JP7015465B2 - A shaping sheet and a method for manufacturing a melamine decorative board using the shaping sheet. - Google Patents

Description

The present invention relates to a shaping sheet and a method for producing a melamine decorative board using the shaping sheet.

Conventionally, a method of manufacturing a melamine decorative plate having an uneven surface by using a metal plate (embossed plate) having an uneven surface or a shaping sheet is known (for example, Patent Documents 1 to 3). In addition, the cured product of the ionized radiation curable resin has a higher crosslink density than that of a general thermoplastic resin, and is deteriorated by the press processing under high pressure and high temperature performed when manufacturing the melamine decorative board. Since it is difficult, it is known that the uneven surface of the shaped sheet is preferably formed by a cured product of an ionizing radiation curable resin (for example, Patent Documents 4 and 5).

In recent years, there has been an increasing demand for melamine decorative boards having a low gloss on uneven surfaces. By miniaturizing the unevenness constituting the uneven surface of the melamine decorative board, the gloss of the uneven surface of the melamine decorative board can be lowered. However, if the unevenness constituting the uneven surface of the melamine decorative board is miniaturized, the ease of sweeping the uneven surface of the melamine decorative board is lowered, and there arises a problem that stains adhering to the uneven surface of the melamine decorative board cannot be easily removed. ..

Japanese Unexamined Patent Publication No. 3-174281 Japanese Unexamined Patent Publication No. 8-072141 Japanese Unexamined Patent Publication No. 9-156063 International Publication No. 2008/11645 Mitsuaki Kai 61-28628 Gazette

Therefore, the present invention relates to a shaping sheet for manufacturing a melamine decorative board having a low gloss and an uneven surface having excellent sweepability, and a method for manufacturing a melamine decorative board using the shaping sheet. The purpose is to provide.

In order to solve the above problems, the present invention provides the following inventions.
[1] A shaping sheet having an uneven surface, which is a shaping sheet.
The average roughness Ra of the center line of the unevenness constituting the uneven surface is 1.7 μm or more and 2.7 μm or less.
The maximum height Rmax of the unevenness constituting the uneven surface is 11 μm or more and 16 μm or less.
The shaping sheet having an average spacing Sm of the unevenness constituting the uneven surface of 30 μm or more and 65 μm or less.
[2] The formula according to [1], wherein the shape sheet includes a support layer and a resin layer provided on the support layer, and the uneven surface is formed by the surface of the resin layer. Shape sheet.
[3] The shaping sheet according to [2], wherein the resin layer contains fine particles.
[4] The shaping sheet according to [3], wherein the average particle size of the fine particles is 6 μm or more and 15 μm or less.
[5] The shaping sheet according to [3] or [4], wherein the amount of the fine particles contained in the resin layer is 40% by mass or more and 60% by mass or less based on the total mass of the resin layer.
[6] The shaping sheet according to any one of [3] to [5], wherein the fine particles are acrylic beads.
[7] The excipient sheet according to any one of [2] to [6], wherein the resin layer contains a cured product of an ionizing radiation curable resin.
[8] The shaping sheet according to any one of [2] to [7], wherein the support layer includes a base material sheet and a primer layer located between the base material sheet and the resin layer.
[9] The shaping sheet according to [8], wherein the primer layer contains fine particles.
[10] The shaping sheet according to [9], wherein the fine particles are silica fine particles.
[11] A method for producing a melamine decorative board having an uneven surface by using the shaping sheet according to any one of [1] to [10].
(A) On the uncured melamine resin layer so that the core layer, the uncured melamine resin layer provided on the core layer, and the uneven surface of the shaping sheet are in contact with the uncured melamine resin layer. A step of preparing a laminated body including the provided shaping sheet,
The method comprising (b) a step of pressurizing and heating the laminate to cure the uncured melamine resin layer, and (c) a step of peeling off the excipient sheet.
[12] The average roughness Ra of the center line of the unevenness constituting the uneven surface of the melamine decorative board is 1.5 μm or more and 2.4 μm or less.
The maximum height Rmax of the unevenness constituting the uneven surface of the melamine decorative board is 14.0 μm or more and 19.5 μm or less.
The method according to [11], wherein the average spacing Sm of the irregularities constituting the uneven surface of the melamine decorative board is 50 μm or more and 120 μm or less.
[13] The production method according to [12], wherein the melamine decorative board exhibits a dark color, and the 60 ° glossiness of the uneven surface of the melamine decorative board is 3 or less.
[14] The production method according to [12], wherein the melamine decorative board exhibits a white color, and the 60 ° glossiness of the uneven surface of the melamine decorative board is 5 or less.

According to the present invention, there is a shaped sheet for manufacturing a melamine decorative board having a low gloss and an uneven surface having excellent sweepability, and a method for manufacturing a melamine decorative board using the shaped sheet. Provided.

FIG. 1 is a cross-sectional view schematically showing the configuration of a shaping sheet according to an embodiment of the present invention. FIG. 2A is a diagram for explaining a method of manufacturing a melamine decorative board using the shaping sheet according to the embodiment of the present invention. FIG. 2B is a diagram for explaining a method of manufacturing a melamine decorative board using the shaping sheet according to the embodiment of the present invention. FIG. 2C is a diagram for explaining a method of manufacturing a melamine decorative board using the shaping sheet according to the embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

≪Structure of excipient sheet≫
Hereinafter, the configuration of the shaping sheet 1 according to the embodiment of the present invention will be described with reference to FIG. FIG. 1 is a cross-sectional view schematically showing the configuration of the shaping sheet 1.

As shown in FIG. 1, the shaping sheet 1 has an uneven surface 10. The center line average roughness Ra, the maximum height Rmax, and the average interval Sm of the unevenness constituting the uneven surface 10 are in the following ranges. As a result, the uneven surface of the melamine decorative board manufactured by using the shaping sheet 1 has a low luster and excellent sweepability.

The average roughness Ra of the center line of the unevenness constituting the uneven surface 10 of the shaping sheet 1 is 1.7 μm or more and 2.7 μm or less, preferably 1.8 μm or more and 2.6 μm or less, and more preferably 1.9 μm or more and 2. It is 6 μm or less. The definition of centerline average roughness Ra follows JIS B0601-1982.

The maximum height Rmax of the unevenness constituting the uneven surface 10 of the shaping sheet 1 is 11 μm or more and 16 μm or less, preferably 13 μm or more and 16 μm or less, and more preferably 15 μm or more and 16 μm or less. The definition of maximum height Rmax follows JIS B0601-1982.

The average spacing Sm of the irregularities constituting the concave-convex surface 10 of the shaping sheet 1 is 30 μm or more and 65 μm or less, preferably 30 μm or more and 64 μm or less, and more preferably 32 μm or more and 64 μm or less. The definition of the average interval Sm follows JIS B0601-1994.

Ra, Rmax and Sm are measured using a surface roughness measuring instrument (3D surface roughness measuring instrument SE-30K manufactured by Kosaka Laboratory) and a surface roughness analyzer (surf coder AY-31 manufactured by Kosaka Laboratory). The measurement was performed according to the following conditions.

