JP7000700B2 - Decorative paper for resin-impregnated decorative board and resin-impregnated decorative board - Google Patents

Description

The present invention relates to a resin-impregnated decorative board used for interiors such as floors, walls and ceilings of buildings, surface decorative materials for furniture and various cabinets, surface decoration of fittings, vehicle interiors, etc., and particularly on the surface. It relates to a decorative paper for a resin-impregnated decorative board having a gloss matte expression and a resin-impregnated decorative board.

Conventionally, resin-impregnated decorative boards such as melamine decorative boards have been widely used as surface materials for buildings and furniture. The resin-impregnated decorative board is manufactured by printing a pattern such as wood grain, stone grain, or abstract pattern on a porous base paper, impregnating it with a thermosetting resin such as melamine resin, and drying it to make a particle board or MDF (medium density fiberboard). It is obtained by laminating with a wood base material such as wood base material or core paper impregnated with phenol resin, etc., and curing the thermosetting resin by heat and pressure molding on a metal plate, and further integrating it with the wood base material. Be done.

By providing a desired embossed shape on the metal plate used during heat-pressurization molding, it is possible to impart a textured expression to the finished resin-impregnated decorative plate surface (for example, Patent Document 1). Further, it is becoming possible to express a gloss matte tone by adjusting the coarse density of the embossed shape.

Furthermore, attempts have been made to synchronize wood grain, stone grain, and abstract patterns with surface textures and gloss matte expressions. In order to synchronize the surface texture and gloss matte expression with the pattern, it is necessary to match the pattern of the decorative paper after impregnation and drying with the embossed shape of the metal plate, laminate them, and heat and press mold.

However, due to the water content of the decorative paper itself after impregnation and drying, shrinkage and elongation occur in the vertical and horizontal directions, making it difficult to always finish to a constant size. Therefore, the embossed shape of the metal plate and the pattern are completely matched. It was very difficult to get them to do it.

On the other hand, on the premise that the embossed shape of the metal plate and the pattern are out of alignment, there is a method to deceive the fact that they do not completely match by providing a certain amount of "escape", but it lacks reality in terms of design. It may end up. In addition, it has been pointed out that a metal plate must be prepared for each number of patterns and a large manufacturing cost is required.

On the other hand, instead of the mechanical shaping method (mechanical embossing method) as described above, a chemical embossing method using a chemical action as proposed in Patent Document 2 is also being studied. This is because the ink for printing a pattern contains a curing inhibitor that has the effect of slowing the curing rate of the thermosetting resin, and by partially using that ink, the finish after heat and pressure molding is normal ink. The aim is to have an effect that appears as a gloss difference between the used part and the part where the ink containing the curing inhibitor is used.

According to this method, it is not necessary to prepare a metal plate for each pattern, and it is possible to produce by the conventional method. However, the thermosetting resin impregnated in the portion where the ink containing the curing inhibitor is used may adhere to the surface of the metal plate and remain, and the removal work is very troublesome, so that the productivity does not increase. Therefore, the manufacturing cost will be increased as well.

Japanese Unexamined Patent Publication No. 60-122149 Japanese Unexamined Patent Publication No. 2-299844

The present invention has been made to solve such a problem, and the subject thereof is a resin-impregnated decorative paper for a resin-impregnated decorative board and a resin-impregnated decorative board having a gloss matte expression while suppressing the manufacturing cost. Is to provide.

The present invention has been made to solve the above problems, and the invention of claim 1 of the present invention includes at least a base paper, a pattern layer, a first liquid-repellent cured film, and a second liquid-repellent cured film in this order. Made by stacking
, In the decorative paper for resin impregnated decorative board used by impregnating with thermosetting resin ,
The thermosetting resin has a property of being repelled by both the first liquid-repellent cured film and the second liquid-repellent cured film.
The first liquid-repellent cured film is laminated on the entire surface of the pattern layer, and the second liquid-repellent cured film is partially different from the first liquid-repellent cured film on the first liquid-repellent cured film. It is a decorative paper for a resin-impregnated decorative board, which is characterized by having a gloss matte expression having a gloss difference.

