JPH03234619A - Manufacture of thermosetting resin decorative board - Google Patents

Abstract

PURPOSE:To reproduce the recesses and projections of a shaped film with a high fidelity and permit the shaping of fine emboss, such as precision ten thousand lines, on that surface under lustered condition by a method wherein a thermoplastic resin film, provided with specified properties, is used between thermosetting resin impregnated paper and the shaped film or the like. CONSTITUTION:When thermosetting resin impregnated paper is pinched between hot plates and hot press molding is effected at a temperature Tp together with a base material laminated in accordance with necessity, a thermoplastic resin film and a shaped film or an embossing plate, whose thermal deformation temperature Tt (under the load of JIS-K-7202, 4.6kg) is lower than the temperature Tp and provided with a surface luster degree after hot-press molding (HIS-Z-8741, 75 deg. mirror luster) of 30-100, are superposed sequentially on the surface of the thermosetting resin impregnated paper to mold through hot-press molding together. Thereafter, the thermoplastic resin film is removed from a mold together with the shaped film or the embossing plate, then, recesses and projections, corresponding to the pattern of a disired fine emboss, can be shaped on the thermoplastic resin layer on the surface of the shaped film or the embossing plate.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a method for manufacturing a decorative board whose surface is embossed, and more specifically, to a method for manufacturing a decorative board whose surface is embossed, and more specifically, to a method of manufacturing a decorative board whose surface is embossed. This invention relates to improvements in the manufacturing method of decorative laminates.

[Prior Art] Conventionally, the production of a thermosetting resin decorative board whose surface is embossed involves contacting the surface of thermosetting resin-impregnated paper with a shaped film or the like having irregularities corresponding to the embossed pattern of the desired pattern. This was done by hot-pressing.

[Problem to be solved by the invention]

However, in the conventional method, especially when the above-mentioned unevenness on the surface of the shaped film is formed in the thermosetting resin layer,
The drawback was that the embossed material lost its luster. In order to avoid this drawback, a method has been proposed in which a thermoplastic resin film with a high surface gloss is sandwiched between thermosetting resin-impregnated paper and excipient film during hot-press molding to give the embossing of the decorative board a glossy appearance. However, in the case of decorative boards with minute embossing, especially precision stripes, the unevenness tends to collapse during hot-press molding, the embossment lacks sharpness, and the gloss changes due to parallax, a design unique to precision strips. An effective manufacturing method that can fully demonstrate its effects has not yet been realized.

Therefore, in view of the need for a manufacturing method that can form fine embossments such as precision lines on the surface of a thermosetting resin decorative board into a sharp shape with ridges, the present inventors have conducted extensive research and have developed the present invention. The invention was completed.

[Means for Solving the Problem] The present invention is intended to solve the above-mentioned problems. The present invention relates to a manufacturing method that uses a plastic resin film to enable fine embossing with an extremely superior aesthetic appearance compared to those obtained by conventional methods.

Specifically, the present invention provides a method for forming the surface of the thermosetting resin-impregnated paper when sandwiching the thermosetting resin-impregnated paper together with a base material to be laminated as necessary between hot platens and hot-pressing molding at a temperature TP. ■ Heat distortion temperature T t (JIS-7202, 4, 6
Based on kg load. ) is lower than Tp, and the surface gloss after hot pressure molding (JIS-Z-8741, 75° specular gloss)
is 30 to 100.

■Shaped film or embossed plate.

A method for producing a thermosetting resin decorative board, characterized in that, after stacking and hot-pressing molding together, the thermoplastic resin film is released from the mold together with the shaping film or embossing plate to form fine embossing on the surface. Regarding.

Hereinafter, the present invention will be explained in detail with reference to the drawings.

In general, thermosetting resin decorative laminates are produced by sandwiching decorative base paper impregnated with thermosetting resin between upper and lower heating plates, along with core paper, overlay paper, base material, etc. to be laminated together as required, and then heat-pressing. It is manufactured by molding. Examples of the thermosetting resin include melamine resin, diallyl phthalate resin, guanamine resin, polyester resin, and phenol resin. As the thermosetting resin decorative board of the present invention, melamine decorative board and diallyl phthalate decorative board are preferable from the point of view of design effect. The thermosetting resin decorative board of the present invention is produced by using various press machines such as a flat plate embossing machine and embossing machines (excluding roll embossing machines) at the time of the above-mentioned hot-press molding process, and then molding the shaped film or embossing plate together. Fine embossing is formed on the surface of paper impregnated with a thermosetting resin.

The fine embossing to which the method of the present invention is applied is a drawing shape in which the interval between protrusions and recesses is about 1 to 100 μm, such as parallel line grain, wood grain conduit groove, etc., but it is unique to embossing such as precision parallel line. It is particularly effective in bringing out the design effect of.

