JP7041765B1 - A method for manufacturing an impregnated paper for a decorative base material, a method for manufacturing a decorative base material, and a method for manufacturing a decorative board. - Google Patents

Abstract

PROBLEM TO BE SOLVED: To suppress the generation of burrs on which a resin is cured and to improve caster resistance. SOLUTION: At least one surface side is integrally bonded to a porous wood board 10 and one surface of the wood board 10 via a water-based adhesive 15, and an impregnating agent containing a water repellent and an impregnating resin is impregnated and dried. The impregnated paper layer 20 is provided, and the water-based adhesive 15 is 5 to 20 parts by mass of the adhesive resin containing 1 to 5 parts by mass of the curing accelerator with respect to 100 parts by mass of the water-based melamine resin. The impregnated paper layer 20 is impregnated and cured so as to contain a mass portion of the emulsion resin and fill the voids of all the layers of the impregnated paper layer 20. [Selection diagram] Fig. 1

Description

The present invention relates to a method for producing an impregnated paper for a decorative base material, a method for producing a decorative base material, and a method for producing a decorative board .

Conventionally, a decorative board for construction is widely known in which a decorative sheet such as a veneer or decorative paper is attached to the surface of a wooden board material such as plywood.

For example, in Patent Document 1, after applying a synthetic resin liquid to the surface of a porous substrate such as plywood, a fibrous sheet is placed on the surface and heated and pressed by a hot press to make the fibrous sheet a porous substrate. Disclosed is a method for surface-strengthening a porous substrate, which forms a surface-reinforcing layer by impregnating and curing a fibrous sheet with a synthetic resin solution.

Japanese Patent No. 3886330

By the way, the surface strengthening method for a porous substrate disclosed in Patent Document 1 requires a large amount of synthetic resin liquid in order to uniformly impregnate and cure the synthetic resin liquid over all layers of the fibrous sheet. .. Further, in order to improve the impregnation property of the synthetic resin liquid into the porous substrate and the fibrous sheet, the viscosity of the synthetic resin liquid cannot be increased so much. Therefore, when a fibrous sheet impregnated with an uncured synthetic resin liquid is placed on the surface of a porous substrate and heated and pressed, the synthetic resin liquid seeps out to the surroundings, and the peripheral portion of the surface of the laminated body after pressing. So-called thermosetting hard burrs are generated, and the burrs fall off and adhere to the pressed substrate and press equipment as dust, and are pressed against the front and back surfaces of the products during pressing and stacking. May cause defects. The surface strengthening method for the porous substrate disclosed in Patent Document 1 has caster resistance because the synthetic resin liquid is uniformly impregnated and cured over the entire layer of the fibrous sheet.

The present invention has been made in view of this point, and an object of the present invention is to suppress the generation of burrs on which the resin has hardened and to improve caster resistance.

In order to achieve the above object, the method for producing an impregnated paper for a decorative base material according to the present invention is to use a sheet-shaped paper material having a thickness of 0.2 mm to 0.5 mm with respect to 100 parts by mass of an aqueous melamine resin. The impregnated resin agent containing 40 to 50 parts by mass of acrylic resin is impregnated with an impregnating agent containing 5 to 15 parts by mass of a water repellent and then pressed by pressing the paper material. It is characterized by comprising an impregnation step of permeating the agent in the thickness direction of the paper material and removing a surplus of the impregnating agent, and a drying step of drying the paper material treated in the impregnation step. ..

According to the above method, in the impregnation step, 5 to 15 parts by mass of a water repellent agent is used with respect to 100 parts by mass of an impregnated resin agent containing 40 to 50 parts by mass of an acrylic resin with respect to 100 parts by mass of an aqueous melamine resin. By squeezing a sheet-shaped paper material having a thickness of 0.2 mm to 0.5 mm impregnated with the impregnating agent containing the above, the impregnating agent is infiltrated in the thickness direction of the paper material and the excess of the impregnating agent is removed. Therefore, the sheet-shaped paper material can be uniformly impregnated with the impregnating agent. Further, after that, by performing a drying step, the impregnating agent is uniformly impregnated and dried in all layers of the paper material. Here, since the thickness of the paper material is 0.2 mm to 0.5 mm, it is possible to produce an impregnated paper for a decorative base material reinforced with an impregnated resin agent. If the thickness of the paper material is less than 0.2 mm, the strength of the impregnated paper for the decorative base material is insufficient, and the paper material is used when the paper material is squeezed to remove the excess of the impregnating agent. There is a risk of tearing. Further, when the thickness of the paper material exceeds 0.5 mm, it becomes difficult to impregnate the entire layer of the paper material with the impregnating resin agent. Further, since the impregnating agent contains 40 to 50 parts by mass of an acrylic resin with respect to 100 parts by mass of an aqueous melamine resin, a flexible impregnated paper for a decorative base material can be produced. If the impregnating agent contains less than 40 parts by mass of acrylic resin with respect to 100 parts by mass of water-based melamine resin, the toughness of the impregnated paper for decorative base material is insufficient (becomes hard and brittle). Cracks are likely to occur. Further, when the impregnating agent contains more than 50 parts by mass of an acrylic resin with respect to 100 parts by mass of the water-based melamine resin, the compatibility with the water-based melamine resin may decrease. Further, since the impregnating agent contains 5 to 15 parts by mass of a water repellent with respect to 100 parts by mass of the impregnated resin agent, the water resistance of the impregnated paper for a decorative base material can be ensured. If the impregnating agent contains less than 5 parts by mass of the water repellent with respect to 100 parts by mass of the impregnated resin agent, it becomes difficult to secure the water resistance of the impregnated paper for the decorative base material. It ends up. Further, when the impregnating agent contains more than 15 parts by mass of a water repellent with respect to 100 parts by mass of the impregnated resin agent, the compatibility with the water-based melamine resin and the acrylic resin is lowered, and the manufacturing cost is high. There is a risk of becoming.