The resin-impregnated decorative plate according to claim 1, wherein the invention of claim 2 of the present invention synchronizes the pattern of the pattern layer with the gloss matt expression of the second liquid-repellent cured film. It is a decorative paper for use.

The third aspect of the present invention is according to claim 1 or 2, wherein the liquid-repellent cured film contains silicone oil in an amount of 0.05% by mass or more and 10% by mass or less. It is a decorative paper for a resin-impregnated decorative board.

The invention according to claim 4 of the present invention is the decorative paper for a resin-impregnated decorative board according to claim 3, wherein the silicone oil contained in the liquid-repellent cured film is an amino-modified silicone oil.

The invention according to claim 5 of the present invention is the decorative paper for a resin-impregnated decorative board according to any one of claims 1 to 4, wherein the printing ink of the pattern layer is made of a water-based ink .

The invention of claim 6 of the present invention is characterized in that the decorative paper for a resin-impregnated decorative board according to any one of claims 1 to 5 and the decorative board base material are integrated. It is a decorative board.

According to the invention according to claim 1, the present invention makes it possible to provide a decorative paper for a resin-impregnated decorative board and a resin-impregnated decorative board capable of expressing gloss mat without changing from the conventional method for producing a resin-impregnated decorative board. became.

It is sectional drawing which shows the sectional composition example of the decorative paper for a resin impregnated decorative board which concerns on embodiment of this invention. It is sectional drawing which shows the sectional structural example of the resin impregnated decorative board which concerns on embodiment of this invention.

Hereinafter, the present invention will be described in detail with reference to the drawings. In each figure, components exhibiting similar or similar functions are designated by the same reference numerals, and duplicate description will be omitted. again,
Each drawing shows an example of the embodiment of the present invention, and is not limited thereto.

FIG. 1 shows a cross-sectional configuration example of a decorative paper for a resin-impregnated decorative board according to an embodiment of the present invention. The decorative paper 1 for a resin-impregnated decorative board has a structure in which a pattern layer 12 and a liquid-repellent cured film 15 are provided on a base paper 11, but the liquid-repellent cured film 15 covers at least the entire pattern layer. It is composed of a first liquid-repellent cured film 13 and a second liquid-repellent cured film 14 provided on a part thereof.

Here, it is desirable that at least the pattern of the second liquid-repellent cured film 14 is provided as a pattern synchronized with the pattern layer 12.

The base paper 11 in the present invention may be a fibrous sheet such as paper having good water absorption that can be impregnated with resin later, and for example, thin leaf paper, titanium paper, woodfree paper, bleached or unbleached kraft paper, etc. are used. It is possible. Of these, titanium paper, which is excellent in both printability and resin impregnation suitability, is the most suitable.

Further, when it is desired to utilize the texture of the surface of the decorative board base material 21, so-called transparent paper having a property of becoming transparent by impregnation with a resin can also be used. The thickness of the base paper 11 is not particularly limited, but generally, a base paper 11 having a basis weight in the range of about 20 to 200 g / m ² is used.

In the present invention, there are no particular restrictions on the type of pattern pattern formed by the pattern pattern layer 12 and the liquid-repellent cured film 15, such as wood grain pattern, stone pattern, cloth pattern, abstract pattern, geometric figure, character, symbol and the like. , Or a combination of two or more of them, which is optional as desired. The liquid-repellent cured film 15 is formed at a portion or the like where a matte or glossy texture is desired to be expressed in a desired pattern. The liquid-repellent cured film 15 may be colorless or colored.

The pattern layer 12 can be provided by a normal printing method using a normal printing ink having no liquid repellency. There are no particular restrictions on the type of printing ink, and oil-based inks may be used, but it is desirable to use water-based inks in consideration of resin impregnation suitability. The water-based ink has better compatibility with the aqueous solution of the impregnated resin than the oil-based ink, can be impregnated quickly and uniformly in the subsequent impregnation step, and exhibits excellent strength by being integrated with the impregnated resin. Because it can be done.

