seconds, and particularly preferably a melamine resin composition having a gel time of 120 seconds to 195 seconds.

  The impregnation temperature is preferably 10 to 35 ° C, and more preferably 20 to 30 ° C.

Main impregnation step In the main impregnation step of the present invention, the decorative paper that has undergone the inter-paper reinforcing impregnation step is impregnated with a melamine resin composition having a gel time of 150 seconds to 400 seconds. The melamine resin composition is preferably a melamine resin composition having a gel time of 190 seconds to 350 seconds, and particularly preferably a melamine resin composition having a gel time of 195 seconds to 300 seconds.

  The impregnation temperature is preferably 10 to 35 ° C, and more preferably 20 to 30 ° C.

  The impregnated decorative paper obtained in this impregnation step becomes the prepreg of the present invention by drying. The drying temperature is preferably 120 to 160 ° C, and more preferably 130 to 150 ° C.

Further, in the present invention, the difference between the gel time of the melamine resin composition in the main impregnation step and the gel time of the melamine resin composition in the inter-paper reinforcing impregnation step is preferably 30 seconds or more, and preferably 45 seconds or more. More preferred. That is, it is preferable to satisfy the following formula.
Gel time (seconds) of melamine resin composition in this impregnation step-Gel time (seconds) of melamine resin composition in inter-paper reinforced impregnation step ≧ 30 (seconds)
It is preferable to satisfy the following formula.
Gel time (seconds) of melamine resin composition in this impregnation step-Gel time (seconds) of melamine resin composition in inter-paper strengthening impregnation step ≧ 45 (seconds)

  Although the resin adhesion amount of the prepreg of the present invention is not particularly limited, it may be 53 to 65% by weight, and is preferably 55 to 60% by weight.

  Volatile matter (solvent) may remain in the prepreg of the present invention, and it may be 5 to 8% by weight, preferably 5 to 6.5% by weight. The remaining volatile matter facilitates handling of the prepreg.

The decorative board is a decorative board in which the prepreg of the present invention and a base material are superposed on a base material, and pressure is applied under heating to cure the resin and bond the decorative paper to the base material. Specifically, the prepreg of the present invention and the substrate are overlapped and formed by hot pressing with a press. The decorative board here includes a so-called laminated decorative board in which multiple layers of the resin composition are laminated.

  As base materials, particle board, MDF (medium density fiberboard), kenaf board, wood base material such as veneer plywood, metal plate base material such as aluminum plate, stainless steel plate, and further, interior materials and exterior materials Magnesium oxide, aluminum hydroxide, aluminum oxide, silicon oxide, titanium oxide, magnesium chloride, calcium silicate, volcanic glassy material, gypsum (calcium sulfate), limestone (calcium carbonate), hydraulic cement and pneumatic cement used An inorganic base material obtained by curing at least one material selected from the group can be exemplified.

The molding is performed by the HOT-HOT press method without cooling as in the case of ordinary short cycle melamine. Preferably molding pressure is 10 to 30 kg / cm ^2, more preferably 12~20kg / cm ^2. The molding temperature is preferably 130 to 250 ° C, and more preferably 140 to 220 ° C. The molding time is preferably 10 seconds to 30 minutes, and more preferably 30 seconds to 15 minutes.

  As for the glossiness of the decorative board of the present invention, the 20-degree gloss value measured by the method defined in JIS Z 8741 is preferably 100 or more, and more preferably 110 or more.

Next, the present invention will be described in detail by way of examples and comparative examples. Here, “parts” in Examples and Comparative Examples represent parts by weight. In addition, the same components as those described in Example 1 were used for the components not specifically described in each Example and Comparative Example.
Hereinafter, each test item will be described.

Gel time: The gel time of the melamine resin composition is that 5 ml of the melamine resin composition is sampled into a glass test tube having a diameter of 16.5 mm and a length of 165 mm, and the surface thereof is about 3 cm below the surface of boiling water having a capacity of about 3 L. And measure the time (seconds) until the resin liquid turns from transparent to cloudy. This measurement was performed twice or more, and the average value was taken as the gel time.

