JPH02123139A - Synthetic resin decorative board and production thereof - Google Patents

Abstract

PURPOSE:To obtain a synthetic resin decorative board, used in curved surfaces, etc., in furniture, building wall surfaces, etc., and excellent in workability and processability by previously containing a synthetic resin in paper, impregnating or coating the above-mentioned resin-containing paper with a thermosetting resin and hot-molding the resultant paper under pressure. CONSTITUTION:A synthetic resin decorative board obtained by previously containing 15-50 pts.wt. synthetic resin, such as thermosetting resin (e.g., melamine or diallyl phthalate resin) or thermoplastic resin (e.g., polyvinyl alcohol) or a mixture thereof, in 100 pts.wt. paper having 0.15-1mm thickness in forming sheets of paper or before or after thereof, then impregnating or coating the resultant resin-containing paper with a thermosetting resin and hot-molding the obtained paper under pressure.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a synthetic resin decorative board with excellent workability for use on curved and flat surfaces such as furniture and architectural walls, and a method for manufacturing the same.

(Prior Art) Decorative boards generally have a surface layer made of a thermosetting resin such as melamine resin or diallyl phthalate resin and decorative paper, and a core layer made of phenolic resin, other thermosetting resin, etc., and core paper.

Furthermore, decorative boards are broadly classified into those used for vertical decorative surfaces such as furniture and architectural walls, and those used for horizontal decorative surfaces (top boards) such as low tables and desk surfaces.

Incidentally, the decorative board used for the vertical decorative surface may be used for corner curved surfaces such as furniture and walls, and when used for the horizontal decorative surface, it may be used for edge curved surfaces such as end surfaces. The decorative board used for such curved surfaces is thin, so the surface layer of melamine resin, diallyl lid, and
-1- The high batting average of resin increases. In other words, the decorative board used for one curved surface.

Generally, plates with a thickness of 0.2 to 0.4 mm are used,
In such a decorative board, the proportion of the thermosetting resin in the surface layer increases. However, the surface layer 8, such as melamine resin, is hard and easily splits or cracks due to distortion during processing of the curved surface.

In view of the problems with such thin decorative boards,
-65!37 publication proposes a "decorative sheet".

As shown in Fig. 11, this decorative sheet has a decorative paper coated and impregnated with a thermosetting resin as the surface layer IO, and a mixed resin such as a thermoplastic resin or synthetic rubber latex is added or impregnated at the time of paper making. The decorative paper is used as the back layer 20, and both layers are heated and pressed to form a two-layer stack.

[Problem to be Solved] 2 However, in the above decorative sheet, the second surface layer 10 is made of a thermosetting resin, and the back layer 20 is made of a thermoplastic resin main layer.
The boundary R30 between the two layers is likely to separate or separate into one ship. Furthermore, since thermosetting resins and thermoplastic resins have poor compatibility, it is difficult to directly join the two resins. Therefore, in the above-mentioned decorative sheet as well, the thermosetting resin J5 of the surface layer 10 and the thermoplastic resin main layer of the m layer 20 are not sufficiently adhered to each other, so that they tend to separate or peel at the boundary layer 30 between the five layers. In particular, when processing the above corner curved surface such as an edge curved surface, bending strain may occur 8 The boundary between both layers 1
It tends to separate or peel at 130°C.

Furthermore, since the decorative sheet is composed of two layers, the first surface layer 10 and the back WJ 20, it takes time and effort to laminate and combine these layers.

In addition, the decorative sheet tends to warp due to an unbalance in the occupation ratio of these two layers and a difference in expansion and contraction.

The present invention has been made to address the problems of conventional decorative sheets, and is a laminated combination of synthetic resin decorative sheets with excellent workability for use on curved and flat surfaces such as 4J for furniture, architectural walls, etc. The aim is to provide high productivity without requiring much effort.