The type of the water-based ink is not particularly limited, but it is most desirable to use a binder resin containing casein or an emulsion resin as a main component. These binder resins have the property of becoming poorly water-soluble by undergoing a drying step after printing the ink, and are difficult to redissolve in the aqueous solution of the impregnated resin in the subsequent resin impregnation step, so that the pattern may be impaired. This is because there is no risk of contamination of the impregnated resin.

As the emulsion resin, for example, acrylic, vinyl acetate, styrene, urethane, etc. can be used, and as the latex resin, for example, styrene-butadiene, acrylonitrile-butadiene, methyl methacrylate-butadiene, etc. can be used. ..

In addition to these casein and emulsion resins, water-soluble resins such as polyvinyl alcohol and polyacrylamide, and water-soluble polymers such as polysaccharides and cellulose derivatives were used in combination for the purpose of improving the stability of ink. It may be a thing.

The method for forming the pattern layer 12 is not particularly limited, and any printing method such as a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a letterpress printing method, and an inkjet printing method can be used. When a solid ink layer is provided for the purpose of coloring the base, as a method for forming the solid ink layer, in addition to the above-mentioned various printing methods, for example, a roll coating method, a gravure coating method, a rod coating method, a knife coating method, and an air knife. Any coating method such as a coating method, a spray coating method, a lip coating method, and a die coating method can also be used.

The resin for forming the liquid-repellent cured film 15 is preferably a thermosetting resin having a urethane bond such as a two-component curable urethane resin or a curable resin such as an ionizing radiation curable resin. Examples of the curable resin include melamine-based resin, epoxy-based resin, urea-based resin, phenol-based resin, unsaturated polyester-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, aminoalkyd-based resin, and silicone-based resin. Thermosetting resins such as resins, ionized radiation curable resins such as (meth) acrylate resins and unsaturated polyester resins can be used.

The same resin may be used for the first liquid-repellent cured film 13 and the second liquid-repellent cured film 14, and there is no problem even if different resins are used.

Further, it is desirable that the first liquid-repellent cured film 13 and the second liquid-repellent cured film 14 have different glossiness, whereby excellent designability can be imparted.

As a method of giving such a change in glossiness, for example, a method of applying a composition to which a gloss adjusting agent (also referred to as a matting agent or a matting agent) capable of adjusting the gloss of the surface is added or not added is applied. Etc. can be exemplified.

As the gloss adjuster, any conventionally known material can be used, and for example, an inorganic substance such as silica, alumina (α-alumina, etc.), calcium carbonate, barium sulfate, kaolinite, alumina silicate, or polycarbonate, nylon. , Fine particles made of organic substances such as urethane resin, acrylic resin, styrene resin, and silicone resin.

The average particle size of such a gloss adjusting agent is preferably about 1 to 10 μm, and the addition amount can be appropriately selected according to the desired gloss, that is, the glossiness.

By forming the first liquid-repellent cured film 13 and the second liquid-repellent cured film 14 having different glossiness depending on the addition or non-addition of the gloss adjusting agent or the difference in the amount of the gloss adjusting agent added, the repellency is repelled. It is possible to form a gloss matte expression of the liquid cured film 15.

Further, it is desirable that silicone oil is added to the liquid-repellent cured film 15 composed of the first liquid-repellent cured film 13 and the second liquid-repellent cured film 14 in order to impart liquid repellency. ..

The silicone oil added to the liquid-repellent cured film 15 is most preferably 0.05 to 10% by mass, but may be 0.01 to 15% by mass. As the silicone oil, non-modified silicone oil, amino-modified silicone oil, epoxy-modified silicone oil, carboxy-modified silicone oil, mercapto-modified silicone oil, carbinol-modified silicone oil, methacryl-modified silicone oil, and phenol-modified silicone oil can be used. ..

In the liquid-repellent cured film 15, the type of the pattern formed by the first liquid-repellent cured film 13 and the second liquid-repellent cured film 14 is not particularly limited, and even if it is synchronized with the pattern layer 12. Although it may be non-tuned, it is generally possible to obtain a resin-impregnated decorative board having better design by tuning.