1) Needle / tip diameter of surface roughness detection part: R2 μm
・ Skid: R40mm x R2mm
・ Material: Sapphire ・ Needle pressure: 0.7μN
・ Feed speed of stylus: 0.5 mm / s

2) Measurement conditions ・ Cutoff value (reference length): 0.08 mm
-Measurement length (cutoff value x 100): 8 mm
・ Vertical magnification: 1000 times ・ Horizontal magnification: 10 times

The 60 ° glossiness of the uneven surface 10 of the shaping sheet 1 is preferably 20 or less, more preferably 17 or less. The lower limit of the 60 ° glossiness is not particularly limited, but is preferably 11 and more preferably 12. The 60 ° glossiness is measured according to JIS Z8741: 1997. Specifically, using a GMX-202 manufactured by Murakami Color Technology Laboratory as a gloss meter, the 60 ° glossiness of the uneven surface 10 of the shaping sheet 1 is measured under the condition of an incident angle of 60 °.

As shown in FIG. 1, the shaping sheet 1 includes a support layer 11 and a resin layer 12 provided on the support layer 11.

<Support layer>
Hereinafter, the support layer 11 will be described with reference to FIG.
As shown in FIG. 1, the support layer 11 has a first main surface S1 and a second main surface S2 located on the opposite side of the first main surface S1.

As shown in FIG. 1, the support layer 11 includes a base sheet 111 and a primer layer 112 provided on the base sheet 111.

As shown in FIG. 1, the base sheet 111 has a first main surface T1 and a second main surface T2 located on the opposite side of the first main surface T1.

The base sheet 111 is not particularly limited as long as it can support the layer provided on the base sheet 111. The base sheet 111 is preferably flexible. When the base sheet 111 has flexibility, the shaped sheet 1 can be easily peeled off from the shaped body. The base sheet 111 is, for example, a plastic sheet. Examples of the synthetic resin constituting the plastic sheet include polyolefin resins such as polyethylene resin, polypropylene resin, polymethylpentene resin, and olefin-based thermoplastic elastomer; polyvinyl chloride resin, polyvinylidene chloride resin, polyvinyl alcohol resin, vinyl chloride- Vinyl-based resins such as vinyl acetate copolymer resin, ethylene-vinyl acetate copolymer resin, ethylene-vinyl alcohol copolymer resin; polyethylene terephthalate resin, polybutylene terephthalate resin, polyethylene naphthalate-isophthalate copolymer resin, polyester-based thermoplastic Polyester resin such as elastomer; Acrylic resin such as poly (meth) methyl acrylate resin, poly (meth) ethyl acrylate resin, poly (meth) butyl acrylate resin; polyamide resin typified by nylon 6 or nylon 66; Examples thereof include cellulose-based resins such as cellulose acetate resin and cellophane; polystyrene resin; polycarbonate resin; polyallylate resin; polyimide resin and the like. Of these, polyester resins such as polyethylene terephthalate, particularly biaxially stretched polyester resins, are preferable from the viewpoint of excellent heat resistance and dimensional stability.

An easy-adhesive layer may be formed on the surface of the base sheet 111 in order to improve the adhesion to the layer provided on the base sheet 111. Examples of the easy-adhesive resin contained in the easy-adhesion layer (sometimes called a primer layer or an anchor layer) include acrylic resin, vinyl chloride-vinyl acetate copolymer, polyester resin, urethane resin, chlorinated polypropylene, and chlorine. Examples include polyethylene chemicals.

In order to improve the adhesion to the layer provided on the base sheet 111, the surface of the base sheet 111 may be subjected to physical or chemical surface treatment such as an oxidation method or an unevenness method. Examples of the oxidation method include corona discharge treatment, chromium oxidation treatment, flame treatment, hot air treatment, ozone / ultraviolet treatment method and the like, and examples of the unevenness method include sandblasting method and solvent treatment method.

The thickness of the base sheet 111 is not particularly limited, but when the plastic sheet is used as the base sheet 111, the thickness of the plastic sheet is preferably 25 μm or more and 75 μm or less, and more preferably 35 μm or more and 50 μm or less.

The primer layer 112 is provided on the first main surface T1 of the base sheet 111. The primer layer 112 may be formed on the entire first main surface T1 of the base sheet 111, or may be formed on a part of the first main surface T1 of the base sheet 111. When the primer layer 112 is formed on the entire first main surface T1 of the base sheet 111, the first main surface S1 of the support layer 11 is formed by the surface of the primer layer 112. When the primer layer 112 is formed on a part of the first main surface T1 of the base sheet 111, the first main surface S1 of the support layer 11 is a part of the first main surface T1 of the base sheet 111 (primer layer). It is formed by the portion where 112 is not provided) and the surface of the primer layer 112.

The present invention also includes an embodiment in which the primer layer 112 is omitted. In the embodiment in which the primer layer 112 is omitted, the first main surface S1 of the support layer 11 is formed by the first main surface T1 of the base sheet 111. The present invention also includes an embodiment in which one or more layers are provided between the base sheet 111 and the primer layer 112. Such a layer can be appropriately selected according to the function required for the layer.

The primer layer 112 contains a binder resin. Examples of the binder resin include urethane resin, (meth) acrylic resin, (meth) acrylic-urethane copolymer resin, vinyl chloride-vinyl acetate copolymer resin, vinyl chloride-vinyl acetate-acrylic copolymer resin, and chlorine. Examples thereof include synthetic polypropylene resin, polyester resin, polyamide resin, butyral resin, polystyrene resin, nitrocellulose resin (nitrated cotton), cellulose acetate resin and the like. As the binder resin, one kind may be used alone, or two or more kinds may be used in combination.

The primer layer 112 preferably contains fine particles. The fine particles contained in the primer layer 112 can contribute to the uneven shape of the surface of the resin layer 12. The fine particles can be appropriately selected from known matting agents (matting agents). Examples of the fine particles include organic fine particles and inorganic fine particles, but inorganic fine particles are preferable from the viewpoint of imparting a fine uneven shape to the surface of the resin layer 12. Examples of the organic fine particles include synthetic resin fine particles such as acrylic beads, urethane beads, silicone beads, nylon beads, styrene beads, melamine beads, urethane acrylic beads, polyester beads, and polyethylene beads. Examples of the inorganic fine particles include fine particles made of calcium carbonate, magnesium carbonate, calcium sulfate, barium sulfate, lithium phosphate, magnesium phosphate, calcium phosphate, aluminum oxide, silicon oxide (silica), kaolin and the like. Of these, silica fine particles are preferable because they can impart fine uneven shapes to the surface of the resin layer 12. As the fine particles, one type may be used alone, or two or more types may be used in combination. The average particle size of the fine particles is preferably 1 μm or more and 5 μm or less, and more preferably 2 μm or more and 3 μm or less. The average particle size is measured on a volume basis by a laser diffraction / scattering method according to JIS Z8825: 2013. As a commercially available device for measuring a volume-based particle size distribution by a laser diffraction / scattering method, for example, a particle size distribution measuring device LS-230 manufactured by Beckman Coulter can be mentioned.