[Means for solving problems]

The present invention is a synthetic resin decorative board made of a sheet of resin-containing paper, in which a synthetic resin such as a thermosetting resin, a thermoplastic resin, or a mixture of both resins is applied to the paper at or before the paper making process. The synthetic resin decorative board is characterized in that the resin-containing paper is impregnated with a thermosetting resin, and the resin-containing paper is molded by heating and pressing.

In the present invention, the above-mentioned resin-containing paper refers to paper containing thermosetting resin, thermoplastic resin, rubber latex, or a mixture thereof added to the raw material for papermaking during the papermaking process, or applied to the paper in a wet state immediately after papermaking. or impregnated, or any paper further coated with or impregnated with a thermosetting resin.

In addition, 1) thermosetting resins include 2) such as melamine resin, diallyl phthalate resin, henzoguanamine resin,
There are phenolic resins, etc.

Examples of the thermoplastic resin include polyvinyl alcohol, polyvinyl resin such as polyacetal, and vinyl acetate resin. Also rubber.

The latex is chlorobrene latex.

There are natural rubber latex, styrene-butadiene rubber latex, etc.

Furthermore, the above-mentioned synthetic resin includes not only thermosetting resins and thermoplastic resins, or mixed resins thereof, but also modified resins thereof.

In addition, the synthetic resin decorative board mentioned above refers to decorative sheets used on vertical surfaces such as furniture and architectural walls, as well as low tables.

This refers to either a decorative board used for the top of a desk surface, etc., or a decorative board used for curved surfaces such as a counter sink, etc.

That is, it is a general term for decorative sheets, decorative boards, post-home decorative boards, etc. made of synthetic resins such as thermosetting resins, thermoplastic resins, and mixtures of these resins, which are made of one sheet of the above-mentioned resin-containing paper.

There is one method for producing the above-mentioned synthetic resin decorative board according to the present invention.

That is, the second invention is a method for manufacturing a synthetic resin decorative board made of a sheet of resin-impregnated paper, in which a thermosetting resin, a thermoplastic resin, a rubber latex, and a mixture thereof are added at or before the paper making process. a step of incorporating it into a cedar board; a step of impregnating and applying a thermosetting resin to the resin-containing paper;
The present invention provides a method for producing a synthetic resin decorative board, which comprises a step of molding the resin-containing paper by heating and pressing.

In this manufacturing method, the resin-containing paper, thermosetting resin, thermoplastic resin 2 and synthetic resin decorative board are the same as those shown in the above first invention.

Here, there is a method (hereinafter also referred to as an internal addition method) in which the synthetic resin is added to a slurry of papermaking raw materials immediately before papermaking.

In addition, the method of incorporating the above synthetic resin into paper after paper making can be roughly divided into two methods: turning it on when the paper is wetted (wetting) immediately after paper making. There is a method of applying and impregnating the synthetic resin on the paper using a machine, and a method of applying and impregnating the synthetic resin on the paper using an off-machine while the paper is semi-dry or dry after a certain period of time has passed after paper making. Here, the above-mentioned on-machine refers to an impregnation machine used in a wet impregnation method performed during paper making.

In addition, the off-machine refers to an impregnation machine used in a dry impregnation method and a processing method used after paper making.

The content of the synthetic resin before and after papermaking is preferably 15 to 50% by weight per 100 parts by weight of one paper.

Further, methods for impregnating the resin-containing paper with the thermosetting resin include 8, for example, dipping the resin-containing paper in a thermosetting resin bath; There is a method of forcibly infiltrating the resin into the resin-containing paper using one of the methods of reducing pressure.

The method for applying the thermosetting resin to the resin-containing paper is to apply a coat of the thermosetting resin onto the resin-containing paper surface using various coating machines such as a sprayer or a roll caulk-curtain flow coater. There is a method of subsequently infiltrating the resin-containing paper.

In addition, impregnation of the above-mentioned resin-containing paper with the thermosetting resin described in 8.
For 100 parts by weight of the thermosetting resin, 15 parts by weight of the thermosetting resin is added.
It is preferable that it is 40% to 40%.