The thickness of the first liquid-repellent cured film 13 and the second liquid-repellent cured film 14 may be about 0.5 μm to 100 μm, but if it is 0.5 μm or less, the thermosetting resin is impregnated. If it exceeds 30 μm, film cracking may occur when the film is wound onto a roll after printing. More preferred is 1 μm to 30 μm.

As the resin to be impregnated in the base paper 11 on which the pattern layer 12 and the liquid-repellent cured film 15 are formed in this way, any known thermosetting resin used for manufacturing the conventional resin-impregnated decorative board is used. Can be adopted.

Specifically, for example, melamine-based resin, epoxy-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, alkyd-based resin, unsaturated polyester-based resin, phenol-based resin, urea-based resin and the like. These are generally impregnated in resin-impregnated decorative paper for decorative boards in the form of an aqueous impregnating liquid dissolved or dispersed in water.

The impregnation of the thermosetting resin may be performed from the liquid-repellent cured film surface side of the base paper on which the pattern layer or the liquid-repellent cured film is formed, or may be performed from the opposite surface side.

Further, a method of impregnating each side in two steps or a method of simultaneously impregnating from both sides may be adopted. Further, a resin-impregnated overlay sheet impregnated with resin and dried in advance may be used as the base paper 11. The impregnation rate of the thermosetting resin (the ratio of the weight of the impregnated resin to the weight after impregnation) is usually about 20 to 80%, and the most desirable range is about 40 to 70%. Further, in order to obtain a resin-impregnated decorative board having excellent physical properties, it is important that the entire base paper is uniformly impregnated with the resin.

FIG. 2 is a cross-sectional view showing a cross-sectional configuration example of the resin-impregnated decorative board 2 according to the embodiment of the present invention.

The decorative paper 1 for a resin-impregnated decorative board produced as described above is placed on the decorative board base material 21, and a metal plate (mirror surface plate) is placed on the surface of the decorative paper 1 for a resin-impregnated decorative board and heated. The resin-impregnated decorative board 2 is obtained by pressure molding.

The type of the decorative plate base material 21 used here is not particularly limited and may be arbitrary depending on the intended use of the resin-impregnated decorative plate 2, for example, wood single plate, plywood, laminated material, particle board, medium density. Wood base material such as fiber board, hard fiber board, fibrous base material such as paperboard, woven cloth, non-woven fabric, resin impregnated paper, resin impregnated cloth, gypsum board, slate board, calcium silicate board, slag gypsum board, wood wool Inorganic base materials such as cement plates, slag cement plates, lightweight bubble concrete plates, glass fiber reinforced concrete plates, metal substrates such as steel plates, brass plates, aluminum plates, duralumin plates, stainless steel plates, acrylic resin plates, styrene resin plates, ABS resin plate, polycarbonate resin plate, nylon resin plate, polystyrene resin plate, polypropylene resin plate, polyester resin plate, synthetic resin base material such as glass fiber reinforced plastic plate, etc., or two or more composites or laminates selected from these The body and the like can be used as appropriate.

When laminating the resin-impregnated decorative paper 1 on the decorative board base material 21, it may be laminated via an appropriate adhesive if necessary, or it may be laminated directly without using an adhesive or the like. May be. Further, if necessary, it can be laminated via the core paper as in the case of the conventional melamine resin decorative board or the like.

The core paper is an appropriate base paper for core paper such as titanium paper, bleached or unbleached kraft paper, and glass fiber non-woven fabric impregnated with a thermosetting resin in an uncured state, and has the thermosetting property. Examples of the resin include melamine-based resin, epoxy-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, alkyd-based resin, unsaturated polyester-based resin, phenol-based resin, urea-based resin, and the like. It may be appropriately selected according to the physical properties required for the resin-impregnated decorative board. As a specific example, phenol resin impregnated kraft paper or the like, which is widely used as a core paper for a melamine resin decorative board, can be used.

As a heat and pressure molding method for laminating and adhering the decorative paper 1 for a resin-impregnated decorative board on the decorative board base material 21, in addition to the above-mentioned method of abutting a metal plate and pressing it under flat pressure, a circular pressure type is used. A continuous laminating method can also be adopted.