The amount of fine particles contained in the primer layer 112 is not particularly limited as long as it can contribute to the uneven shape of the surface of the resin layer 12. The amount of fine particles contained in the primer layer 112 is preferably 15% by mass or more and 30% by mass or less, and more preferably 20% by mass or more and 25% by mass or less, based on the total mass of the primer layer 112. The amount of fine particles contained in the primer layer 112 is preferably 20 parts by mass or more and 35 parts by mass or less, and more preferably 25 parts by mass or more and 30 parts by mass or less with respect to 100 parts by mass of the binder resin contained in the primer layer 112. .. The total mass of the primer layer 112 means the total mass of the primer layer 112 when dried (that is, the total mass of the solid content of the primer layer 112).

The primer layer 112 may contain one or more additives such as a stabilizer, a lubricant, an antioxidant, an antistatic agent, an antifoaming agent, and an optical brightener, if necessary.

The thickness of the primer layer 112 is not particularly limited, but is preferably 1 μm or more and 5 μm or less, and more preferably 2 μm or more and 3 μm or less.

<Resin layer>
Hereinafter, the resin layer 12 will be described with reference to FIG.
As shown in FIG. 1, the resin layer 12 is provided on the entire first main surface S1 of the support layer 11. The resin layer 12 may be provided on a part of the first main surface S1 of the support layer 11. When the resin layer 12 is provided on a part of the first main surface S1 of the support layer 11, the region of the first main surface S1 of the support layer 11 where the resin layer 12 is provided is one continuous region. It may be a plurality of discontinuous regions. The resin layer 12 may be composed of one continuous layer or may be composed of a plurality of discontinuous layers.

As shown in FIG. 1, the surface of the resin layer 12 has an uneven shape and forms the uneven surface 10 of the shaping sheet 1.

The resin layer 12 is a layer containing a curable resin. For example, a resin layer forming composition containing (A) fine particles and a curable resin is applied to the support layer 11 to form a coating film of the resin layer forming composition. After forming, a method of curing the coating film, (B) a resin layer forming composition containing a curable resin is applied to the support layer 11 to form a coating film of the resin layer forming composition, and then predetermined unevenness is formed. It can be formed by a method of pressing a mold having a surface against a coating film to cure the coating film (for example, a drum printing method, a nanoimprint method) or the like. Of these, method A is preferable because it is easy to manufacture. The Drum Printing System is an ionizing radiation that includes the uneven shape on the plate surface as disclosed in Japanese Patent Application Laid-Open No. 5-238196, Japanese Patent No. 3083380, and the like. This is a rotary intaglio printing method that can faithfully shape the surface of the curable resin layer.

In the method A, when the curable resin is cured to become a binder resin, the curable resin shrinks as a whole because the curable resin undergoes curing shrinkage in the portion where the fine particles do not exist. On the other hand, in the portion where the fine particles are present, the fine particles do not undergo curing shrinkage, so that only the curable resin existing above and below the fine particles causes curing shrinkage. As a result, the film thickness of the resin layer 12 is thicker in the portion where the fine particles are present than in the portion where the fine particles are not present, so that the surface of the resin layer 12 has an uneven shape. Therefore, the resin layer 12 having a desired uneven shape can be formed by appropriately selecting the type, particle size, content, etc. of the fine particles, the type of the curable resin, and the like to adjust the coating film forming conditions.

Hereinafter, an embodiment in which the resin layer 12 contains fine particles and a binder resin (an embodiment in which the resin layer 12 is formed by the method A) will be described.

The fine particles contained in the resin layer 12 are preferably organic fine particles. Examples of the organic fine particles include plastic beads. Examples of the plastic beads include acrylic beads, polystyrene beads, melamine resin beads, acrylic-styrene beads, silicone beads, benzoguanamine beads, benzoguanamine / formaldehyde condensed beads, polycarbonate beads, polyethylene beads and the like. Of these, acrylic beads are preferable. Acrylic beads do not easily swell with respect to the solvent contained in the composition for forming the resin layer. Further, when the composition for forming the resin layer contains an ionizing radiation curable resin, the acrylic beads may exist in the resin layer 12 in a state of being bonded to the cured product of the ionizing radiation curable resin, so that the acrylic beads are not easily peeled off from the resin layer 12. ..

The average particle size of the fine particles contained in the resin layer 12 is preferably 6 μm or more and 15 μm or less, and more preferably 7 μm or more and 14 μm or less. The average particle size is measured on a volume basis by a laser diffraction / scattering method according to JIS Z8825: 2013. As a commercially available device for measuring a volume-based particle size distribution by a laser diffraction / scattering method, for example, a particle size distribution measuring device LS-230 manufactured by Beckman Coulter can be mentioned.

The amount of fine particles contained in the resin layer 12 is preferably 35% by mass or more and 60% by mass or less, and more preferably 40% by mass or more and 55% by mass or less, based on the total mass of the resin layer 12. The amount of fine particles contained in the resin layer 12 is preferably 50 parts by mass or more and 150 parts by mass or less, and more preferably 65 parts by mass or more and 120 parts by mass or less with respect to 100 parts by mass of the binder resin contained in the resin layer 12. .. The total mass of the resin layer 12 means the total mass of the resin layer 12 when dried (that is, the total mass of the solid content of the resin layer 12).

The shape of the fine particles in a single particle state is preferably spherical. When the shape of the fine particles is spherical, it is easy to adjust the shape of the uneven surface 10. The spherical shape includes, for example, a true spherical shape, an elliptical spherical shape, and the like.

The resin layer 12 formed by the method A is a layer formed by curing a resin layer forming composition containing fine particles and a curable resin, and contains a cured product of the curable resin as a binder resin. The curable resin contained in the composition for forming the resin layer is preferably an ionizing radiation curable resin, and the resin layer 12 preferably contains a cured product of the ionizing radiation curable resin. The fine particles contained in the composition for forming the resin layer may be present in the resin layer 12 in a state of being bound to the cured product of the ionizing radiation curable resin.

The ionizing radiation curable resin composition contains one or more ionizing radiation curable resins. The ionizing radiation curable resin is a resin that undergoes a cross-linking polymerization reaction by irradiation with ionizing radiation and changes into a three-dimensional polymer structure. Ionizing radiation means an electromagnetic wave or a charged particle beam that has an energy quantum capable of polymerizing or cross-linking a molecule, and usually ultraviolet (UV) or electron beam (EB) is used, but in addition, X It also includes electromagnetic waves such as rays and γ-rays, and charged particle beams such as α-rays and ion rays. Among the ionizing radiation curable resins, the electron beam curable resin is preferable in that it can be made solvent-free and stable curing characteristics can be obtained.

As the ionizing radiation curable resin, for example, one or more of a monomer, an oligomer, a prepolymer, etc. having a polymerizable unsaturated bond, a cationically polymerizable functional group, etc. in the molecule, which can be crosslinked by irradiation with ionizing radiation, shall be used. Can be done. The ionizing radiation curable resin contained in the ionizing radiation curable resin composition may be one kind or two or more kinds.

