JPH04191040A - Thermosetting resin decorative laminated sheet - Google Patents

Abstract

PURPOSE:To obtain decorative laminated sheet having heating effect without impairing designedness and physical properties peculiar to decorative laminated sheet by a method wherein laminate molding is performed under the condition that planar heat generating body with electrodes made of metal foil is arranged under decorative surface layer. CONSTITUTION:For example, impregnated paper 1 or melamine resin- impregnated white pigment-filled paper as decorative surface layer carbon fiber-containing glass fiber non-woven fabric as planar heat generating body 3 and five sheets of phenolic resin-impregnated paper 4 as core material layer are piled up one another in the order named and formed so as to obtain decorative laminated sheet. The carbon fiber-containing non-woven fabric 3 is employed under the condition being bonded with copper foil 5 by means of silver paste. The resultant thermosetting resin decorative laminated sheet can easily be connected with power source without impairing the designedness as decorative laminated sheet and is excellent in physical properties on surface such as safety, hardness, wear resistance, heat resistance and the like and is used for floor heating and wall heating and, when used for the ceiling material of a bow window, has condensation preventing effect.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a decorative board that generates heat when energized and has a heating effect without impairing the design and physical properties of the decorative board.

[Conventional technology]

BACKGROUND ART Conventionally, various types of planar heating elements that generate heat from interior materials such as flooring and wall materials have been studied for heating floors and walls.

Planar heating elements that have been developed so far include (1) synthetic resin films coated with or printed with heat-generating resistance ink films, and (j) metal materials with high resistance such as nichrome alloys. has been made into Various methods have been used to attach electrodes to such planar heating elements, but all of them waste space and increase the thickness of the planar heating element.
Improvement in this respect has been desired.

[Problem to be solved by the invention]

The inventor of the present invention has conducted various studies with the aim of producing a decorative board that has a heat-generating effect, having the same shape, appearance, and physical properties as a normal decorative board, and using normal manufacturing methods. By bonding a highly conductive copper foil to the heating element,
It was discovered that the intended purpose could be achieved, and the present invention was completed.

[Means to solve the problem]

The present invention provides a thermosetting resin decorative board formed by laminating and molding fiber base materials such as paper, cloth, and non-woven fabric coated or impregnated with a thermosetting resin, in which electrodes made of metal foil are provided under the surface decorative layer. This is a thermosetting resin decorative board formed by laminating and molding a planar heating element.

In the present invention, thermosetting resins include melamine resins, phenol resins, epoxy resins, etc., and are not particularly limited to melamine resins. Resins and phenolic resins are preferred, with melamine resins being most preferred. These resins may be partially modified with other resins, or may be mixed with other resins.

The fiber base material impregnated or coated with these thermosetting resins is paper, woven fabric made of natural fibers or synthetic fibers, or nonwoven fabric made of these fibers.

Furthermore, woven fabrics and nonwoven fabrics made of inorganic fibers can also be used. A thermosetting resin-impregnated fiber base material is obtained by impregnating or coating such a fiber base material with the above-mentioned thermosetting resin by a conventional method. The content of thermosetting resin in this resin-impregnated fiber base material is usually 25 to 55% by weight.

As mentioned above, the sheet heating element used in the present invention is
These include a synthetic resin film coated or printed with a heat-generating resistive ink film, or a metal material with high resistance such as a nichrome alloy. Preferred materials include, but are not limited to, carbon-containing fiber base materials, or The resin film coated with resistive ink is thin (and has moderate conductivity (electrical resistance), so it generates an appropriate amount of heat.
Moreover, it is preferable because it is easy to attach the electrodes. The closer the sheet heating element is to the surface decorative layer, the better; however, in consideration of the design of the decorative board, it is appropriate to place it immediately below the surface decorative layer, or under the surface decorative layer and the thin core material layer. Usually, a reinforcing core layer is provided under the planar heating element to which the electrodes are attached.

The surface decorative layer is most preferably melamine resin-impregnated paper in order to make the design of the decorative board clear, but phenol resin-impregnated paper can also be preferably used. Generally, phenol resin-impregnated paper is preferably used for the core material layer. Since it is better for the core material layer to be laminated on the planar heating element to be thin, a sheet of impregnated paper may be sufficient. In order to obtain the decorative laminate of the present invention, the above-mentioned resin-impregnated fiber base materials and planar heating elements to which electrodes are attached are stacked on top of each other in a predetermined order, and heated and press-molded by a conventional method.