Further, the amount of the thermosetting resin applied is preferably 10 to 50 g per 1 rd sheet of the resin-containing paper.

Further, the above-mentioned paper has a thickness of 0.15 to 100+++n, and a density of 0.45 to 1. Preferably, it is OOg/cffl.

In addition, the above-mentioned paper is a resin-containing paper in which a synthetic resin is added during the papermaking process, and the paper is calender-finished to smooth the surface of the cedar board in order to improve printability.

Furthermore, it is preferable to apply decorative printing such as various decorative patterns on the surface. Furthermore, in the case where the decorative printing is not applied, coloring such as a pigment or an ia material can be mixed into the paper.

Further, as a method of heating and pressurizing the resin-containing paper, 1, for example, using a multistage flat plate press machine or a continuous molding press machine, the resin-containing paper is centrifuged one sheet at a time, or the resin-impregnated paper is continuously rolled. and heat with IJ1. It is preferable to do so.

In addition, the heating and pressing conditions using the above multi-stage flat plate press machine include a temperature of 140° to 200°C, a pressure of IO to 100°C, and a pressure of IO to 100°C.
kg/cj, heating time 10-60 minutes, cooling time 1
It is preferable that it is 0 to 30 minutes.

In addition, the heating and pressing conditions using the continuous molding press machine are as follows: temperature is 140° to 170'' C1 pressure is 10 to 50 k
g/c4. It is preferable that the heating time is 30 to 60 seconds.

Moreover, the above synthetic resin decorative board has a molded board thickness of 0.00 mm after heating and pressing. It is preferable that it is lO~0.80mm.

Moreover, it is preferable that the synthetic resin decorative board has a curved surface finish of 2R to 3OR in terms of workability (・\nding properties). In addition, the synthetic resin decorative board has more flexibility than conventional decorative boards made only of thermosetting resin, so
Easy to cut, no cracks or scratches occur during cutting. Furthermore, since the base material is particularly flexible, it has good adhesion and excellent workability.

[Action and effect]

The synthetic resin decorative board according to the present invention is constructed from a single sheet of resin-containing paper. Therefore, decorative paper impregnated with resin as one surface layer (1
paper) and resin-impregnated core paper (one to several sheets) as the core material layer.
There is no need to stack and combine them. Therefore, such a combination step can be omitted. Since two or more sheets of resin-containing paper are not laminated, the product thickness can be made uniform.

In addition, the above-mentioned resin gold can be made into paper by internal addition or external addition before and after the paper making process using either one or two modified resins of thermosetting resin, thermoplastic resin, a mixture of both resins, and 5 resins.
One sheet of paper contains more than one seed. Therefore,
Unlike the conventional decorative sheets mentioned above, there is no separation or peeling of the thermosetting resin and thermoplastic resin, and a synthetic resin decorative board with excellent workability and workability can be obtained.

Further, the resin-containing paper contains a resin having excellent flexibility, such as a thermoplastic resin. Therefore, the two-paper white body also has excellent flexibility, and can be stored or transported in an endless state by winding it up into rolls. Therefore, it is necessary to supply the roll-wound state to a continuous forming press and heat and press it to form a long object, or to cut the roll into a predetermined size and form each piece using a multi-stage flat plate press. Can be done.

Further, the above-mentioned elongated molded article is produced by heating and molding a sheet of resin-containing paper while pressing it between molding belts of a continuous molding press machine. Therefore, by selecting molding conditions such as heating and pressing, and conditions such as thickness and density, it is possible to obtain a synthetic resin decorative board with a thickness that is suitable for the purpose of use.

In addition, the method for producing synthetic resin decorative laminates of the present invention involves directly heating and press-molding one sheet of resin-containing paper to continuously produce long decorative laminates or single sheet decorative laminates. can do. As a result, it is possible to homogeneously and efficiently mass-produce products of various thicknesses suitable for various usage locations such as curved surfaces or flat surfaces such as furniture, architectural walls, etc.