Further, in the method for producing a decorative base material according to the present invention, at least one surface side is integrally bonded to a porous wood board material and the above one surface of the wood board material with a water-based adhesive, and the product is manufactured by the above-mentioned manufacturing method. A method for producing a decorative base material including an impregnated paper layer made of an impregnated paper for a decorative base material, wherein the water-based adhesive has 1 to 5 parts by mass with respect to 100 parts by mass of the water-based melamine resin. The impregnated paper contains 5 to 20 parts by mass of the emulsion resin with respect to 100 parts by mass of the adhesive resin containing the curing accelerator, and the water-based adhesive fills the voids of all the layers of the impregnated paper layer. It is characterized by comprising an bonding step of impregnating and curing the impregnated paper layer with the water-based adhesive so that the entire surface of the layer is soaked and excess resin is not generated as burrs during hot pressure pressing.

According to the above method , one of the porous surfaces of the wood board is impregnated with a water repellent and impregnated with a water-based adhesive containing a water-based melamine resin as a main component, instead of the fibrous sheet as in Patent Document 1. An impregnated paper layer that has been previously impregnated and dried with an impregnating agent containing a resin is integrally bonded. As a result, the fibers of the paper constituting the impregnated paper layer are coated with an impregnating agent containing a water repellent and an impregnating resin, so that the amount of the water-based adhesive used can be reduced and the generation of burrs on which the resin is cured is suppressed. be able to.

The water-based adhesive contains 5 to 20 parts by mass of an emulsion resin with respect to 100 parts by mass of the adhesive resin agent containing 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin. Therefore, the adhesive performance of the water-based adhesive can be ensured. As a result, the impregnated paper layer impregnated and cured with the water-based adhesive is strengthened, so that the caster resistance of the impregnated paper layer can be improved. Here, if the water-based adhesive contains 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin, the water-based melamine resin can be reliably thermally cured. If the water-based adhesive contains less than 1 part by mass of the curing accelerator with respect to 100 parts by mass of the water-based melamine resin, the thermosetting of the water-based melamine resin may be insufficient. Further, when the water-based adhesive contains a curing accelerator of more than 5 parts by mass with respect to 100 parts by mass of the water-based melamine resin, the thickening of the water-based adhesive proceeds rapidly and the curing of the water-based adhesive accelerates. There is a risk that the pot life will be shortened. Further, in the water-based adhesive, 5 to 20 parts by mass of an emulsion resin is contained with respect to 100 parts by mass of the adhesive resin agent containing 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin. For example, as described above, the adhesive performance of the water-based adhesive can be ensured. When the water-based adhesive contains less than 5 parts by mass of the emulsion resin with respect to 100 parts by mass of the adhesive resin, the water-based adhesive is difficult to form a film, so that the water-based adhesive is a wood board material or an impregnated paper layer. There is a risk that the bonding strength between the wood board and the impregnated paper layer will be insufficient because it will penetrate too much. Further, when the water-based adhesive contains an emulsion resin exceeding 20 parts by mass with respect to 100 parts by mass of the adhesive resin, the water-based adhesive easily forms a film, so that the water-based adhesive permeates the impregnated paper layer. It becomes difficult and the impregnated paper layer is insufficiently strengthened by the water-based adhesive, so that the caster resistance and hardness performance of the impregnated paper layer may be insufficient.

Therefore, it is possible to suppress the generation of burrs on which the resin is cured and to improve the caster resistance.

Further, if the water-based adhesive impregnated and cured in the impregnated paper layer contains an emulsion resin, the water resistance of the impregnated paper layer may be lowered, but the impregnated agent impregnated and dried in the impregnated paper layer is water repellent. Since the agent is contained, the water resistance of the impregnated paper layer can be ensured.

Further, since the water-based adhesive for integrally joining the impregnated paper layer to one of the porous surfaces of the wood board is impregnated and cured in the impregnated paper layer so as to fill the voids of all the layers of the impregnated paper layer. Delamination of the impregnated paper layer can be suppressed, and caster resistance can be specifically improved .

The water repellent may contain 80 to 95% by mass of a water-based water repellent and 5 to 20% by mass of blocked isocyanate.

According to the above method , since the water repellent contains 80 to 95% by mass of the water-based water repellent and 5 to 20% by mass of the blocked isocyanate, the water resistance of the impregnated paper layer can be ensured. If the content of the water-based water repellent is less than 80% by mass and the content of the blocked isocyanate exceeds 20% by mass, the water resistance of the impregnated paper layer may be insufficient. Further, in the water repellent, when the content of the water-based water repellent is more than 95% by mass and less than 95% by mass and the content of the blocked isocyanate is less than 5% by mass, the effect of water repellency in the initial stage in the impregnated paper layer. May decrease.

Further, the method for manufacturing a decorative board according to the present invention is characterized in that a decorative sheet is integrally attached to the surface of the decorative substrate manufactured by the above-mentioned manufacturing method on the impregnated paper layer side .