Examples of the monomer used as the ionizing radiation curable resin include (meth) acrylate monomers having a radically polymerizable unsaturated group in the molecule, and polyfunctional (meth) acrylate monomers are particularly preferable. In addition, "(meth) acrylate" means acrylate or methacrylate.

The polyfunctional (meth) acrylate monomer may be any (meth) acrylate monomer having two or more (bifunctional or higher), preferably three or more (trifunctional or higher) polymerizable unsaturated bonds in the molecule. Not limited. Examples of the polyfunctional (meth) acrylate include ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, and 1,6-hexanediol di (meth). Acrylate, Neopentyl glycol di (meth) acrylate, Polyethylene glycol di (meth) acrylate, Neopentyl glycol di (meth) acrylate hydroxypivalate, Dicyclopentanyldi (meth) acrylate, Caprolactone-modified dicyclopentenyldi (meth) Acrylate, ethylene oxide-modified di (meth) acrylate, allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethyl propanetri (meth) acrylate, ethylene oxide-modified trimethyl propanetri (meth) acrylate, di Pentaerythritol tri (meth) acrylate, propionic acid-modified dipentaerythritol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, propylene oxide-modified trimethylolpropanetri (meth) acrylate, tris (acryloxyethyl) isocyanurate, propion Examples thereof include acid-modified dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, ethylene oxide-modified dipentaerythritol hexa (meth) acrylate, and caprolactone-modified dipentaerythritol hexa (meth) acrylate. The polyfunctional (meth) acrylate may be used alone or in combination of two or more. A monofunctional (meth) acrylate may be used in combination with the polyfunctional (meth) acrylate for the purpose of lowering the viscosity thereof.

Examples of the oligomer used as the ionizing radiation curable resin include (meth) acrylate oligomers having a radically polymerizable unsaturated group in the molecule, and in particular, two polymerizable unsaturated bonds in the molecule. A polyfunctional (meth) acrylate oligomer having the above (bifunctional or higher) is preferable. Examples of the polyfunctional (meth) acrylate oligomer include polycarbonate (meth) acrylate, acrylic silicone (meth) acrylate, urethane (meth) acrylate, epoxy (meth) acrylate, polyester (meth) acrylate, and polyether (meth) acrylate. , Polybutadiene (meth) acrylate, silicon (meth) acrylate, oligomers having a cationically polymerizable functional group in the molecule (for example, novolak type epoxy resin, bisphenol type epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, etc.) and the like. .. Here, the polycarbonate (meth) acrylate is not particularly limited as long as it has a carbonate bond in the polymer main chain and has a (meth) acrylate group in the terminal or side chain, and for example, a polycarbonate polyol (meth) is used. It can be obtained by esterification with acrylic acid. The polycarbonate (meth) acrylate may be, for example, urethane (meth) acrylate having a polycarbonate skeleton or the like. Urethane (meth) acrylate having a polycarbonate skeleton can be obtained, for example, by reacting a polycarbonate polyol with a polyhydric isocyanate compound and a hydroxy (meth) acrylate. Acrylic silicone (meth) acrylate can be obtained by radically copolymerizing a silicone macromonomer with a (meth) acrylate monomer. Urethane (meth) acrylate can be obtained, for example, by esterifying a polyurethane oligomer obtained by a reaction between a polyether polyol or a polyester polyol and a polyisocyanate with (meth) acrylic acid. Epoxy (meth) acrylate can be obtained, for example, by reacting (meth) acrylic acid with an oxylan ring of a relatively low molecular weight bisphenol type epoxy resin or a novolak type epoxy resin to esterify it. Further, a carboxyl-modified epoxy (meth) acrylate obtained by partially modifying this epoxy (meth) acrylate with a dibasic carboxylic acid anhydride can also be used. The polyester (meth) acrylate can be obtained, for example, by esterifying the hydroxyl group of a polyester oligomer having hydroxyl groups at both ends obtained by condensation of a polyvalent carboxylic acid and a polyhydric alcohol with (meth) acrylic acid, or to a polyvalent carboxylic acid. It can be obtained by esterifying the hydroxyl group at the end of the oligomer obtained by adding an alkylene oxide with (meth) acrylic acid. The polyether (meth) acrylate can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid. Polybutadiene (meth) acrylate can be obtained by adding (meth) acrylic acid to the side chain of the polybutadiene oligomer. Silicon (meth) acrylate can be obtained by adding (meth) (meth) acrylic acid to the terminal or side chain of silicon having a polysiloxane bond in the main chain. Among these, urethane (meth) acrylate oligomers are preferable from the viewpoint of further increasing the hardness of the resin layer 12. These oligomers may be used alone or in combination of two or more.

The weight average molecular weight of the ionizing radiation curable resin is preferably 500 or more, more preferably 1000 or more. When the weight average molecular weight of the ionizing radiation curable resin is within the above range, when the composition for forming the resin layer is applied to the support layer 11, the composition for forming the resin layer does not easily penetrate into the support layer 11, so that the resin layer is not easily penetrated. It is easy to form a coating film of the forming composition.

The weight average molecular weight of the ionizing radiation curable resin is preferably 80,000 or less, more preferably 50,000 or less. When the weight average molecular weight of the ionizing radiation curable resin is in the above range, it is easy to adjust the viscosity of the resin layer forming composition to a viscosity suitable for coating.

The "weight average molecular weight" is a value measured by gel permeation chromatography (GPC) using polystyrene as a standard substance.

The ionizing radiation curable resin is preferably at least one selected from polyfunctional monomers and oligomers having a weight average molecular weight of 500 or more. Examples of such a polyfunctional monomer or oligomer include acrylate resins such as dipentaerythritol hexaacrylate, dipentaerythritol pentaacrylate, urethane acrylate, polyester acrylate, and epoxy acrylate.

If necessary, the resin layer forming composition may contain a component involved in the curing reaction of the ionizing radiation curable resin, for example, a photopolymerization initiator (sensitizer). For example, when the ionizing radiation curable resin is cured by irradiation with ultraviolet rays, it is preferable that the composition for forming the resin layer contains a photopolymerization initiator (sensitizer). Since the ionized thermosetting resin is sufficiently cured by irradiating it with an electron beam, when the ionized thermosetting resin is cured by irradiating it with an electron beam, the resin layer forming composition is a photopolymerization initiator (sensitizer). ) May not be included.

When the ionizing radiation curable resin has a radically polymerizable unsaturated group, the photopolymerization initiator may be, for example, acetophenones, benzophenones, thioxanthones, benzoins, benzoin methyl ethers, Michler benzoyl benzoates, Michler ketones, diphenyl sulfides, etc. At least one of dibenzyldisulfide, diethyloxide, triphenylbiimidazole, isopropyl-N, N-dimethylaminobenzoate and the like can be used. When the ionizing radiation curable resin has a cationically polymerizable functional group, the photopolymerization initiator may be, for example, an aromatic diazonium salt, an aromatic sulfonium salt, a metallocene compound, a benzoin sulfonic acid ester, or a freele oxysulfoxonium. At least one kind such as diallyl iodosyl salt can be used.