Precision parallel lines, as shown in Figure 1, are a collection of patterns consisting of a group of unevenness or grooves forming parallel straight lines or curves and a closed boundary line surrounding them. The directions of the groups of parallel straight lines or curves of adjacent patterns are different, the depth and interval of the lines are 0.1 to 100 μm, and the difference in direction of the groups of lines adjacent through the boundary line clearly shows the difference in gloss. The angle is desirably 5° or more in order to reduce the angle.

This type of pattern is characterized by the fact that the gloss of each closed area changes depending on the parallax. In order for the directions of adjacent line groups to all be different, it is a necessary and sufficient condition from the theorem of the four-color problem in topology that there are four or more types of direction differences.

The thermoplastic resin film used between the surface of the thermosetting resin-impregnated paper and the shaping film, which is an important component in the method of the present invention, is characterized by the fact that the irregularities on the surface of the shaping film are made of thermosetting resin. In order not to interfere with the thermosetting resin on the surface of the impregnated paper and form the desired embossment, it must be easily deformed by the heat during hot press molding, and on the other hand, it must be easily deformed by the heat used to form it. In order to be able to give gloss to the embossed surface of the curable resin layer, it is necessary to have a gloss that can withstand hot pressure molding.

In other words, the thermoplastic resin film used in the present invention is made of thermoplastic polyester commonly used in the market,
Resins that can be made into films or sheets such as polyformaldehyde, polytetrafluoroethylene, polyethylene, polypropylene, polybutadiene, polycarbonate, polyamide, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyvinyl acetal, polyacrylic, polystyrene, polyvinyl acetate, etc. Among thermoplastic films consisting of a single substance or several of these components, J
IS-ni-7202 load 4.5 kg/clll
The heat deformation temperature Tt is lower than the temperature TP during hot press molding (Tt<Tp), and the surface gloss after hot press molding (JIS
-Z-8741, 75° specular gloss) is selected and used in the range of 30 to 100.

When the heat deformation temperature Tt is Tt≧Tp, the thermoplastic resin film does not sufficiently conform to the shape of the extruded film during hot press molding, and the sharpness of the embossed shape cannot be obtained. Further, if the glossiness is not within the above range, the gloss of the fine embossing of the product will be reduced, and the design effect peculiar to precision parallel lines, especially the change in gloss due to parallax, will not be fully exhibited.

The heat distortion temperature Tt is preferably Tt≦TP-40°C.

The temperature Tp during hot press molding is usually 130 to 150°C, but specifically, it depends on the type of thermoplastic resin on which the surface of the forming film is made uneven, and the type of thermosetting resin decorative board to be formed. It depends on the type of thermosetting resin, etc.

The thickness of the thermoplastic resin film is preferably 12 to 25μ
It is m. If it is too thick, it will be difficult to form the embossing, and if it is too thin, the workability will be difficult.

As the thermoplastic resin film used in the present invention, uniaxially oriented polypropylene films and biaxially oriented polypropylene films are preferable from the viewpoint of forming fine embossing and molding temperature. The heat deformation temperature Tt of this -axially stretched polypropylene film and two-wheel stretched polypropylene film is preferably 90 to 110''C, and when the temperature Tp during hot press molding is 130 °C (7), the gloss after hot press molding is (JIS-Z-8741, 75° mirror gloss) is 30~
100, and the thickness is 16 to 20 μm.

These polypropylene stretched films are, for example, -i
A commercially available uniaxially stretched polypropylene film or two-wheel stretched polypropylene film is used, and if necessary, a desired matte finish is applied.

The shaping film used in the method of the present invention is for thermosetting resin decorative laminates, and the base sheet, which is resistant to heat pressure or tension, is made of thermoplastic polyolefin or ethylene vinyl alcohol copolymer resin. A sheet is formed by laminating layers, and an embossed pattern is provided on the resin layer of the polyolefin or ethylene vinyl alcohol copolymer.

The base sheet is used for thermosetting resin decorative boards, so in order to prevent the resin layer of polyolefin or ethylene vinyl alcohol copolymer from deforming due to heat pressure, it must be made of polyolefin or ethylene vinyl alcohol copolymer resin. Plastic sheets with high heat deformation temperatures, such as polyethylene terephthalate, polyimide, polyacrylate, polyetheretherketone, and triacetyl cellulose, as well as art paper, coated paper, glassine paper, parchment paper, etc., have a uniform surface. Paper with high smoothness can be used. Also, its thickness is 3~250μ
m is preferable, and 12 to 100 μm is more preferable.

Particularly in the case of paper, a paint having release properties (including silicone, wax, fluororesin, etc.) may be applied to the thermosetting resin decorative board or the like to be processed.

Further, as the polyolefin resin layer, polymethylpentene, polypropylene, polyethylene, etc. can be used. Note that the thickness of the resin layer is set depending on the depth of the embossing to be processed.

Furthermore, methods for laminating the base sheet and the polyolefin resin layer include commonly used dry lamination, wet lamination, extrusion coating of polyolefin resin, and so-called doubling, which involves fusing with heat and pressure at the same time as heat-pressure embossing. Embossing etc. can be used.