According to the above method , it is possible to suppress the generation of burrs on which the resin is cured in the decorative base material. Therefore, in the decorative board on which the decorative sheet is integrally adhered to the surface of the decorative base material on the impregnated paper layer side. , It is possible to suppress the occurrence of defects during the pasting process due to the occurrence of burrs .

According to the present invention, one surface of the porous wood plate is 5 parts by mass of an adhesive resin containing 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of an aqueous melamine resin. Since the impregnated paper layer pre-impregnated and dried with the water-repellent agent and the impregnating agent containing the impregnating resin is integrally bonded by the water-based adhesive containing up to 20 parts by mass of the emulsion resin, the generation of burrs on which the resin is cured is generated. It can be suppressed and caster resistance can be improved.

It is sectional drawing of the decorative board which concerns on 1st Embodiment of this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. The present invention is not limited to the following embodiments.

<< First Embodiment >>
FIG. 1 shows a first embodiment of a method for producing a decorative base material, a decorative board, and an impregnated paper for a decorative base material according to the present invention. Here, FIG. 1 is a cross-sectional view of the decorative plate 50 of the present embodiment.

As shown in FIG. 1, the decorative plate 50 includes a decorative base material 30 provided in a plate shape and a decorative sheet 40 integrally attached to the surface of one of the decorative base materials 30 (upper side in the drawing). I have.

As shown in FIG. 1, the decorative base material 30 is integrally bonded to the surface of at least one surface of the porous wood board 10 and the surface of one of the wood boards 10 (upper side in the figure) by the water-based adhesive 15. It is provided with an impregnated paper layer 20.

The wood board material 10 includes, for example, a plywood having a thickness of about 3 mm to 25 mm, a wood fiber board (insulation board (IB), medium density fiberboard (MDF), etc.), and an oriented strand board (OSB). : Oriented Strand Board), particle board (PB: particle board), these single units or composites. In the present embodiment, the porous wood board 10 is exemplified over all the layers in the thickness direction, but the wood board 10 is porous even if one surface side to which the impregnated paper layer 20 is bonded is porous. good.

The impregnated paper layer 20 is formed of, for example, impregnated paper (for decorative base material) having a thickness of about 0.2 mm to 0.5 mm (preferably 0.25 mm to 0.35 mm). Here, the impregnated paper is, for example, a sheet-shaped paper material having a thickness of about 0.2 mm to 0.5 mm impregnated with an impregnating agent and dried. If the thickness of the impregnated paper layer 20 is 0.2 mm to 0.5 mm, the impregnated paper layer reinforced by the impregnated resin agent and the water-based adhesive 15 described later can be formed. Further, when the thickness of the impregnated paper layer 20 (paper material) is less than 0.2 mm, the strength of the impregnated paper is insufficient, and in the manufacturing method described later, the paper material is squeezed to obtain a surplus amount of the impregnating agent. There is a risk that the paper material will be torn when removing. Further, when the thickness of the impregnated paper layer 20 (paper material) exceeds 0.5 mm, it becomes difficult to impregnate the entire layer of the paper material with the impregnated resin agent, so that the impregnated resin agent is not impregnated. Delamination may occur in the intermediate layer, and water resistance and hardness performance may be insufficient. Further, since the water-based adhesive 15 is soaked on the entire surface of the impregnated paper layer 20, the entire surface of the impregnated paper layer 20 is before being bonded to the wood board 10 by the water-based adhesive 15 (for decorative base material). It is a wet color that is darker than the color of the impregnated paper.

As the paper material constituting the impregnated paper layer 20, for example, resin impregnated paper, core base paper, base paper for decorative board, etc. can be used, but the impregnation property (water absorption) of the water-based adhesive and the wet strength at the time of impregnation are high. Any product that does not cause any manufacturing problems can be used. Further, as the paper material constituting the impregnated paper layer 20, both an unbleached type and a bleached bleached type can be used. Further, as the paper material constituting the impregnated paper layer 20, in order to suppress the color transmission of the wood board material 10, a base paper in which fine titanium oxide or a coloring pigment is squeezed may be used.