The amount of the photopolymerization initiator contained in the resin layer forming composition is not particularly limited, but is usually 0.1 part by mass or more and 10 parts by mass or less with respect to 100 parts by mass of the ionizing radiation curable resin.

The resin layer 12 is a solvent-drying resin (a resin such as a thermoplastic resin that can be formed into a film simply by drying a solvent added to adjust the solid content at the time of coating) and thermosetting property, if necessary. It may contain a resin or the like. By adding the solvent-drying resin to the resin layer-forming composition, it is possible to effectively prevent film defects on the coated surface of the resin layer-forming composition when the resin layer 12 is formed. As the solvent-drying resin, for example, a thermoplastic resin can be used, and as the thermoplastic resin, for example, a styrene resin, a (meth) acrylic resin, a vinyl acetate resin, a vinyl ether resin, and a halogen-containing resin can be used. , Alicyclic olefin resin, polycarbonate resin, polyester resin, polyamide resin, cellulose derivative, silicone resin and rubber or elastomer. Examples of the thermosetting resin include phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, unsaturated polyester resin, polyurethane resin, epoxy resin, aminoalkyd resin, melamine-urea cocondensation resin, and silicon resin. Examples thereof include polysiloxane resin.

The resin layer 12 formed by the method B is, for example, a layer formed by curing a resin layer forming composition containing a curable resin, and contains a cured product of the curable resin. The curable resin contained in the resin layer forming composition is, for example, a thermosetting resin, an ionizing radiation curable resin, or the like, and is preferably an ionizing radiation curable resin. The description of the ionizing radiation curable resin is the same as described above. Examples of the thermosetting resin include unsaturated polyester resin, polyurethane resin (including two-component curable polyurethane), epoxy resin, aminoalkyd resin, phenol resin, urea resin, diallyl phthalate resin, melamine resin, guanamine resin, and melamine. -Urea cocondensation resin, silicon resin, polysiloxane resin and the like can be mentioned. The composition for forming a resin layer may contain, if necessary, components involved in the curing reaction of the thermosetting resin, for example, a catalyst, a curing agent (including a cross-linking agent, a polymerization initiator, a polymerization accelerator, etc.) and the like. good. For example, examples of the curing agent for unsaturated polyester resin and polyurethane resin include isocyanate and organic sulfonate, and examples of curing agent for epoxy resin and the like include organic amine and the like, and radical initiation of unsaturated polyester resin. Examples of the agent include peroxides such as methyl ethyl ketone peroxide and azoisobutylnitrile.

The thickness of the resin layer 12 is not particularly limited, but is preferably 5 μm or more and 12 μm or less, and more preferably 6 μm or more and 10 μm or less. It is preferable that both the minimum thickness and the maximum thickness of the resin layer 12 are within the above ranges.

≪Manufacturing of excipient sheet≫
Hereinafter, the production of the shaping sheet 1 using the method A will be described.
First, the primer layer 112 is formed on the first main surface T1 of the base sheet 111. Even if the first main surface T1 of the base sheet 111 is formed with an easy-adhesion layer or physically or chemically surface-treated by an oxidation method, an unevenness method, or the like before forming the primer layer 112. good. This makes it possible to improve the adhesion of the primer layer 112.

The primer layer 112 can be formed by applying the primer layer forming composition to the first main surface T1 of the base sheet 111. Examples of the method for applying the primer layer forming composition include a spin coating method, a dip method, a spray method, a slide coating method, a bar coating method, a roll coating method, a gravure coating method, and a die coating method.

The composition for forming a primer layer is, for example, a mixture of a solvent or a dispersion medium and a solid content such as a binder resin and fine particles. Examples of the solvent or dispersion medium include petroleum-based organic solvents such as hexane, heptane, octane, toluene, xylene, ethylbenzene, cyclohexane, and methylcyclohexane; ethyl acetate, butyl acetate, -2-methoxyethyl acetate, and -2-ethoxy acetate. Ether-based organic solvents such as ethyl; alcohol-based organic solvents such as methyl alcohol, ethyl alcohol, normal propyl alcohol, isopropyl alcohol, isobutyl alcohol, ethylene glycol and propylene glycol; ketone-based organic solvents such as acetone, methyl ethyl ketone, methyl isobutyl ketone and cyclohexanone. Solvents; ether-based organic solvents such as diethyl ether, dioxane, tetrahydrofuran; chlorine-based organic solvents such as dichloromethane, carbon tetrachloride, trichloroethylene, tetrachloroethylene; inorganic solvents such as water and the like can be mentioned. As the solvent or the dispersion medium, one type may be used alone, or two or more types may be used in combination.

The amount of the primer layer forming composition applied is not particularly limited, but is preferably 1 g / m ² or more and 5 g / m ² or less, and more preferably 2 g / m ² or more and 3 g / m ² or less.

After forming the primer layer 112, the resin layer forming composition is applied onto the primer layer 112. Specific examples of the coating method of the resin layer forming composition are the same as described above.

The composition for forming a resin layer is, for example, a mixture of a solvent or a dispersion medium and a solid content such as an ionizing radiation curable resin and fine particles. Specific examples of the solvent or the dispersion medium are the same as described above. As the solvent or the dispersion medium, one type may be used alone, or two or more types may be used in combination. The resin layer forming composition may contain a thermoplastic resin, a thermosetting resin, a photopolymerization initiator and the like, if necessary. Further, the composition for forming a resin layer is a dispersant, a surfactant, an antistatic agent, a silane coupling agent, a thickener, and a coloring inhibitor for the purpose of increasing the hardness of the resin layer and suppressing curing shrinkage. , Coloring agent (pigment, dye), defoaming agent, leveling agent, flame retardant, ultraviolet absorber, adhesion imparting agent, polymerization inhibitor, antioxidant, surface modifier, slipper, and the like may be contained.

The coating amount of the resin layer forming composition is not particularly limited, but is preferably 5 g / m ² or more and 12 g / m ² or less, and more preferably 6 g / m ² or more and 10 g / m ² or less.

After applying the resin layer forming composition on the primer layer 112, the coating film of the resin layer forming composition is dried. By adjusting the drying conditions, the distribution state of the fine particles can be adjusted. The drying temperature is preferably 40 ° C. or higher and 100 ° C. or lower, and more preferably 40 ° C. or higher and 60 ° C. or lower. By performing the drying treatment under such drying conditions once or a plurality of times, the distribution state of the fine particles can be adjusted to a desired state.

After the coating film of the resin layer forming composition is dried, the ionizing radiation curable resin is cured by irradiating it with ionizing radiation such as ultraviolet rays and electron beams to form the resin layer 12.