Cracks: Whether or not cracks occurred on the decorative plate surface was visually observed. A case where no crack was observed was evaluated as “◯”, and a case where even a small micro crack was generated was evaluated as “×”.

Glossiness: Glossiness Measured according to a method defined in JIS Z 8741 using a micro-TRI-gloss (Gardner product). Here, the 20 degree gloss value was evaluated as ◯ for 100 or more, Δ for 80 or more and Δ for less than 100, and × for less than 80.

Sharpness: Using a portable sharpness / glossiness meter PGD-IV (PGD meter, Nippon Color Research Laboratories, manufactured by Tokyo Koden Co., Ltd.), the sharpness measurement value (GD value) to be displayed was measured. . A GD value of 0.4 or more was evaluated as ◯, 0.3 or more and less than 0.4 was evaluated as Δ, and less than 0.3 was evaluated as ×.

Smoothness: Evaluation was made by placing a decorative plate at a position 1 meter away from the fluorescent lamp and visually observing the deformation state of the linear portion of the fluorescent lamp reflected on the surface. The evaluation was ○ when the straight line portion of the fluorescent lamp reflected on the surface maintained a good straight line, Δ when the wavy shape was strong, and × when the boundary line was sharp and the boundary line was not clear.

Pencil hardness test: Measured according to the pencil scratch value according to the method defined in JIS K 5600.

Scratch hardness: A scratch was made according to the method specified in the JIS B test (diamond needle, 200 g load), and the depth of the scratch was measured with a surface roughness meter. A three-point average depth of scratches of 4 microns or less was evaluated as ◯, and a scratch depth exceeding that was evaluated as ×.

Contamination resistance: Measured according to the method defined in JIS K6902.

Adhesion: according to JAS2 immersion test, soaked in 70 ° C warm water for 2 hours, dried in a 60 ° C oven for 3 hours, evaluated as “O” when there was no delamination from the substrate, and evaluated as x when slight peeling occurred. did.

Resin composition A
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) is dissolved in 40 ° C. warm water to give a solid content concentration of 56% by weight. 6 g of 20 wt% aqueous solution of diammonium imide disulfonate catalyst (Catanit, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solids (1.2 parts by weight with respect to 100 parts by weight of resin liquid solids) , 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of the resin liquid solid content), an antifoaming agent (1% by weight diluted solution of BYK-093 manufactured by BYK) 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was blended to prepare Resin Composition A. The gel time of the resin composition A was 120 seconds.

Resin composition B
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) is dissolved in 40 ° C. warm water to give a solid content concentration of 56% by weight. 3 g of a 50 wt% aqueous solution of 2-amino-2-methyl-1-propanol catalyst (Catanit A, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solid content (based on 100 parts by weight of resin liquid solid content) 0.6 parts by weight), 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of resin liquid solids), an antifoaming agent (1 of BYK-093) A resin composition B was prepared by blending 0.5 g of a weight% diluted solution (by BYK) (0.1 part by weight with respect to 100 parts by weight of the solid content of the resin liquid). The gel time of the resin composition B was 250 seconds.

Resin composition C
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved at a ratio of 90:10 in hot water at 40 ° C. to obtain a solid content. The concentration is 56% by weight. 6 g of 20 wt% aqueous solution of diammonium imide disulfonate catalyst (Catanit, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solids (1.2 parts by weight with respect to 100 parts by weight of resin liquid solids) , 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of the resin liquid solid content), an antifoaming agent (1% by weight diluted solution of BYK-093 manufactured by BYK) 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was blended to prepare Resin Composition C. The gel time of the resin composition C was 150 seconds.

