JPH0382542A - Sheet for decorative plate - Google Patents

Abstract

PURPOSE:To mold the title sheet under low pressure since a usable time is long during storage and curing is fast at the time of hot-press molding, by making use of a solid and powdery curing agent which is insoluble in water and melted-into fixed plasticity and uncured thermosetting resin, which becomes heat-meltable type under a solid state when the same is mixed into on aqueous system and dried. CONSTITUTION:powder 1 of a curing agent in solid form insoluble in water and heat-meltable type, resin powder 2 which is insoluble in water, an uncured solid, thermosetting and heat-meltable, and emulsified matter 3 of thermosetting resin, which is uncured and heat-meltable, with water, a fiber 4 cut into pieces and a filler 5 are mixed and compounded with aqueous system. When the same is wet by coating the same on release paper, extremely rough nonwoven cloth 9 is sunk into the same, the same is made into an inner core and dried, which is peeled off from the release paper and a sheet is made.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a sheet for decorative laminates. Decorative boards are broadly divided into surface materials and base materials, and base materials include wood materials such as plywood and boards, gypsum boards, asbestos boards,
There are various materials such as cement plate and steel plate. As a surface material, veneer overlay processing, plastic overlay processing,
Other overlay processing, painting processing, etc. are available.

Plastic overlay processing includes resin sheet overlay, resin film overlay, and resin foot overlay processing, and the present invention is a resin sheet overlay processing.
It is related to.

The current method for thermosetting resin sheet overlay processing is to immerse impregnated base paper in a synthetic resin liquid, then dry it to volatilize the solvent to create impregnated paper, coat the surface of the base material with it, and heat and pressurize it with a hot press to harden the resin. Formation of the surface coating and adhesion to the base material are performed simultaneously. As the resin, melamine resin, diallyl phthalate resin, unsaturated polyester resin, etc. are used. The impregnation rate of the resin is determined for the impregnated base paper, and the solvent evaporates, making it porous. During hot-pressure molding, the air between the heating plate and the impregnated paper escapes to the outside through the pores of the impregnated paper, resulting in air pockets. It is done in a way that does not come out. (If the impregnation rate is too high and it is no longer porous, it will accumulate and will not form a decorative board.) With this method, air escapes through the pores, and the fibers of the impregnated paper are made of wood pulp, which allows the paper and resin to become one. Since it is composed of intertwined elements, it takes a lot of pressure to integrate them. Currently, melamine decorative boards require a pressure of 100 KP/crn, and diallyl phthalate resin requires a pressure of about 3 Q/crn. Also, impregnated paper mostly contains a curing agent, but if the amount used is small, curing time will be long and productivity will be very poor. Moreover, if the amount used is large, impregnated paper is produced, which shortens the pot life during storage at room temperature, causing difficulties in inventory control and export.

The present invention solves the conventional drawbacks, has a long pot life during storage, hardens very quickly during hot-press molding, and can produce similar porous properties at low pressure without using impregnated paper that requires pressure during conventional molding. This is a sheet for decorative laminates that can be molded at low pressure by removing air.

This invention will be explained with reference to the drawings: (1) Solid, water-insoluble heat-melting type curing agent powder. ■Water-insoluble, uncured solid, thermosetting, heat-melting resin powder. ■ Emulsion of uncured heat-melting thermosetting resin in water ■ Shredded fibers, ■ Filler These are mixed and blended in an aqueous system and coated on release paper. Rough ■ Sink the nonwoven fabric into the core, dry it, and peel it off from the release paper to make a sheet. With this sheet, it takes a considerable amount of pressure to integrate the intertwined wood pulp fibers and the impregnated resin as in conventional heat-pressure molding with impregnated paper, but the heat is generated between the fibers. Since there is a resin that melts and flows well, when the resin reaches the melting temperature, everything is easily integrated under low pressure. In addition, since the thermosetting resin is porous and allows air to escape to the outside, since the thermosetting resin is a powder, there are voids between the particles, and through these voids, air similarly escapes to the outside during heat pressure, so there is no accumulation of air. Decorative boards can be formed with low pressure.

Also, during the molding time, during storage, the hardening agent is a solid powder that does not dissolve in water, and the resin is also a solid powder that does not dissolve in water. Since there is no hardening agent, it is stable and has a long pot life, and when exposed to heat, it melts and mixes well, and if you add a large amount of hardening agent, it will harden very quickly. Conventional hot-press molding using impregnated paper requires considerable pressure, which is a drawback.For example, when plywood is used, if the base plate has a tunnel, high pressure cannot be used, and the selection of base materials is limited. However, with the present invention, low pressure is required, which gives more flexibility in selecting the base material, and with the present invention, the heat-pressing molding time can be shortened, so the number of sheets per press time can be increased significantly, and the production quantity can be increased. The cost of converting to a fue press becomes extremely low.