When ultraviolet rays are used as ionizing radiation for curing an ionizing radiation curable resin, the ultraviolet sources include, for example, ultra-high pressure mercury lamps, high pressure mercury lamps, low pressure mercury lamps, carbon arc lamps, black light fluorescent lamps, metal halide lamps, etc. Light source can be used. The wavelength of ultraviolet rays is usually 190 nm or more and 380 nm or less. When an electron beam is used as the ionizing radiation for curing the ionizing radiation curable resin, the electron beam source may be, for example, a cockcroftwald type, a bandegraft type, a resonance transformer type, an insulated core transformer type, or a linear type. , Dynamitron type, high frequency type and other electron beam accelerators can be used. The energy of the electron beam is usually 100 keV or more and 1000 keV or less, preferably 100 keV or more and 300 keV or less. The irradiation amount of the electron beam is usually 2 Mrad or more and 15 Mrad or less.

≪Use of excipient sheet≫
The shaping sheet 1 is used for producing a melamine decorative board having an uneven surface. Hereinafter, an embodiment of a method for manufacturing a melamine decorative board having an uneven surface using the shaping sheet 1 will be described with reference to FIGS. 2A to 2C. 2A to 2C are diagrams for explaining a method of manufacturing a melamine decorative board 3 using the shaping sheet 1.

The method for producing a melamine decorative board according to the present embodiment is as follows: (a) a step of preparing the laminated body 2, (b) a step of pressurizing and heating the laminated body 2, and (c) peeling off the shaping sheet 1. Including the process.

As shown in FIG. 2A, the laminate 2 prepared in the step (a) is formed by impregnating the core layer 21 and the base paper for a decorative board provided on the core layer 21 with an uncured melamine resin. The uncured melamine resin layer 22 is provided, and the shaping sheet 1 provided on the uncured melamine resin layer 22 is provided. The shaping sheet 1 is provided on the uncured melamine resin layer 22 so that the uneven surface 10 of the shaping sheet 1 is in contact with the uncured melamine resin layer 22. As a result, the surface of the uncured melamine resin layer 22 is shaped into an uneven shape along the uneven surface 10 of the shaping sheet 1. The uncured melamine resin is obtained by reacting melamine and formaldehyde under neutral or alkaline conditions, and the reaction product of melamine and formaldehyde is methylol melamines (monomethylol melamine, dimethylol melamine, etc.). Hexamethylol melamine) is contained. Melamine resin is also called melamine-formaldehyde resin.

The core layer 21 is, for example, a phenol resin impregnated paper or a laminate thereof. As the phenol resin impregnated paper, kraft paper having a basis weight of about 150 to 300 g / m ² is mixed with a resin containing phenol resin as a main component so that the impregnation rate calculated by the formula described later is about 30 to 80%. Obtained by impregnation and drying.

The core layer 21 may be a glass cloth or a glass non-woven fabric, or a prepreg using a glass cloth or a glass non-woven fabric as a base material. The prepreg can be obtained, for example, by impregnating a glass cloth or a glass nonwoven fabric with a resin composition containing a thermoplastic resin, a thermosetting resin, or the like.

The uncured melamine resin layer 22 is, for example, a melamine resin-impregnated paper or a laminate thereof. The melamine resin-impregnated paper is, for example, a base paper for a decorative board having a basis weight of about 70 to 140 g / m ² , and an uncured melamine resin, typically a resin containing methylol melamine as a main component, is calculated by the following formula. It is obtained by impregnating and drying so that the impregnation rate is about 70 to 160%.

The uncured melamine resin layer 22 may be a laminate containing a melamine resin-impregnated overlay paper or a melamine resin-impregnated overlay paper. The melamine resin-impregnated overlay paper is calculated by using, for example, an overlay base paper having a basis weight of about 23 to 60 g / m ² and a melamine resin unrefined product, typically a resin containing methylol melamine as a main component, using the formula described below. It is obtained by impregnating and drying so that the impregnation rate is about 200 to 400%. The melamine resin-impregnated overlay paper can be used as the uncured melamine resin layer 22 after being laminated on the base paper for decorative boards, for example.

The uncured melamine resin layer 22 may be a laminate containing both the melamine resin-impregnated paper and the melamine resin-impregnated overlay paper.

The impregnation rate in the phenol resin impregnated paper and the melamine resin impregnated paper is determined based on the following formula.
Impregnation rate (%) = [(mass of impregnated paper after impregnation)-(mass of base paper before impregnation)] / (mass of base paper before impregnation × 100

The pressurization and heating of the laminated body 2 in the step (b) are carried out, for example, in a state where the laminated body 2 is sandwiched between two mirror-finished metal plates P1 and P2, as shown in FIG. 2B. By pressurizing and heating the laminate 2, the uncured melamine resin contained in the uncured melamine resin layer 22 is cured. By pressurizing and heating the laminate 2, the uncured melamine resin layer 22 is cured in a state where the surface thereof is shaped into an uneven shape along the uneven surface 10 of the shaping sheet 1, and the cured product of the melamine resin is cured. A cured resin layer containing the same is formed. The cured resin layer becomes the surface layer 32 after the shaping sheet 1 is peeled off. The core layer 31 is formed from the core layer 21 by pressurizing and heating the laminate 2. When a phenol resin impregnated paper or a laminate thereof is used as the core layer 21, the phenol resin contained in the core layer 21 is also cured at this stage.

The pressure applied by the mirror-finished metal plates P1 and P2 is usually 9.0 N / m ² or more and 10.5 N / m ² or less. The heating temperature is usually 130 ° C. or higher and 180 ° C. or lower, and the heating time is usually 5 minutes or longer and 50 minutes or shorter.

In the step (c), the shaping sheet 1 is peeled off from the rest of the laminated body 2, so that the melamine decorative plate 3 having the uneven surface 30 is manufactured as shown in FIG. 2C. The melamine decorative board 3 includes a core layer 31 and a surface layer 32 containing a cured product of the melamine resin. The surface of the surface layer 32 has an uneven shape imparted by the shaping sheet 1 and forms the uneven surface 30 of the melamine decorative plate 3. The precursor layer of the core layer 31 is the core layer 21 of the laminated body 2, and when the laminated body 2 is pressurized and heated in the step (b), the core layer 31 is generated from the core layer 21. The precursor layer of the surface layer 32 is the uncured melamine resin layer 22 of the laminated body 2, and when the laminated body 2 is pressurized and heated in the step (b), the uncured melamine resin layer 22 becomes a cured resin layer. A surface layer 32 is created.

It is preferable that the center line average roughness Ra, the maximum height Rmax, and the average interval Sm of the unevenness constituting the uneven surface 30 of the melamine decorative board 3 are in the following ranges. As a result, the uneven surface 30 of the melamine decorative plate 3 has a low luster and excellent sweepability.

The average roughness Ra of the center line of the unevenness constituting the uneven surface 30 of the melamine decorative plate 3 is preferably 1.6 μm or more and 2.4 μm or less, and more preferably 1.8 μm or more and 2.4 μm or less. The definition of centerline average roughness Ra follows JIS B0601-1982.