In particular, if a continuous laminating method using a metal endless belt is adopted, a high-quality resin-impregnated decorative board that has no surface warpage or waviness and is densely cured and integrated with good interlayer adhesion can be continuously produced at high speed. There is an advantage that it can be manufactured in a targeted manner.

In the process of heat and pressure molding, if necessary, any desired matte or textured metal plate, an embossed sheet made of a metal endless belt curable resin, or the like can be used. It is also possible to obtain the resin-impregnated decorative plate 2 in the surface-finished state of.

The resin-impregnated decorative board of the present invention is not limited to the embodiment described in detail above, and can be carried out with various modifications without departing from the spirit of the present invention.

Hereinafter, the present invention will be specifically described with reference to Examples, but the present invention is not limitedly interpreted by this.

(Example 1)
A wood grain pattern is printed by a direct gravure printing method on titanium paper for decorative paper with a basis weight of 80 g / m ² with good water absorption, using water-based ink containing casein as the main component, and then in-line, silicone oil 2 is applied. Using a heat-curable urethane resin-based ink containing 5.5% by mass, the first liquid-repellent cured film was applied to the entire surface of the wood grain pattern by a direct gravure printing method. Further, a second liquid-repellent cured film having a gloss higher than that of the first liquid-repellent cured film previously applied is printed and formed on the conduit pattern in synchronization with the wood grain pattern, and the resin-impregnated makeup of the present invention is formed. I got a decorative paper for a board.

After that, an aqueous melamine-based resin solution having the property of being repelled by the liquid-repellent cured film is immersed, the impregnated resin coating layer on the liquid-repellent cured film is sufficiently repelled, and then sufficiently dried. A decorative paper for an impregnated and dried resin-impregnated decorative board was produced. At that time, the resin impregnation amount was adjusted so that the basis weight of the resin-impregnated pattern paper after impregnation drying was 200 g / m ² .

The obtained impregnated / dried resin-impregnated decorative board decorative paper is placed on a particle board base material, and a mirror surface plate is brought into contact with the surface of the resin-impregnated decorative board decorative paper and cured by heating and pressure molding. , A resin-impregnated decorative board was obtained.

(Comparative Example 1)
A resin-impregnated decorative board decorative paper was obtained in the same manner as in Example 1 except that the silicone oil was set to 0% by mass, and further impregnated with a thermosetting resin and dried to obtain an impregnated / dried resin-impregnated decorative board decorative paper. Further, heat and pressure molding was performed to obtain a resin-impregnated decorative plate.

(Comparative Example 2)
A decorative paper for a resin-impregnated decorative board was obtained in the same manner as in Example 1 except that 0.03% by mass of silicone oil was contained, and further impregnated with a thermosetting resin and dried for impregnated / dried resin-impregnated decorative board. A decorative paper was obtained, and further heat and pressure molding was performed to obtain a resin-impregnated decorative board.

(Comparative Example 3)
A decorative paper for a resin-impregnated decorative board is obtained in the same manner as in Example 1 except that 12.5% by mass of silicone oil is contained, and further impregnated with a thermosetting resin and dried for an impregnated / dried resin-impregnated decorative board. A decorative paper was obtained, and further heat and pressure molding was performed to obtain a resin-impregnated decorative board.

(Comparative Example 4)
A resin-impregnated decorative board decorative paper was obtained in the same manner as in Example 1 except that the silicone oil content was 17.5% by mass, and further impregnated with a thermosetting resin and dried to impregnate and dry the resin-impregnated decorative board cosmetic. Paper was obtained and further heat-press molded to obtain a resin-impregnated decorative plate.

(Performance evaluation)
The performance evaluations shown below were performed on the above Examples 1 and Comparative Examples 1 to 4.

[Thermosetting resin repellent]
The degree of the thermosetting resin remaining on the liquid-repellent cured film without being repelled by the resin-impregnated decorative paper impregnated with the thermosetting resin and dried was evaluated.