An example of the present invention is shown.

fl) Example, first drawing (2) shows a suspension of pensol peroxide solid powder 75% water 2596 by using a surfactant and rolling with three rolls to form a suspension with an average particle size of 10 microns in water. In (2), a side-type unsaturated polyester resin with a melting point of 75°C and a solid monomer with a melting point of 106°C were melted at 120°C, mixed, cooled, and powdered with an average particle size of 30 microns. In (2), the same resin and hexamer were dissolved in toluene and emulsified in water using an emulsifier to form an emulsion with an average particle size of 1 micron. ■Shredded glass fiber with diameter lO microns and length 300 microns ■Average particle size 30
Micron calcium carbonate. ■It is an inorganic colored pigment. All of the above was kneaded and mixed in water. Side mold 200y/IW'
■Polypropylene film and ■231/rr? Coat the film side of a sheet made of printed paper pasted together with urethane adhesive to create a 20 Y/N rough polyester non-woven fabric. Place it on top and submerge it in the paint to make a core material, dry it to make a sheet, and heat it at a temperature of 1200C and a pressure of 5 b/cr using a 2mm thick girder stainless steel plate.
When pressed for n'4 Q seconds and removed, a single-colored decorative board with uneven wood grain patterns was obtained.

(2) Example A paint product obtained by removing ■pigment and ■calcium carbonate from the paint of Example +11 was applied onto a film made of ■20y/rd polypropylene film and ■239/lrl print base paper laminated together.20y/- The polyester nonwoven fabric was used as a core material and dried to make an overlay sheet. Also, examples (
Coat the surface of the release paper with 1001/rl of the mixture of 1) using a side mold, place a coarse polyester nonwoven fabric 209/- on top, submerge it in the paint, and place the 0 adhesive sheet on the plywood. Place 23y/d [Co., Ltd.] print paper with wood grain print on top, place the 0 overlay sheet on top of it so that the resin side is in contact with the wood grain print side, and put it in a hot press machine◎
Hang a 2mm thick stainless steel plate with a wood grain pattern on it and heat it at a temperature of 120°C and a pressure of 5 $/an" for 40 seconds. Take it out and peel it off to see the wood grain pattern. A decorative board with an uneven pattern was completed.

As shown in the examples, conventional pressure (melamine decorative board 80~
1204/crn' dap decorative board 30 Kp/cm
When selecting a base material, it is necessary to select a uniform base material that can withstand pressure, but since the pressure is low, materials with a slight tornado such as plywood can also be used, and the molding temperature is lower than that of conventional melamine decorative board (150°C). 'C~170'C diallyl phthalate decorative board (about 140'C-150°C), lower molding time at 120°C (melamine decorative board 1 hour ~
1.5 hours. It can be processed in 40 seconds, which is considerably shorter than the diallyl phthalate decorative board (10 to 20 minutes), and can be processed under significantly different molding conditions.

Therefore, when a decorative laminate is manufactured using the decorative laminate sheet of the present invention, a thermosetting decorative laminate can be produced with much higher productivity and lower cost than ever before.

[Brief explanation of drawings]

The numbers are the same for Figures 1 and 2. Shredded fiber. ■Filling agent. ■Pigments. ■Film. ■Paper. ■Rough non-woven fabric. [Co., Ltd.] Base material. ■Uneven heating plate. @overreceipt. O adhesive sheet. [Phase] Printed paper. @Stainless steel plate. [Phase] Decorative sheet. FIG. 1 is an enlarged sectional view of the present invention. FIG. 2 is a block diagram of the embodiment (2). FIG. 3 is a block diagram of the embodiment (2).

Claims (8)

[Claims] (1) In the production of hot-press molded decorative laminates, [1] a solid powder curing agent that is insoluble in water and melts under a certain amount of heat, and [2] an uncured thermosetting agent that enters the water system and melts as a solid when dried. [3] Decorative board sheet using synthetic resin. (2) A combination with the curing agent [1] according to claim 1, wherein the [2] resin that enters the aqueous system is a water-soluble heat-melting solid thermosetting resin. (3) A combination with the curing agent [1] according to claim 1, wherein the resin [2] that enters the aqueous system is an emulsion type thermosetting resin that melts solidly under heat when dried. (4) [1] as set forth in claim 1, wherein the two resins entering the water system are heat-melting thermosetting resins in the form of water-insoluble solid powders.
] Combination with hardening agent. (5) [3] Decorative laminate sheet according to claim 1, which is for overlay. (6) [3] described in claim 1, which is a pigment mixture.
Sheet for decorative boards. (7) [3] stated in claim 1, which is a backer
Sheet for decorative boards. (8) The adhesive sheet described in claim 1 [
3] Sheet for decorative board.