In the decorative board of the present invention, metal foil of an appropriate thickness is used for the electrodes. Metal foils include copper, aluminum, etc.
Metal foil with good conductivity is preferable, and its thickness is usually 10~
It is 60μ. This metal foil is bonded to the planar heating element in advance using a conductive adhesive or paint such as silver base. Although it is preferable to attach the electrodes to a pair of opposing ends of the planar heating element in order to generate heat uniformly over the entire surface, the electrodes may be attached to other positions if necessary. The width of the electrode depends on the material and size of the planar heating element, but it is preferably 13 mm or more because the voltage drop is small.

When molding the decorative laminate of the present invention, depending on the size, one decorative laminate can be molded into a plurality of sheets of a predetermined size, and after molding, it can be cut into a predetermined size.

For example, as shown in FIG. 3, the electrode 5 is joined to the planar heating element 3, and another impregnated paper is laminated and molded. Thereafter, the decorative board of the present invention is obtained by cutting into a predetermined size.

In the present invention, since the electrode is firmly integrated with the sheet heating element at the same time as the decorative board is formed, the bond between the electrode and the sheet heating element before molding does not need to be strong, and therefore, productivity is improved. This is the method. Furthermore, if a tape with copper foil is used for the electrode, it can be easily joined to the planar heating element.

〔Example〕

The present invention will be explained below using examples.

Example 1 As shown in FIG. 1, an impregnated paper 1 made of white pigmented paper impregnated with melamine resin was used as a surface decorative layer, and a carbon fiber-containing glass fiber nonwoven fabric (carbon-containing 65%) and 5 sheets of phenolic resin-impregnated paper 4 as a core material layer were stacked in this order, 150%
A decorative board was obtained by molding at ℃ and JOOkg/cm2 for 60 minutes. The size of the decorative board is 30x30cm.

The carbon fiber-containing nonwoven fabric 3 has a width of 1 on two opposing sides in advance.
A 5 mm copper foil 5 (thickness 30 μm) bonded with silver paste was used.

Example 2 As shown in FIG. 2, impregnated paper 11, which is made by impregnating paper with wood grain printed with melamine resin, is used as the surface decorative layer, one sheet of phenol resin-impregnated paper 12 is used as the core material layer, and thick paper is used as the planar heating element 13. A polyester resin film coated with a resistive ink film with a diameter of 10 μm was layered with 5 sheets of phenolic resin-impregnated paper 14 as a core material layer in this order, and heated at 150°C for 1 hour.
A decorative board was obtained by molding at 00 kg/cm2 for 60 minutes.

The size of the decorative board is 30 x 30 cm as in Example 1.

The resistive ink coated film 13 is coated with conductive adhesive-coated copper foil 15 (thickness: 30 μm) with a width of 15 mm on two opposite sides.
) bonded with silver paste was used.

These decorative boards generated heat almost uniformly over the entire surface of the decorative boards by connecting a power source to the electrodes and energizing the planar heating element. Glue a 10mm thick plywood to the back of the decorative board,
When we measured the heat generation temperature on the surface of the decorative board, the heat generation temperature fluctuated somewhat depending on the outside temperature, but at a voltage of 100V it was approximately 70%.
℃ and 50V, it was about 40℃.

[Effects of the Invention] The thermosetting resin decorative board of the present invention has electrodes made of metal foil attached to the planar heating element placed under the surface decorative layer, so the design as a decorative board is not impaired. It can be easily connected to a power source without any need for power.

Furthermore, the amount of heat generated per area can be freely designed depending on how the electrodes are arranged, and since the electrodes are arranged between the layers of the decorative board, it is highly safe.

On the other hand, like ordinary thermosetting resin decorative boards, it also has excellent surface properties such as hardness, abrasion resistance, and heat resistance.

Therefore, it can be used for floor heating, wall heating, in kitchens, toilets, etc., and is also effective in preventing dew condensation when used as a ceiling material for bay windows.

[Brief explanation of drawings]

FIGS. 1 and 2 are cross-sectional views of examples of thermosetting resin decorative boards of the present invention, respectively. FIG. 3 is a plan view showing the configuration of the planar heating element with electrodes used in the present invention.

Claims (1)

[Claims] (1) A thermosetting resin decorative board formed by laminating and molding a fiber base material such as paper, cloth, or nonwoven fabric coated or impregnated with a thermosetting resin, which has an electrode made of metal foil under the surface decorative layer. A thermosetting resin decorative board made by laminating and molding a planar heating element.