The maximum height Rmax of the unevenness constituting the uneven surface 30 of the melamine decorative plate 3 is preferably 14 μm or more and 19.5 μm or less, and more preferably 17 μm or more and 19.5 μm or less. The definition of maximum height Rmax follows JIS B0601-1982.

The average spacing Sm of the irregularities constituting the uneven surface 30 of the melamine decorative plate 3 is preferably 50 μm or more and 110 μm or less, and more preferably 50 μm or more and 100 μm or less. The definition of the average interval Sm follows JIS B0601-1994.

The melamine veneer 3 exhibits, for example, a dark color. Whether or not the melamine decorative plate 3 exhibits a dark color can be determined by visually observing the melamine decorative plate 3 from the uneven surface 30 side of the melamine decorative plate 3. The "dark color" means that the color tone is a chromatic color or an achromatic color with low lightness. For example, achromatic colors such as black and dark gray, and chromatic colors such as dark blue, brown, yellowish brown, dark green, dark purple, and enji correspond to dark colors. The dark color is preferably black.

Since the surface layer 32 exhibits a dark color, the melamine decorative board 3 can exhibit a dark color. Since the uncured melamine resin layer 22 contains a dark pigment, the surface layer 32 can exhibit a dark color. The dark pigment is contained in, for example, a base paper for a decorative board. The dark pigment can be appropriately selected from known dark pigments. As the dark pigment, one type may be used alone, or two or more types may be used in combination. Examples of the black pigment include organic black pigments and inorganic black pigments. Examples of the organic black pigment include azomethine azo black pigment, perylene black pigment, azo black pigment, aniline black, acetylene black, carbon black, lamp black, benzimidazolone pigment brown 25 (brown) and phthalocyanine blue (blue). Examples include mixed pigments with. Examples of the inorganic black pigment include composite oxides, iron black, titanium black and the like. The composite oxide is an oxide containing at least two kinds of metal elements. The composite oxide is preferably a composite oxide containing at least a manganese element, that is, an oxide containing a manganese element and at least one metal element other than the manganese element. The metal element other than the manganese element contained in the composite oxide is not particularly limited and may be appropriately selected. The metal element other than the manganese element contained in the composite oxide may be one kind alone or a combination of two or more kinds. Metallic elements other than manganese elements contained in the composite oxide include, for example, Group 2 elements such as calcium element and barium element; ittrium element, lanthanum element, placeodium element; Group 3 element such as neodymium element, titanium element, and the like. Group 4 elements such as zirconium elements; Group 13 elements such as boron elements, aluminum elements, gallium elements and indium elements; metal elements such as Group 15 elements such as antimony elements and bismuth elements can be mentioned. Among these, Group 2 elements, Group 4 elements, and Group 15 elements are preferable, calcium elements, titanium elements, and bismuth elements are more preferable, and calcium elements and titanium elements are even more preferable. Particularly preferable specific examples of the composite oxide include a composite oxide containing a manganese element, a calcium element and a titanium element.

The melamine veneer 3 exhibits, for example, white color. Whether or not the melamine decorative plate 3 exhibits white color can be determined by visually observing the melamine decorative plate 3 from the uneven surface 30 side of the melamine decorative plate 3.

When the surface layer 32 exhibits white color, the melamine decorative board 3 can exhibit white color. Since the uncured melamine resin layer 22 contains a white pigment, the surface layer 32 can exhibit white color. The white pigment is contained in, for example, a base paper for a decorative board. The white pigment can be appropriately selected from known white pigments. As the white pigment, one kind may be used alone, or two or more kinds may be used in combination. Examples of the white pigment include titanium white and antimony white.

When the melamine decorative plate 3 exhibits a dark color, the 60 ° glossiness of the uneven surface 30 of the melamine decorative plate 3 is preferably 3 or less, more preferably 2.5 or less. The lower limit of the 60 ° glossiness is not particularly limited, but is preferably 1.5, more preferably 1.7.

When the melamine decorative plate 3 exhibits white color, the 60 ° glossiness of the uneven surface 30 of the melamine decorative plate 3 is preferably 5 or less, more preferably 4 or less. The lower limit of the 60 ° glossiness is not particularly limited, but is preferably 2.0, more preferably 2.5.

The 60 ° glossiness of the uneven surface 30 of the melamine decorative plate 3 is measured according to JIS Z8741: 1997. Specifically, using a GMX-202 manufactured by Murakami Color Technology Laboratory as a gloss meter, the 60 ° glossiness of the uneven surface 30 of the melamine decorative plate 3 is measured under the condition of an incident angle of 60 °.

Hereinafter, the present invention will be described based on examples.

[Example 1]
(1) Manufacture of shaped sheet Silica fine particles (average particle size: 3 μm) on the easily adhesive surface of an easily adhesive polyester (PET) film (A4100 manufactured by Toyobo Co., Ltd.) having a thickness of 50 μm using a gravure printing method. And a two-component curable urethane resin (EBF manufactured by Showa Ink Kogyo Co., Ltd.) was applied with a primer layer forming composition to a thickness of 1 μm to form a primer layer. The amounts of the silica fine particles and the two-component curable urethane resin contained in the primer layer forming composition are 28% by mass and 70% by mass, respectively, based on the total mass of the solid content contained in the primer layer forming composition. be.

An electron beam curable resin composition containing acrylic beads (average particle size: 12 μm) and tetrafunctional acrylate oligomer (weight average molecular weight: 2,000) is applied onto the primer layer using a gravure printing method. The solvent was removed by drying at 80 ° C. for 1 minute. The amount of acrylic beads contained in the electron beam curable resin composition is 50% by mass based on the total mass of the solid content contained in the electron beam curable resin composition, and the amount of the acrylic beads is P. The / V ratio (amount of acrylic beads / amount of acrylate oligomer) is 1.0. The coating film of the electron beam curable resin composition was adjusted so that the weight after drying was 9.0 g / m ² . The dried coating film was cured by irradiating it with an electron beam under the conditions of 165 KV and 50 kGry to form a resin layer having an uneven surface as an exposed surface (the surface opposite to the primer layer) to obtain a shaped sheet. .. Table 1 shows the manufacturing conditions and characteristics (60 ° glossiness, surface roughness) of the shaped sheet. The shaping sheet was heat-cured at 50 ° C. for 24 hours and then used for producing a melamine decorative board.

(2) Manufacture of melamine decorative board using shaped sheet 100 parts by mass of water-soluble methylol melamine (Nikaresin S-260 manufactured by Nippon Carbide) is diluted with 60 parts by mass of water to prepare a melamine-formaldehyde aqueous solution, and then tsubo. A melamine resin-impregnated paper was produced by impregnating a base paper for a decorative board having an amount of 80 g / m ² with an impregnation amount of 80 g / m ² (when dried) and drying. At this time, titanium paper is used as the base paper for the decorative board, KW-801P manufactured by KJ Special Paper Co., Ltd. is used as the titanium base paper when manufacturing the white decorative board, and the titanium base paper is used when manufacturing the black decorative board. As, PM-802PK manufactured by KJ Special Paper Co., Ltd. was used.