Therefore, according to the present invention, it is possible to provide a synthetic resin decorative board with excellent workability and workability for use on curved or flat surfaces such as furniture and architectural walls.

〔Example〕

1st Example Softwood drifted kraft valve 70% (% of fiber)
, hereinafter the same) and 30% softwood drifted sulfide pulp
Canadian standard freeness (hereinafter c, s, f,
) Adjusted to 600C, C1, impregnated with 30% chloroprene rubber by wet impregnation method, thickness 0.465+n
ii. A cardboard weighing 294 g/nr was obtained.

Next, diallyl phthalate resin (DAP) was applied to the above-mentioned paper.
was impregnated with 40 g/rrT and then dried to produce resin-containing paper A containing chloroprene rubber 1 in the core and diallylphthalate resin 2 in both the front and back layers as shown in Figure 1. did.

Then, the above-mentioned resin-containing paper bag was heated and molded using a continuous molding press at a temperature of 140° C., a pressure of 12 kg/c+J, and a molding time of 40 seconds.5. As shown in FIG. 2, the plate j1 is 0.
Diaryl phthalate resin makeup cloth A of 33++u++
I got 2.

Since the diallyl phthalate resin decorative board 2 contains chloroprene rubber in the core, it has better workability (hending characteristics) and curved surface workability than ordinary diallyl phthalate resin decorative boards.

Second example Coniferous drifted sulfide pulp c, s, f.

Adjusted to 600C,C, 10% clay as white filler
1% of paper strength enhancer was added, 20% of styrene-butadiene rubber (SBR) was impregnated by wet impregnation method, and after papermaking, a clay coat was applied to the surface to a thickness of 0.365mm+.
A base paper with a weight of 260 g/r+ was obtained.

Next, the above cardboard was impregnated with 30 g/rd of melamine resin, and then dried, so that the core contained styrene-butadiene rubber 3 and both the front and back layers contained melamine resin 4, as shown in Figure 3. A resin-containing paper B was prepared.

Then, the resin-containing paper B was heat-formed using a continuous molding press at a temperature of 160°C, a pressure of 50 kg/cd, 2 hours and 60 seconds, and the thickness was 0.26 m as shown in Figure 4.
A melamine resin decorative board B4 of m was obtained.

The above-mentioned melamine resin makeup machine +ff1B4 contains styrene-butadiene rubber in the core, so it has better curved surface workability and the like than ordinary melamine resin makeup machines.

Third embodiment Sulfide pulp derived from coniferous trees is C, S, R.

The paper was adjusted to 620C, C, and impregnated with 21% methyl methacrylate rubber (MBR) by wet impregnation method, and then a resin clear coat was applied to the surface after papermaking to a thickness of 0.617.
A base paper weighing 372 g/po was obtained.

Next, add 35g/M of diallyl phthalate resin to the above-mentioned layer paper.
The resin-containing paper C containing methyl methacrylate-I/rubber 5 in the 5-core portion and diallylphthale-1/resin 2 in both the front and back layers is obtained by impregnating the resin and then drying it as shown in Fig. 5. It was created.

Then, the resin-containing paper C was continuously molded in a press at a temperature of 160°C and a pressure of 20kg/c4. Heat-formed under the molding conditions for a time of 40 seconds, and the plate thickness was 0.43mm as shown in Figure 6.
A diallyl phthalate resin decorative board C2 was obtained.

The diallyl phthalate resin decorative board C2 has excellent workability and curved surface workability, similar to the diallyl phthalate resin decorative board according to the first embodiment.

Fourth example Sulfide pulp derived from coniferous trees is C, S, F.

Adjusted to 620C, C, impregnated with 25% acrylic resin by wet impregnation method, and after papermaking, the surface was coated with resin clear] -
Apply 1-, H0. 51'Jm, weight 325
A B/ni base paper was obtained.

Next, the base paper is impregnated with benzoguanamine-modified melamine resin per 408/rrf, and then dried to form an acrylic resin 6 in the five cores as shown in FIG. 7, and a benzoguanamine-modified melamine resin 7 in both the front and back layers. A resin-containing paper was prepared.