Resin composition D
A water-soluble methylol melamine resin (Nikaresin S-176, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved at a ratio of 90:10 in 40 ° C. hot water to obtain a solid content. The concentration is 56% by weight. 3 g of a 50 wt% aqueous solution of 2-amino-2-methyl-1-propanol catalyst (Catanit A, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solid content (based on 100 parts by weight of resin liquid solid content) 0.6 parts by weight), 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of resin liquid solids), an antifoaming agent (1 of BYK-093) 0.5% by weight (diluted solution BYK) (0.1 parts by weight with respect to 100 parts by weight of resin liquid solids) and 5 g of KC Flock (W-100GK, manufactured by Nippon Paper Industries Co., Ltd.) The resin composition D was prepared by blending 1 part by weight with respect to 100 parts by weight. The gel time of the resin composition D was 260 seconds.

Resin composition E
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved at a ratio of 90:10 in hot water at 40 ° C. to obtain a solid content. The concentration is 56% by weight. 7.5 g of a 20% by weight aqueous solution of diammonium imidodisulfonate catalyst (Catanit, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solid content (1.5 weight with respect to 100 parts by weight of resin liquid solid content) Part), leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) 1 g (0.2 part by weight with respect to 100 parts by weight of resin liquid solid content), antifoaming agent (1% by weight diluted solution of BYK-093 BYK 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was blended to prepare Resin Composition E. The gel time of the resin composition E was 195 seconds.

Resin composition F
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved in warm water at 40 ° C. at a ratio of 80:20 to obtain a solid content. The concentration is 56% by weight. 6 g of 20 wt% aqueous solution of diammonium imide disulfonate catalyst (Catanit, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solids (1.2 parts by weight with respect to 100 parts by weight of resin liquid solids) , 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of the resin liquid solid content), an antifoaming agent (1% by weight diluted solution of BYK-093 manufactured by BYK) 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was blended to prepare Resin Composition F. The gel time of the resin composition F was 100 seconds.

Resin composition G
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved in 40 ° C. hot water at a ratio of 70:30 to obtain a solid content. The concentration is 56% by weight. 6 g of 20 wt% aqueous solution of diammonium imide disulfonate catalyst (Catanit, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solids (1.2 parts by weight with respect to 100 parts by weight of resin liquid solids) , 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of the resin liquid solid content), an antifoaming agent (1% by weight diluted solution of BYK-093 manufactured by BYK) 0.5 g (0.1 parts by weight with respect to 100 parts by weight of resin liquid solids), 5 g of KC floc (W-100GK, manufactured by Nippon Paper Industries Co., Ltd.) with respect to 100 parts by weight of resin liquid solids, 1 part by weight) was blended to prepare a resin composition G. The gel time of the resin composition G was 280 seconds.

Resin composition H
A water-soluble methylol melamine resin (Nical Resin S-260, manufactured by Nippon Carbide Co., Ltd.) and a butyl glycoside resin (Gunei Chemical Co., Ltd.) are dissolved in 40: 30 ° C. warm water at a ratio of 70:30, and the solid content concentration is 56% by weight. And 6 g of 20 wt% aqueous solution of diammonium imide disulfonate catalyst (Catanit, manufactured by MRC Unitech Co., Ltd.) with respect to 500 g of the resin liquid solids (1.2 parts by weight with respect to 100 parts by weight of resin liquid solids) , 1 g of a leveling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of the resin liquid solid content), an antifoaming agent (1% by weight diluted solution of BYK-093 manufactured by BYK) 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was blended to prepare Resin Composition H. The gel time of the resin composition H was 105 seconds.

Resin composition I
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) is dissolved in 40 ° C. warm water to give a solid content concentration of 56% by weight. A 50% aqueous solution of ammonium chloride catalyst (manufactured by Wako Pure Chemical Industries, Ltd.) is 8 g (1.6 parts by weight with respect to 100 parts by weight of resin liquid solids) with respect to 500 g of the resin liquid solids, and a leveling agent (Nobco). 1 g of wet 50 (manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of resin liquid solid content), 0.5 g of antifoaming agent (1% by weight diluted solution of BYK-093 manufactured by BYK) The resin composition I was prepared by blending 0.1 parts by weight with respect to 100 parts by weight of the resin liquid solid content. The gel time of the resin composition I was 150 seconds.