Two sheets of phenol resin impregnated core paper (Ota core manufactured by Ota Sangyo Co., Ltd.) prepared by impregnating kraft paper with a resin composition containing a phenol resin and having a basis weight of 245 g / m ² are laminated to form a phenol resin impregnated core paper. The melamine resin impregnated paper is laminated on the laminated body of the above, and further, the shaped sheet is placed on the melamine resin impregnated paper so that the uneven surface of the resin layer (the shaped surface of the shaped sheet) is in contact with the melamine resin impregnated paper. Was laminated.

The laminate thus formed was sandwiched between two press plates and pressed for 30 minutes under the conditions of a temperature of 135 ° C. and a press pressure of 9.8 N / m ² . After the press working, the shaping sheet was peeled off to obtain a melamine decorative plate having an uneven surface. Table 1 shows the characteristics (60 ° glossiness, surface roughness, easy sweepability) of the melamine decorative board.

(3) Evaluation method The evaluation method of the characteristics of the shaping sheet and the melamine decorative board is as follows.

[Surface roughness]
Concerning the uneven surface of the shaping sheet and the uneven surface of the melamine decorative board (melamine decorative board manufactured using black titanium paper), the center line average roughness Ra (JIS B0601-1982) of the unevenness constituting the uneven surface, the unevenness The maximum height Rmax (JIS B0601-1982) of the unevenness constituting the surface and the average spacing Sm (JIS B0601-1994) of the unevenness constituting the uneven surface are measured by the surface roughness measuring instrument (three-dimensional surface manufactured by Kosaka Laboratory). The measurement was performed according to the following conditions using a roughness measuring instrument SE-30K) and a surface roughness analyzer (Surf Coder AY-31 manufactured by Kosaka Laboratory).
1) Needle / tip diameter of surface roughness detection part: R2 μm
・ Skid: R40mm x R2mm
・ Material: Sapphire ・ Needle pressure: 0.7μN
・ Feeding speed of stylus: 0.5 mm / s
2) Measurement conditions ・ Cutoff value (reference length): 0.08 mm
-Measurement length (cutoff value x 100): 8 mm
・ Vertical magnification: 1000 times ・ Horizontal magnification: 10 times

[60 ° gloss]
With respect to the uneven surface of the shaped sheet and the uneven surface of the melamine decorative board (melamine decorative board manufactured using black titanium paper and melamine decorative board manufactured using white titanium paper), the 60 ° glossiness of the uneven surface is determined. , JIS Z8741: 1997. Specifically, a GMX-202 manufactured by Murakami Color Technology Laboratory was used as a gloss meter, and the 60 ° glossiness of the uneven surface was measured under the condition of an incident angle of 60 °.

[Easy to sweep]
Regarding the uneven surface of the melamine decorative board (melamine decorative board manufactured using white titanium paper), write letters on the uneven surface using a water-based felt-tip pen (manufactured by Pentel), wipe it off with a dry cloth, and wipe the uneven surface. The condition of was evaluated according to the following criteria.
A: The characters written with felt-tip pen can be easily wiped off, and there is no ink contamination.
B: The characters written with a felt-tip pen can be wiped off, and there is almost no ink contamination.
C: The characters written with a felt-tip pen cannot be wiped off, causing contamination with ink.

[Examples 2 to 4 and Comparative Examples 1 to 8]
A shaping sheet was manufactured in the same manner as in Example 1 except that the blending amount of the acrylic beads and the average particle size were changed, and the melamine decorative board was manufactured using the manufactured shaping sheet. Tables 1 and 2 show the manufacturing conditions and characteristics of the shaped sheet (60 ° glossiness, surface roughness) and the characteristics of the melamine decorative board (60 ° glossiness, surface roughness, easy sweepability).

[Comparative Example 9]
As the means for forming the uneven surface, a shaping sheet was manufactured in the same manner as in Example 1 except that amorphous silica having an average particle size of 4 μm was used instead of the acrylic beads, and the manufactured shaping sheet was used. Manufactured a melamine veneer. Table 2 shows the manufacturing conditions and characteristics (60 ° glossiness, surface roughness) of the shaping sheet and the characteristics (60 ° glossiness, surface roughness, easy sweepability) of the melamine decorative board.

[Comparative Examples 10 to 11]
As the shaping sheet, the shaping sheet was used in the same manner as in Example 1 except that Sandblast PET W3 manufactured by Somar Corporation (Comparative Example 10) or Sandblast PET UG manufactured by Kimoto Corporation (Comparative Example 11) was used. Manufactured a melamine veneer. Table 2 shows the characteristics of the shaped sheet (60 ° glossiness, surface roughness) and the characteristics of the melamine decorative board (60 ° glossiness, surface roughness, easy sweepability).

As shown in Tables 1 and 2, with respect to the unevenness constituting the uneven surface of the shaping sheet, the center line average roughness Ra is 1.7 μm or more and 2.7 μm or less, and the maximum height Rmax is 11 μm or more and 16 μm or less. When the average interval Sm is 30 μm or more and 65 μm or less, the gloss is low (when the melamine decorative board exhibits black color, the 60 ° glossiness of the uneven surface of the melamine decorative board is 3 or less, and the melamine decorative board is white. In this case, the uneven surface of the melamine decorative board has a 60 ° glossiness of 4 or less), and a melamine decorative board having an uneven surface having excellent sweepability can be manufactured.

1 ... Shaped sheet 10 ... Concavo-convex surface of shaped sheet 11 ... Support layer 111 ... Base sheet 112 ... Primer layer 12 ... Resin layer 2 ... Laminated body 21.・ ・ Core layer 22 ・ ・ ・ Uncured melamine resin layer 3 ・ ・ ・ Melamine decorative board 30 ・ ・ ・ Concavo-convex surface of melamine decorative board 31 ・ ・ ・ Core layer 32 ・ ・ ・ Surface layer

Claims (5)

A melamine decorative board having a core layer and a surface layer containing a cured product of a melamine resin provided on the core layer and exhibiting a dark color or a white color.
The surface layer has an uneven surface forming the surface of the melamine decorative board.
The average roughness Ra of the center line of the unevenness constituting the uneven surface is 1.5 μm or more and 2.4 μm or less.
The maximum height Rmax of the unevenness constituting the uneven surface is 14.0 μm or more and 19.5 μm or less.
The average spacing Sm of the unevenness constituting the uneven surface is 50 μm or more and 120 μm or less.
When the melamine decorative board exhibits a dark color, the 60 ° glossiness of the uneven surface is 3 or less.
When the melamine decorative board exhibits white color, the 60 ° glossiness of the uneven surface is 5 or less.
The melamine decorative board. The melamine decorative plate according to claim 1, wherein the surface layer exhibits a dark color, whereby the melamine decorative plate exhibits a dark color. The melamine decorative board according to claim 2, wherein the surface layer contains a dark pigment. The melamine decorative plate according to claim 1, wherein the surface layer exhibits white color, whereby the melamine decorative plate exhibits white color. The melamine decorative board according to claim 4, wherein the surface layer contains a white pigment.

Images