The impregnating agent constituting the impregnated paper layer 20 contains a water repellent and an impregnating resin, and more specifically, 40 to 100 parts by mass of a water-based melamine resin (for example, a melamine / urea copolymer resin or the like). For 100 parts by mass of the impregnated resin agent containing 50 parts by mass of acrylic resin (for example, acrylic acid ester copolymer resin, etc.), 5 to 15 parts by mass of water repellent is contained in all layers of the impregnated paper layer 20. It is uniformly impregnated and dried. Here, if the impregnating agent contains 40 to 50 parts by mass of an acrylic resin with respect to 100 parts by mass of an aqueous melamine resin, the impregnated paper layer 20 having flexibility can be formed. If the impregnating agent contains less than 40 parts by mass of acrylic resin with respect to 100 parts by mass of water-based melamine resin, the toughness of the impregnated paper layer 20 is insufficient (becomes hard and brittle), and cracks occur. It is easy to occur. Further, when the impregnating agent contains more than 50 parts by mass of an acrylic resin with respect to 100 parts by mass of the water-based melamine resin, the compatibility with the water-based melamine resin may decrease or the manufacturing cost may increase. There is. Further, if the impregnating agent contains 5 to 15 parts by mass of a water repellent with respect to 100 parts by mass of the impregnated resin agent, the water resistance of the impregnated paper layer 20 can be ensured. If the impregnating agent contains less than 5 parts by mass of the water repellent with respect to 100 parts by mass of the impregnated resin agent, it becomes difficult to secure the water resistance of the impregnated paper layer 20. Further, when the impregnating agent contains more than 15 parts by mass of a water repellent with respect to 100 parts by mass of the impregnated resin agent, the compatibility with the water-based melamine resin and the acrylic resin is lowered, and the manufacturing cost is high. There is a risk of becoming. Further, the water repellent contains 80 to 95% by mass of a water-based water repellent (for example, a hydrocarbon-based water repellent, etc.) and 5 to 20% by mass of blocked isocyanate. Here, if the water repellent contains 80 to 95% by mass of the water-based water repellent and 5 to 20% by mass of the blocked isocyanate, the water resistance of the impregnated paper layer 20 can be ensured. If the content of the water-based water repellent is less than 80% by mass and the content of the blocked isocyanate exceeds 20% by mass, the water resistance of the impregnated paper layer 20 may be insufficient. Further, in the water repellent, when the content of the water-based water repellent is more than 95% by mass and less than 95% by mass and the content of the blocked isocyanate is less than 5% by mass, the effect of water repellency in the initial stage in the impregnated paper layer. May decrease. Further, in the water repellent, when the content of the water-based water repellent is more than 95% by mass and less than 95% by mass and the content of the blocked isocyanate is less than 5% by mass, the water repellency in the initial stage in the impregnated paper layer 20 is reached. The effect may be reduced.

The water-based adhesive 15 is 100 parts by mass of an adhesive resin containing 1 to 5 parts by mass of a curing accelerator (for example, ammonium chloride) with respect to 100 parts by mass of the water-based melamine resin (for example, melamine / formaldehyde condensate). However, the impregnated paper layer 20 is impregnated and cured so as to contain 5 to 20 parts by mass of an emulsion resin (for example, a modified styrene / butadiene copolymer resin, etc.) and fill the voids of all the layers of the impregnated paper layer 20. ing. Here, if the water-based adhesive 15 contains 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin, the water-based melamine resin can be reliably thermally cured. If the water-based adhesive 15 contains less than 1 part by mass of the curing accelerator with respect to 100 parts by mass of the water-based melamine resin, the thermal curing of the water-based melamine resin may be insufficient. Further, when the water-based adhesive 15 contains more than 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin, the thickening of the water-based adhesive 15 proceeds rapidly, or the water-based adhesive 15 is cured. May accelerate and shorten the pot life. Further, the water-based adhesive 15 contains 5 to 20 parts by mass of an emulsion resin with respect to 100 parts by mass of the adhesive resin agent containing 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin. If so, the adhesive performance of the water-based adhesive 15 can be ensured. When the water-based adhesive 15 contains less than 5 parts by mass of the emulsion resin with respect to 100 parts by mass of the adhesive resin, the water-based adhesive 15 is difficult to form a film, so that the water-based adhesive 15 is a wood board material 10. And because it penetrates too much into the impregnated paper layer 20, the bonding strength between the wood board 10 and the impregnated paper layer 20 may be insufficient. Further, when the water-based adhesive 15 contains an emulsion resin exceeding 20 parts by mass with respect to 100 parts by mass of the adhesive resin, the water-based adhesive 15 easily forms a film, so that the water-based adhesive 15 impregnates the paper layer. Since it becomes difficult to penetrate the impregnated paper layer 20 and the impregnated paper layer 20 is insufficiently strengthened by the water-based adhesive, the caster resistance and hardness performance of the impregnated paper layer 20 may be insufficient.

The decorative sheet 40 is formed of, for example, an olefin sheet having a thickness of about 0.1 mm to 0.5 mm, a veneer having a thickness of about 0.1 mm to 3 mm, or the like. Here, the decorative sheet 40 is integrally attached to the surface of the decorative base material 30 with, for example, an ethylene-vinyl acetate-based adhesive or a PUR (Poly Urethane Reactive) -based adhesive.

Next, a method for manufacturing the decorative board 50 of the present embodiment will be described. The method for manufacturing the decorative board 50 of the present embodiment includes a method for manufacturing an impregnated paper for a decorative base material, which includes an impregnant preparation step, an impregnation step, a drying step, a water-based adhesive preparation step, an adhesive step, and a decorative sheet attachment. Equipped with a process.

<Impregnant preparation process>
First, an impregnated resin agent is prepared by mixing 40 to 50 parts by mass of an acrylic resin with 100 parts by mass of an aqueous melamine resin.

Subsequently, a predetermined amount of blocked isocyanate is mixed with the water-based water repellent to prepare a water-repellent agent containing 80 to 95% by mass of the water-based water repellent and 5 to 20% by mass of the blocked isocyanate.

Then, 5 to 15 parts by mass of the above-prepared water repellent is mixed with 100 parts by mass of the above-prepared impregnated resin agent to prepare an impregnating agent. When the viscosity of the impregnating agent is high, water may be added so that the total resin content is 30 to 70% by mass to adjust the viscosity.

<Immersion process>
For example, a sheet-shaped paper material having a thickness of about 0.3 mm is impregnated with the impregnating agent prepared in the above-mentioned impregnating agent preparation step, and then handled with a roll or the like to squeeze the paper material to obtain the impregnating agent. Infiltrate in the thickness direction of the paper material and remove the excess of the impregnating agent.