Then, the above resin-containing paper was heat-formed using a continuous molding press at a temperature of 150°C, a pressure of 15 kg/cd, and a time of 60 seconds, to obtain a plate with a thickness of 0.5 mm as shown in Fig. 8.
A benzoguanamine-modified melamine resin decorative board D7 of 36 m1++ was obtained.

The benzoguanamine-modified melamine resin decorative board D7 is
The melamine resin makeup machine B4 according to the second embodiment was even more unsatisfactory in its curved surface workability.

Fifth Example Craft pulp made from coniferous wood C, S, R, 55OC, C
, and 15% carrion as a white filler and 1.2% paper strength enhancer were added to make paper, and then 20% styrene-butadiene rubber was impregnated by a dry impregnation method. Furthermore, a clay coat and a resin clear coat were applied to the surface of the paper to obtain a base paper having a thickness of 0.149 mm and a weight of 134 g/Po.

Next, the base paper was impregnated with 40 g/++ (per liter) of benzoguanamine-modified melamine resin, and then dried to form a core containing styrene-butadiene rubber 3 and benzoguanamine-modified melamine resin on both the front and back layers. Resin 7
Resin-containing paper E was prepared.

Then, the resin-containing paper E described in "2" was heat-formed using a continuous molding press under the molding conditions of 145'C, pressure 15kg/cJ, and 45 seconds to obtain a plate thickness of 0.1 as shown in Figure 10.
A 1 mm benzoguanamine-modified melamine resin E7 was obtained.

The benzoguanamine-modified melamine resin decorative board E7 is in sheet form, extremely easy to wind up, and has excellent workability on nine curved surfaces.

[Brief explanation of drawings]

1 and 2 show a first embodiment, in which FIG. 1 is a cross-sectional view of resin-containing paper, and FIG. 2 is a cross-sectional view of a decorative board. 3 and 4 show a second embodiment, in which FIG. 3 is a sectional view of resin-containing paper, and FIG. 4 is a sectional view of a decorative board. 5 and 6 show the third embodiment, FIG. 5 shows the resin-containing paper, and FIG. 6 shows the cross-sectional view of the decorative board. The figure is a cross-sectional view of resin-containing paper, Figure 8 is a cross-sectional view of a decorative board, Figures 9 and 10 show the fifth embodiment, Figure 9 is a cross-sectional view of resin-containing paper, and Figure 10 is a decorative board. A cross-sectional view of the plate, FIG. 11, is a cross-sectional view of a conventional decorative sheet. Chloroprene rubber diallyl phthalate resin. Styrene butadiene rubber melamine resin. Methyl methacrylate rubber Acrylic resin Penduguanamine modified melamine resin Applicant Tokushu Paper Co., Ltd. IBIDEN Co., Ltd.

Claims (4)

[Claims] (1) A synthetic resin decorative board consisting of a sheet of resin-containing paper, in which a synthetic resin such as a thermosetting resin, a thermoplastic resin, or a mixture of both resins is added to the paper at or before the paper making process. A synthetic resin decorative board characterized in that the resin-containing paper is further impregnated and coated with a thermosetting resin and molded by heating and pressing. (2) The synthetic resin decorative board according to claim 1, wherein the paper has a thickness of 0.15 to 1.00 mm. (3) The synthetic resin decorative board according to claim 1, wherein the synthetic resin decorative board contains 15 to 50% by weight of synthetic resin based on 100 parts by weight of paper. (4) A method for manufacturing a synthetic resin decorative board consisting of a sheet of resin-impregnated paper, the paper containing a thermosetting resin, thermoplastic resin, rubber, latex, or a mixture thereof at or before the papermaking time. A method for manufacturing a synthetic resin decorative laminate, comprising: impregnating and applying a thermosetting resin to the resin-containing paper; and molding the resin-containing paper by heating and pressing.