[Silicone oil decorative paper backside settling property]
A decorative paper for a resin-impregnated decorative board was printed by a gravure printing method and allowed to stand in a rolled state, and the amount of transfer of silicone oil on the back side overlapping with the front side was measured and the degree was evaluated.

[Magic repellent]
A decorative paper for a resin-impregnated decorative board was printed by a gravure printing method, and a part of the surface thereof was painted with magic to evaluate the degree of magic repelling of the liquid-repellent cured film.
The above results are shown in Table 1.

From the results of Example 1 and Comparative Example 1, when the silicone oil was not added to the liquid-repellent cured film, the impregnated thermosetting resin was liquid-repellent cured, although there was no set-off of the silicone oil. It can be seen that it remains on the film without being repelled, impairing the design and not being able to repel magic.

Further, from the results of Example 1 and Comparative Example 2, when the amount of the silicone oil added is 0.03% by mass, which is a value smaller than 0.05% by mass with respect to the curable binder resin, it is impregnated. Although relatively good results were obtained with respect to the repellent property of the thermosetting resin and the set-off property of the silicone oil, it was found that the repellent property against magic was insufficient.

From the results of Comparative Example 3, when the amount of silicone oil added was 12.5% by mass, which is a value larger than 10% by mass, with respect to the curable binder resin, the repellent property to the thermosetting resin to be impregnated. Although the repellent property against magic is good, the result is that the set-off of silicone oil begins to stand out.

Furthermore, from the results of Comparative Example 4, when the amount of the silicone oil added was 17.5% by mass, which was excessive with respect to the curable binder resin, the set-off of the silicone oil became severe.

From the above results, it was found that the amount of the silicone oil added to the liquid-repellent cured film is preferably 0.05% by mass or more and 10% by mass or less with respect to the curable binder resin.

In this range, by adding silicone oil to the liquid-repellent cured film, it is possible to produce a resin-impregnated decorative board having a highly designed and liquid-repellent cured film, which is simple and does not incur manufacturing costs. It will be possible.

The decorative sheet of the present invention can be used for interior decoration such as floors, walls and ceilings of buildings, surface decorative materials for furniture and various cabinets, surface makeup for fittings, surface makeup for vehicle interiors and the like.

1 ... Decorative paper for resin-impregnated decorative board 11 ... Base paper 12 ... Pattern layer 13 ... 1st liquid-repellent cured film 14 ... 2nd liquid-repellent cured film 15 ... Liquid-repellent cured film 2 ... Resin-impregnated decorative board 21 ... Decorative board base material

Claims (6)

In a resin-impregnated decorative board decorative paper which is made by laminating at least a base paper, a pattern layer, a first liquid-repellent cured film, and a second liquid-repellent cured film in this order and impregnated with a thermosetting resin .
The thermosetting resin has a property of being repelled by both the first liquid-repellent cured film and the second liquid-repellent cured film.
The first liquid-repellent cured film is laminated on the entire surface of the pattern layer, and the second liquid-repellent cured film is partially different from the first liquid-repellent cured film on the first liquid-repellent cured film. A decorative paper for a resin-impregnated decorative board, which has a gloss matte expression having a gloss difference. The decorative paper for a resin-impregnated decorative board according to claim 1, wherein the pattern of the pattern layer and the gloss matt expression of the second liquid-repellent cured film are synchronized. The first or second liquid-repellent cured film according to claim 1 or 2, wherein the first liquid-repellent cured film and the second liquid-repellent cured film contain silicone oil in an amount of 0.05% by mass or more and 10% by mass or less. Resin-impregnated decorative paper for decorative boards. The decorative paper for a resin-impregnated decorative board according to claim 3, wherein the silicone oil contained in the first liquid-repellent cured film and the second liquid-repellent cured film is an amino-modified silicone oil. The decorative paper for a resin-impregnated decorative board according to any one of claims 1 to 4, wherein the printing ink of the pattern layer is made of a water-based ink. A resin-impregnated decorative board according to any one of claims 1 to 5, wherein the decorative paper for the resin-impregnated decorative board and the decorative board base material are integrated.

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