<Drying process>
The impregnated paper for a decorative base material is produced by drying the paper material treated in the impregnation step with a heated ventilation dryer or the like.

<Water-based adhesive preparation process>
Adhesive resin containing 1 to 5 parts by mass of curing accelerator with respect to 100 parts by mass of water-based melamine resin Emulsion resin in water-based melamine resin so as to contain 5 to 20 parts by mass of emulsion resin with respect to 100 parts by mass. After mixing, a curing accelerator is mixed to prepare a water-based adhesive.

<Adhesion process>
For example, after applying the water-based adhesive prepared in the above-mentioned water-based adhesive preparation step at about 160 g / m ² to the surface of a wood board material 10 made of plywood having a thickness of about 12 mm, the above-mentioned decorative base produced above is applied to the coated surface. The decorative base material 30 is manufactured by placing an impregnated paper for a material and hot-pressing it at a pressure of about 6.37 mPа at about 110 ° C. for about 120 seconds.

<Cosmetic sheet pasting process>
After applying, for example, an ethylene-vinyl acetate adhesive to the surface of the manufactured decorative base material 30 on the impregnated paper layer 20 side, a decorative sheet 40 made of an olefin sheet having a thickness of about 0.2 mm is applied to the coated surface. Stick it on.

As described above, the decorative board 50 of the present embodiment can be manufactured.

Next, a specific experiment will be described.

Specifically, the impregnated papers of the following impregnation experimental examples 1 to 13 were produced.

<Impregnated Experiment Example 1>
First, an impregnated resin agent was prepared by mixing 100 parts by mass of an aqueous melamine resin (resin content 60%) composed of a melamine / urea / formaldehyde polycondensate with 45 parts by mass of an acrylic emulsion resin (resin content 50%). Later, 12.5 parts by mass of the water repellent was mixed with 100 parts by mass of the impregnated resin agent to prepare an impregnating agent. Here, the water repellent is 90% by mass of a water-based water repellent (Rikenparan PG-10 manufactured by Miki Riken Kogyo Co., Ltd.) and 10% by mass of blocked isocyanate (Riken Resin MBX-31 manufactured by Miki Riken Kogyo Co., Ltd.). A mixture was used.

Subsequently, the resin-impregnated paper having a thickness of 0.3 mm is impregnated with the impregnating agent prepared above, and then handled with a roll to squeeze the resin-impregnated paper and allow the impregnating agent to permeate the resin-impregnated paper. After removing the excess of the impregnating agent, the impregnated paper for a decorative base material was produced by drying with a ventilation heating jet dryer.

<Impregnated Experiment Example 2>
The amount of the water repellent in the above impregnation experiment example 1 was changed from 12.5 parts by mass to 15 parts by mass to prepare an impregnating agent, and the impregnating agent was used to prepare an impregnated paper for a decorative base material.

<Impregnated Experiment Example 3>
The amount of the water repellent in the above impregnation experiment example 1 was changed from 12.5 parts by mass to 5 parts by mass to prepare an impregnating agent, and the impregnating agent was used to prepare an impregnated paper for a decorative base material.

<Impregnated Experiment Example 4>
An impregnating agent was prepared by changing the amount of the acrylic emulsion resin in the above impregnation experiment example 1 from 45 parts by mass to 50 parts by mass, and an impregnated paper for a decorative base material was prepared using the impregnating agent.

<Impregnated Experiment Example 5>
An impregnating agent was prepared by changing the amount of the acrylic emulsion resin in the above impregnation experiment example 1 from 45 parts by mass to 40 parts by mass, and an impregnated paper for a decorative base material was prepared using the impregnating agent.

<Impregnated Experiment Example 6>
The amount of the water repellent in the above impregnation experiment example 1 was changed from 12.5 parts by mass to 3 parts by mass to prepare an impregnating agent, and the impregnating agent was used to prepare an impregnated paper for a decorative base material.

<Impregnated Experiment Example 7>
The amount of the water repellent in the above impregnation experiment example 1 was changed from 12.5 parts by mass to 0 parts by mass to prepare an impregnating agent, and the impregnating agent was used to prepare an impregnated paper for a decorative base material.

<Impregnated Experiment Example 8>
The amount of the water repellent in the above impregnation experiment example 1 was changed from 12.5 parts by mass to 20 parts by mass to prepare an impregnating agent. In this experimental example, the water repellent was excessive and the compatibility with the impregnating agent was poor, so that the resin-impregnated paper could not be impregnated with the impregnating agent.

<Impregnated Experiment Example 9>
The amount of the acrylic emulsion resin in the above impregnation experiment example 1 was changed from 45 parts by mass to 30 parts by mass to prepare an impregnating agent, and the impregnating paper for a decorative base material was prepared using the impregnating agent.

<Impregnated Experiment Example 10>
The amount of the acrylic emulsion resin in the above impregnation experiment example 1 was changed from 45 parts by mass to 60 parts by mass to prepare an impregnating agent. In this experimental example, the acrylic resin became excessive and the compatibility with the impregnating agent was poor, so that the resin-impregnated paper could not be impregnated with the impregnating agent.

<Impregnated Experiment Example 11>
The thickness of the resin-impregnated paper in the above impregnation experiment example 1 was changed from 0.3 mm to 0.2 mm to prepare an impregnated paper for a decorative base material.