Further, as the embossing method applied to the polyolefin resin side of the laminated shaped film, a known embossing method can be used.

That is, a hot pressure embossing method using a flat plate or a roll plate, a method of transferring the uneven shape on a cooling roll used during extrusion coating, a method of casting a molten resin, etc. can be used.

The embossing plate used in the method of the present invention has a fine embossed uneven shape on the plate surface, the interval between the unevenness is 1 to 100 μm, the depth of the unevenness is about lθ to 100 μm, and the shape is hairline, straight line, grain, etc. Wood grain conduit etc.

Hereinafter, the present invention will be explained in more detail with reference to Examples, but the present invention is not limited thereto.

[Example] As shown in Figure 2, a, 0PP2 was added to Coat Gi 1 (manufactured by Choyo Kokusaku Pulp ■, SK Coat Gi; 73.3 g/Bo).
(manufactured by Nisho Kagaku ■, FOR-20; 20 μm) was dry laminated, and precision parallel lines were applied to the PP surface to produce a shaped film 3. However, OPP represents two-wheel oriented polypropylene.

Next, balance sheet 8, core ZI 7, melamine resin-impregnated titanium paper 6 (black, manufactured by Kojin ■, 80 g/BO), melamine resin-impregnated overlay GI 5 (manufactured by Daifuku Paper ■), glossiness (J l5-Z- 8741, 75° specular gloss 97.5
) CPP film 4 (FHK-20 manufactured by Nisho Kagaku ■, FHK-20;
20 μm) and the above-mentioned shaping film 3 were stacked one after another, and after hot-pressing was performed using a hot-pressing press machine under the conditions of 130°C, 100 kg, and 20 minutes, the shaping film 3 was shaped as shown in Fig. 2, b. Release the CPP film 4 together with the film 3,
A melamine decorative board 9 with precision line embossing was produced.

However, CPP represents uniaxially oriented polypropylene with ridges.

Glossiness of released CPP film (JIS-Z-874
1.75° specular gloss) was 35.

The obtained thermosetting resin decorative board had a three-dimensional effect on the embossed surface, the gloss changed sharply depending on the parallax, and it was excellent in design as a precision maroon.

In addition, the luster of the embossed surface is due to the C of the thermoplastic resin film.
The glossiness was the same as that of the PP film.

[Effects of the Invention] As is clear from the above, according to the present invention, by using a thermoplastic resin film having specific properties between the thermosetting resin-impregnated paper and the shaping film, the unevenness of the shaping film can be reduced. The surface gloss can be faithfully reproduced, and the surface gloss can reflect the glossiness of the thermoplastic resin film surface, and it is not affected by the gloss of the excipient film, and can fully demonstrate the design effect unique to fine embossing, especially precision manryoku. It is possible to provide a method for manufacturing an excellent thermosetting resin decorative board that can produce gloss.

[Brief explanation of drawings]

Figure 1, a is a detailed line enlarged view, Figure 1, b is its A-A
FIG. 2 is a schematic cross-sectional view showing the steps of the method of the present invention. l...Court Gion 2...0PP

Claims (1)

[Claims] 1. When thermosetting resin-impregnated paper is sandwiched between hot platens together with a base material to be laminated as necessary and hot-press molded at a temperature Tp, the surface of the thermosetting resin-impregnated paper is , sequentially (1) heat distortion temperature Tt (JIS-K-7202, 4.6
Depends on kg/cm^2 load. ) is lower than Tp, and the surface gloss after hot pressure molding (JIS-Z-8741, 75°
A thermoplastic resin film having a specular gloss of 30 to 100. (2) Shaped film or embossed plate. A method for producing a thermosetting resin decorative board, characterized in that, after stacking and hot-pressing molding together, the thermoplastic resin film is released from the mold together with the shaping film or embossing plate to form fine embossing on the surface. . 2. The thermosetting resin according to claim 1, wherein the unevenness corresponding to the desired fine embossing pattern of the shaping film or embossing plate is provided on the thermoplastic resin layer on the surface of the shaping film or embossing plate. Method of manufacturing decorative board. 3. The method for manufacturing a thermosetting resin decorative board according to claim 1 or 2, wherein the fine embossing is a precision parallel line. 4. The thermoplastic resin film is made of polyester, polyformaldehyde, polytetrafluoroethylene, polyethylene, polypropylene, polybutadiene, polycarbonate, polyamide, polyvinyl chloride, polyvinylidene chloride, polyvinyl alcohol, polyvinyl acetal, polyacrylic, polystyrene, polyvinyl acetate. The method for producing a thermosetting resin decorative board according to any one of claims 1 to 3, wherein the film is made of one or more resins selected from the following. 5. The method for producing a thermosetting resin decorative board according to any one of claims 1 to 3, wherein the thermoplastic resin film is a stretched polypropylene film.