Resin composition J
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved in warm water at 40 ° C. at a ratio of 80:20 to obtain a solid content concentration. 56% by weight. 4 g of a 50 wt% aqueous solution of p-toluenesulfonic acid catalyst (manufactured by Wako Pure Chemical Industries, Ltd.) with respect to 500 g of the resin liquid solids (0.8 parts by weight with respect to 100 parts by weight of resin liquid solids) 1 g of a belling agent (Nobco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of the resin liquid solid content), an antifoaming agent (a 1% by weight diluted solution of BYK-093 manufactured by BYK) 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was blended to prepare Resin Composition J. The gel time of the resin composition J was 140 seconds.

Resin composition K
A water-soluble methylol melamine resin (Nikaresin S-260, manufactured by Nippon Carbide Co., Ltd.) and a methyl glycoside resin (MEGA-6, Gunei Chemical Co., Ltd.) are dissolved in 40 ° C. hot water at a ratio of 70:30 to obtain a solid content concentration. 56% by weight. 4 g of a 50 wt% aqueous solution of ammonium p-toluenesulfonate catalyst (manufactured by Wako Pure Chemical Industries, Ltd.) with respect to 500 g of the resin liquid solids (0.8 parts by weight with respect to 100 parts by weight of the resin liquid solids), 1 g of leveling agent (Nobuco Wet 50, manufactured by San Nopco Co., Ltd.) (0.2 parts by weight with respect to 100 parts by weight of resin liquid solid content), antifoaming agent (1% by weight diluted solution of BYK-093, manufactured by BYK) 0.5 g (0.1 part by weight with respect to 100 parts by weight of the resin liquid solid content) was added to prepare a resin composition solution K. The gel time of this resin liquid was 160 seconds.

Example 1
After impregnating 80 g / m ² of titanium paper into the resin composition A (strengthening inter-paper impregnation), drying in a hot air circulating oven at 135 ° C. for 1 minute, and then impregnating into the resin composition B (main impregnation), It was dried at 135 ° C. for 3 minutes to obtain a prepreg having a resin adhesion amount (RC) of 58 wt%. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 2
After impregnating resin composition C with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition B, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 3
After impregnating resin composition E with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition D, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 4
After impregnating resin composition I with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition D, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 5
After impregnating resin composition I with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated in resin composition E, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 6
After impregnating resin composition J with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition G, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 18 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 7
After impregnating resin composition K with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition B, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 59% by weight was obtained. This was placed on a 18 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Comparative Example 1
After impregnating resin composition B with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition A, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Comparative Example 2
After impregnating resin composition D with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot-air circulating oven for 1 minute, then impregnated into resin composition C, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 15 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Comparative Example 3
After impregnating resin composition F with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition E, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 18 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Comparative Example 4
After impregnating resin composition G with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition J, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 18 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.), and a decorative board was obtained by hot-pressure molding at 150 ° C., 12 kg / cm ² for 7 minutes. Table 2 shows the physical properties of the decorative board obtained.

Comparative Example 5
After impregnating resin composition F with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot-air circulating oven for 1 minute, then impregnated into resin composition K, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 59% by weight was obtained. This was placed on a 18 mm thick particle board (manufactured by Okura Kogyo Co., Ltd.) to obtain a decorative board by hot pressing at 155 ° C., 15 kg / cm ² for 10 minutes. Table 2 shows the physical properties of the decorative board obtained.

Example 8
After impregnating resin composition A with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition B, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Example 9
After impregnating resin composition C with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition B, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Example 10
After impregnating resin composition E with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition D, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Example 11
After impregnating resin composition I with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition D, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Example 12
After impregnating resin composition I with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated in resin composition E, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Example 13
After impregnating resin composition J with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition G, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 3 mm thick die light (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Example 14
After impregnating resin composition K with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition B, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 59% by weight was obtained. This was placed on a 3 mm thick die light (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Comparative Example 6
After impregnating resin composition B with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition A, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Comparative Example 7
After impregnating resin composition D with 80 g / m ² of titanium paper, it was dried in a 135 ° C. hot-air circulating oven for 1 minute, then impregnated into resin composition C, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Comparative Example 8
After impregnating resin composition F with 80 g / m ² of titanium paper, it was dried in a hot air circulating oven at 135 ° C. for 1 minute, then impregnated into resin composition E, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 6 mm thick MDF (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Comparative Example 9
After impregnating resin composition G with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot air circulating oven for 1 minute, then impregnated into resin composition J, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 58% by weight was obtained. This was placed on a 3 mm thick die light (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