<Impregnated Experiment Example 12>
The thickness of the resin-impregnated paper in the above impregnation experiment example 1 was changed from 0.3 mm to 0.5 mm to prepare an impregnated paper for a decorative base material.

<Impregnated Experiment Example 13>
The thickness of the resin-impregnated paper in the above impregnation experiment example 1 was changed from 0.3 mm to 0.6 mm to prepare an impregnated paper for a decorative base material. In this experimental example, it was confirmed that the central layer of the resin-impregnated paper in the thickness direction was not impregnated with the impregnating agent.

In addition, the following adhesive experimental examples 1 to 8 water-based adhesives were prepared.

<Adhesive Experiment Example 1>
An adhesive resin agent is prepared by mixing 1.5 parts by mass of a curing accelerator (ammonium chloride) with 100 parts by mass of an aqueous melamine resin (resin content 75%), and a latex emulsion is added to 100 parts by mass of the prepared adhesive resin agent. A water-based adhesive was prepared by mixing 10 parts by mass of a resin (resin content 50%).

<Adhesive Experiment Example 2>
An aqueous adhesive was prepared by changing the amount of the latex emulsion resin in the above adhesive experimental example 1 from 10 parts by mass to 5 parts by mass.

<Adhesive Experiment Example 3>
An aqueous adhesive was prepared by changing the amount of the latex emulsion resin in the above adhesive experimental example 1 from 10 parts by mass to 20 parts by mass.

<Adhesive Experiment Example 4>
An aqueous adhesive was prepared by changing the amount of the curing accelerator in the above adhesive experimental example 1 from 1.5 parts by mass to 1 part by mass.

<Adhesive Experiment Example 5>
An aqueous adhesive was prepared by changing the amount of the curing accelerator in the above adhesive experimental example 1 from 1.5 parts by mass to 5 parts by mass.

<Adhesive Experiment Example 6>
An aqueous adhesive was prepared by changing the amount of the latex emulsion resin in the above adhesive experimental example 1 from 10 parts by mass to 0 parts by mass.

<Adhesive Experiment Example 7>
An aqueous adhesive was prepared by changing the amount of the latex emulsion resin in the above adhesive experimental example 1 from 10 parts by mass to 30 parts by mass.

<Adhesive Experiment Example 8>
An aqueous adhesive was prepared by changing the amount of the curing accelerator in Experimental Example 1 of the above adhesive from 1.5 parts by mass to 0.5 parts by mass.

Further, the following decorative boards of Experimental Examples 1 to 18 were prepared, and a wet heat test, a caster resistance test, a falling ball impact test, and an adhesion test were performed.

<Presentation board experiment example 1>
First, the water-based adhesive of the above-mentioned adhesive experimental example 1 is applied at 160 g / m ² on the surface of a Lauan plywood having a thickness of 11.7 mm, and then the impregnated paper for the decorative base material of the above-mentioned impregnation experiment example 1 is applied to the coated surface. A decorative substrate was prepared by mounting and hot-pressing at 110 ° C. at a pressure of 6.37 mPа for about 120 seconds.

Subsequently, for example, an ethylene-vinyl acetate adhesive is applied to the surface of the prepared decorative base material on the impregnated paper layer side, and then an olefin sheet having a thickness of 0.16 mm is attached to the coated surface to form a decorative plate. Was prepared, and the peripheral ends of the four sides were subjected to actual processing.

~ Wet heat test ~
The male and female seeds of the decorative board subjected to the above-mentioned actual processing are fitted, 1 mL of boiling water is dropped aiming at the actual fitting portion, and a beaker containing 500 mL of boiling water is placed on the dropped water. After leaving it for 20 minutes, the beaker was removed, and after 24 hours, the appearance (presence or absence of wrinkles, swelling, etc.) of the actual fitting portion was confirmed. As a result of this test, no wrinkles or swelling were confirmed.

~ Caster resistance test ~
An iron single-wheel caster having a diameter of 50 mm was placed on the prepared decorative plate, and after reciprocating a distance of 300 mm 5000 times with a load of 25 kg, the surface of the decorative plate was observed to confirm the presence or absence of peeling of the impregnated paper. As a result of this test, no peeling of the impregnated paper was confirmed.

~ Falling ball impact test ~
A test piece is prepared by cutting the above-mentioned decorative board into 150 mm × 150 mm, and standard sand, Toyoura sand, or a sieve with an opening of 1.2 mm specified in JIS R5201 can be supported on the entire surface of the test piece. A dry river sand that had passed through the sand was spread over the test piece, and a 500 g steel ball was dropped from a height of 75 cm onto the test piece supported by the sand, and cracks on the surface were observed. As a result of this test, no surface cracks were confirmed.

~ Adhesive test ~
(Class 1 immersion peeling test)
The prepared test piece was immersed in boiling water for 4 hours, dried at 60 ° C. for 20 hours, further immersed in boiling water for 4 hours again after 5 hours, dried at 60 ° C. for 4 hours, and then had an appearance (peeling). Presence or absence) was confirmed. As a result of this test, no peeling was confirmed.
(Class 2 immersion peeling test)
The prepared test piece was immersed in water at 70 ± 3 ° C. for 2 hours, dried at 60 ± 3 ° C. for 3 hours, and then the appearance (presence or absence of peeling) was confirmed. As a result of this test, no peeling was confirmed.
(Room temperature water immersion test)
The prepared test piece was immersed in water at 25 ° C. for 7 days, dried at 60 ° C. for 20 hours, and then the appearance (presence or absence of peeling) was confirmed. As a result of this test, no peeling was confirmed.

<Experimental examples 2 to 7 of decorative board>
In the decorative board experimental example 1, instead of the impregnated paper for the decorative base material of the impregnation experiment example 1, the impregnated paper for the decorative base material of the impregnation experimental examples 2 to 5, 11 and 12 is used for the decorative base material and the decorative material. Each plate (including actual processing) was prepared and subjected to a wet heat test, a caster resistance test, a falling ball impact test, an adhesion test, and a warp confirmation test, respectively. As a result of this test, there was no problem in any of the moist heat test, the caster resistance test, the falling ball impact test, the adhesion test and the warp confirmation test.

<Experimental examples 8 to 11 of decorative board>
In the above-mentioned decorative board experimental example 1, the decorative base material and the decorative board (including the actual processing) are prepared by using the water-based adhesives of the above-mentioned adhesive experimental examples 2 to 5 instead of the water-based adhesive of the adhesive experimental example 1. Each was prepared and subjected to a wet heat test, a caster resistance test, a falling ball impact test, and an adhesion test, respectively. As a result of this test, there was no problem in any of the moist heat test, the caster resistance test, the falling ball impact test and the adhesion test.

<Decorative board experimental examples 12-14>
In the decorative board experimental example 1, instead of the impregnated paper for the decorative base material of the impregnation experiment example 1, the impregnated paper for the decorative base material of the impregnation experimental examples 6, 7 and 9 was used to make the decorative base material and the decorative board (the decorative base material and the decorative board. Wet heat test, caster resistance test, falling ball impact test and adhesion test were carried out respectively. As a result of this test, the decorative plate experimental example 12 using the impregnation experimental example 6 has a problem in the moist heat test because the water repellent is insufficient, and the decorative plate experimental example 13 using the impregnation experimental example 7 has a problem. In the case, since the water repellent is not contained, there is a problem in the moist heat test, and in the decorative plate experiment example 14 using the impregnation experiment example 9, the acrylic resin is insufficient, so that the impregnated paper layer becomes brittle and the ball drop impact. There was a problem with surface cracks in the test.

<Experimental examples of decorative boards 15 to 17>
In the decorative board experimental example 1, the decorative base material and the decorative board (including the actual processing) are prepared by using the water-based adhesives of the adhesive experimental examples 6 to 8 instead of the water-based adhesive of the adhesive experimental example 1. Each was prepared and subjected to a wet heat test, a caster resistance test, a falling ball impact test, and an adhesion test, respectively. As a result of this test, in the decorative board Experimental Example 15 using the adhesive Experimental Example 6, since the latex emulsion resin was not contained, the layer of the water-based adhesive was not formed, and there was a problem in the adhesive test, and the adhesive was used. Decorative board using Experimental Example 7 In Experimental Example 16, the amount of the latex emulsion resin was too large, so that the water-based adhesive did not penetrate into the impregnated paper layer, and delamination occurred in the impregnated paper layer in the caster resistance test. In the decorative board experimental example 17 using Example 8, since the curing accelerator of the water-based melamine resin was insufficient, the water-based melamine resin was not sufficiently cured, and there was a problem in the adhesion test.

<Decorative board experimental example 18>
In the above-mentioned decorative board experimental example 1, the coating amount of the water-based adhesive was changed from 160 g / m ² to 100 g / m ² to prepare a decorative base material and a decorative board (including actual processing), and subjected to a wet heat test and resistance to heat and heat. A caster test, a falling ball impact test, and an adhesion test were performed, respectively. As a result of this test, delamination occurred in the impregnated paper layer in the caster resistance test. In the decorative base material, the surface of the impregnated paper layer has a portion where the water-based adhesive is soaked and a portion where the water-based adhesive is not soaked, and the wet color of the impregnated paper layer due to the water-based adhesive 15 is non-uniform. there were.

Based on the above experimental results, the thickness of the impregnated paper layer is preferably 0.2 mm to 0.5 mm, and 40 to 50 parts by mass of the acrylic resin is 40 to 50 parts by mass with respect to 100 parts by mass of the aqueous melamine resin in the impregnating agent. It was found that it is preferable that the impregnating agent contains 5 to 15 parts by mass of the water repellent agent with respect to 100 parts by mass of the impregnated resin agent. Further, the water-based adhesive preferably contains 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin, and 5 to 20 parts by mass with respect to 100 parts by mass of the adhesive resin. It was found that it was preferable to contain an emulsion resin.

As described above, according to the decorative base material 30 of the present embodiment, the water-based adhesive 15 containing the water-based melamine resin as a main component is applied to one of the porous surfaces of the wood board material 10 to obtain the above-mentioned Patent Document 1. The impregnated paper layer 20 which has been impregnated and dried in advance with an impregnating agent containing a water repellent and an impregnating resin is integrally bonded instead of such a fibrous sheet. As a result, the fibers of the paper constituting the impregnated paper layer 20 are coated with the impregnating agent containing the water repellent agent and the impregnating resin, so that the amount of the water-based adhesive 15 used can be reduced and the resin is hardened to generate burrs. It can be suppressed. Further, the water-based adhesive 15 contains 5 to 20 parts by mass of an emulsion resin with respect to 100 parts by mass of the adhesive resin agent containing 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin. Therefore, the adhesive performance of the water-based adhesive 15 can be ensured. As a result, the impregnated paper layer 20 impregnated and cured with the water-based adhesive 15 is strengthened, so that the caster resistance of the impregnated paper layer 20 can be improved. Therefore, it is possible to suppress the generation of burrs on which the resin is cured and to improve the caster resistance.