Comparative Example 10
After impregnating resin composition F with 100 g / m ² of titanium paper, it was dried in a 135 ° C. hot-air circulating oven for 1 minute, then impregnated into resin composition K, and dried at 135 ° C. for 3 minutes to adhere the resin. A prepreg having an amount (RC) of 59% by weight was obtained. This was placed on a 3 mm thick die light (manufactured by Daiken Kogyo Co., Ltd.), and a decorative board was obtained by hot pressing at 180 ° C., 18 kg / cm ² for 60 seconds. Table 3 shows the physical properties of the decorative sheet obtained.

The composition formulation used in the examples is summarized in Table 1.

Tables 2 and 3 show examples and comparative examples.

The decorative boards of Examples 1 to 14 have general properties necessary for a decorative board having pencil hardness, scratch hardness, stain resistance, and adhesion as defined in JIS and JAS, as well as good gloss and freshness. It was shown that the film had good visual properties and smoothness.
It was shown that the decorative boards of Comparative Examples 1-10 were clearly inferior in glossiness, sharpness, and smoothness as compared with the decorative boards of Examples 1-14.

  The decorative board manufacturing method of the present invention makes it possible to manufacture a decorative board having high gloss, high definition and good smoothness comparable to a high-pressure melamine decorative board, even with a decorative board manufactured by the short cycle method. Become.

Claims (4)

In a method for producing a decorative board in which a prepreg obtained by impregnating and drying a melamine resin on a decorative paper is superimposed on a base material, pressure is applied under heating, the resin is cured and the decorative paper is adhered to the base material.
A step of impregnating a decorative paper with a melamine resin composition having a gel time of 120 seconds or more and 250 seconds or less (inter-paper reinforcing impregnation step); and a melamine resin composition having a gel time of more than 150 seconds and not more than 400 seconds, A method for producing a decorative board, wherein the decorative paper impregnated with melamine resin is impregnated by a step of impregnating the decorative paper that has undergone the intertempering impregnation step (this impregnation step), and the following formula is satisfied.
Gel time (seconds) of the main impregnation step-Gel time (seconds) of the inter-paper reinforced impregnation step ≧ 30 (seconds)   Base material is particle board selected from particle board, MDF (medium density fiberboard), kenaf board, veneer plywood, aluminum plate, metal plate base material selected from stainless steel plate, magnesium oxide, aluminum hydroxide, At least one selected from the group of aluminum oxide, silicon oxide, titanium oxide, magnesium chloride, calcium silicate, volcanic glassy material, gypsum (calcium sulfate), limestone (calcium carbonate), hydraulic cement and pneumatic cement 2. The method for producing a decorative board according to claim 1, wherein the decorative board is any one of inorganic base materials obtained by curing the material.   The method for producing a decorative board according to claim 1 or 2, wherein the decorative board has a 20-degree gloss value of 100 or more as measured by a method defined in JIS Z 8741. A step of impregnating a decorative paper with a melamine resin composition having a gel time of 120 seconds or more and 250 seconds or less (inter-paper reinforcing impregnation step); and a melamine resin composition having a gel time of more than 150 seconds and not more than 400 seconds, A method for producing a prepreg characterized by impregnating decorative paper with melamine resin through a step of impregnating decorative paper that has undergone an intertempering impregnation step (this impregnation step) and satisfying the following formula.
Gel time (seconds) of the main impregnation step-Gel time (seconds) of the inter-paper reinforced impregnation step ≧ 30 (seconds)