Further, according to the decorative base material 30 of the present embodiment, even if the water-based adhesive 15 impregnated and cured in the impregnated paper layer 20 contains the emulsion resin, it repels the impregnated agent impregnated and dried in the impregnated paper layer 20. Since the liquid agent is contained, the water resistance of the impregnated paper layer 20 can be ensured.

Further, according to the decorative base material 30 of the present embodiment, the water-based adhesive 15 for integrally joining the impregnated paper layer 20 to one of the porous surfaces of the wood board 10 is a void in all the layers of the impregnated paper layer 20. Since the impregnated paper layer 20 is impregnated and cured so as to fill the impregnated paper layer 20, delamination of the impregnated paper layer 20 can be suppressed, and caster resistance can be improved.

Further, according to the decorative base material 30 of the present embodiment, since the water repellent contains 80 to 95% by mass of the water-based water repellent and 5 to 20% by mass of the blocked isocyanate, the water resistance of the impregnated paper layer 20 is ensured. can do.

Further, according to the decorative board 50 of the present embodiment, the generation of burrs on which the resin is cured can be suppressed in the decorative base material 30, so that the decorative sheet 40 is on the surface of the decorative base material 30 on the impregnated paper layer 20 side. In the decorative board 50 to which is integrally attached, it is possible to suppress the occurrence of defects during the attachment process due to the occurrence of burrs.

Further, according to the method for producing an impregnated paper for a decorative base material of the present embodiment, in the impregnation step, 100 parts by mass of an impregnated resin agent containing 40 to 50 parts by mass of an acrylic resin is added to 100 parts by mass of an aqueous melamine resin. On the other hand, by pressing a sheet-shaped paper material having a thickness of 0.2 mm to 0.5 mm impregnated with an impregnating agent containing 5 to 15 parts by mass of a water repellent agent, the impregnating agent is applied in the thickness direction of the paper material. Since the excess of the impregnating agent is removed, the sheet-shaped paper material can be uniformly impregnated with the impregnating agent. Further, by performing a drying step thereafter, the impregnating agent can be uniformly impregnated and dried in all layers of the paper material. Further, since the thickness of the paper material is 0.2 mm to 0.5 mm, it is possible to produce an impregnated paper for a decorative base material reinforced with an impregnated resin agent. Further, since the impregnating agent contains 40 to 50 parts by mass of an acrylic resin with respect to 100 parts by mass of an aqueous melamine resin, a flexible impregnated paper for a decorative base material can be produced. Further, since the impregnating agent contains 5 to 15 parts by mass of a water repellent with respect to 100 parts by mass of the impregnated resin agent, the water resistance of the impregnated paper for a decorative base material can be ensured.

<< Other Embodiments >>
In the above embodiment, the decorative base material and the decorative board in which the impregnated paper layer is integrally bonded to the surface of the wood board are exemplified, but the present invention is a non-decorative in which the impregnated paper layer is integrally bonded to the surface of the wood board. It can also be applied to a base material, a non-decorative board, and the like.

As described above, the present invention is extremely useful because it can suppress the generation of burrs on which the adhesive has hardened and can improve the caster resistance.

10 Wood board 15 Water-based adhesive 20 Impregnated paper layer 30 Decorative base material 40 Decorative sheet 50 Decorative board

Claims (4)

A sheet-like paper material having a thickness of 0.2 mm to 0.5 mm contains 40 to 50 parts by mass of acrylic resin with respect to 100 parts by mass of an aqueous melamine resin, and 5 to 15 parts with respect to 100 parts by mass of an impregnated resin agent. After impregnating the impregnating agent containing a mass portion of the water repellent, the paper material is squeezed to allow the impregnating agent to permeate in the thickness direction of the paper material and remove the excess of the impregnating agent. Impregnation process and
A method for producing an impregnated paper for a decorative base material, which comprises a drying step of drying the paper material treated in the impregnation step. At least one surface side is a porous wood board,
A decorative base material provided with an impregnated paper layer made of an impregnated paper for a decorative base material manufactured by the production method according to claim 1, which is integrally bonded to the one surface of the wood board material with a water-based adhesive. It ’s a manufacturing method.
The water-based adhesive contains 5 to 20 parts by mass of an emulsion resin with respect to 100 parts by mass of the adhesive resin agent containing 1 to 5 parts by mass of a curing accelerator with respect to 100 parts by mass of the water-based melamine resin.
The water-based adhesive is applied so that the water-based adhesive soaks into the entire surface of the impregnated paper layer so as to fill the voids of all the layers of the impregnated paper layer, and excess resin is not generated as burrs during hot pressure pressing. A method for producing a decorative base material, which comprises an adhesive step of impregnating and curing the impregnated paper layer. In the method for producing a decorative base material according to claim 2,
The method for producing a decorative base material, wherein the water repellent contains 80 to 95% by mass of a water-based water repellent and 5 to 20% by mass of blocked isocyanate. A method for manufacturing a decorative board, characterized in that a decorative sheet is integrally attached to the surface of the decorative substrate manufactured by the manufacturing method according to claim 2 or 3 on the impregnated paper layer side.

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