JPH04325248A - Decorative laminated sheet - Google Patents

Abstract

PURPOSE:To combine the high-grade felling of a decorative material and the durability of a thermo-setting resin decorative laminated sheet by placing and hot-pressing molding a thermoplastic synthetic resin film not bonded with the surface of a laminate though all laminating materials for manufacturing the decorative laminated sheet are superposed and thermal deformation is generated under the conditions of hot- pressing molding. CONSTITUTION:A decorative material, a surface of which has fine irregularities, is used, and a thermo-setting resin decorative laminated sheet is manufactured. All laminating materials for manufacturing the decorative laminated sheet are superposed first and thermal deformation is generated under the conditions of hot-pressing molding on the superposed materials at that time, but a thermoplastic sunthetic resin film not bonded with the surface of a laminate is placed and hot-pressing molded. The thermoplastic synthetic resin film fast stuck on the surface of the laminate is peeled. A fancy veneer, a woven fabric or paper is used as the decorative material, the surface of which has fine irregularities, at that time. Accordingly, surface irregularities originarlly formed to the decorative material are not flattened by a thermo-setting resin and are left as they are in products, thus combining the high-grade feeling of the decorative material and the durability of the thermo-setting resin decorative laminated sheet.

Description

[Detailed description of the invention]

0001

[Industrial Application Field] The present invention is applicable to veneer sheets, textiles,
The present invention relates to a method of manufacturing a thermosetting resin decorative board that makes use of the natural irregularities of the decorative material by using a sheet-like material such as Japanese paper having fine irregularities on the surface as the decorative material.

0002

[Prior Art] Decorative laminates are made by adhering a sheet-like surface decorative material to a base material made of an inexpensive board such as plywood or particle board, and are laminated using plywood, paper, textiles, etc. as the decorative material. There are two types of thermosetting resins, which are made by impregnating the decorative material with a thermosetting resin and then heating it in the lamination process to harden it. There is also a curable resin decorative board. The former makes use of the complex and minute surface irregularities and texture of decorative materials, giving it a luxurious feel, but it has problems with surface properties and is easily stained, so it is often painted to protect the surface after being processed into furniture, etc. It is necessary to apply

[0003] On the other hand, thermosetting resin decorative boards have excellent surface properties, are resistant to staining, and do not need to be painted later, since their surfaces are essentially resinized. However, the surface decorative material is completely covered with the cured product of the impregnated thermosetting resin, and therefore the fine surface irregularities that the decorative material originally has cannot be visually or tactually recognized. . Therefore, the role of the decorative material in thermosetting resin decorative boards is simply to add patterns, so there is little point in using high-quality natural materials such as wood veneers as decorative materials. It is common to use printed designs. In order to change the surface properties, heat and pressure molding is performed using a roughened mirror plate to create a matte surface, or fine irregularities are added by embossing, but this is done by hardening the resin. It is a mechanical processing of the surface and is not intended to take advantage of the features of the decorative material.

0004

[Problems to be Solved by the Invention] In view of the above-mentioned advantages and disadvantages of conventional decorative laminates, the purpose of the present invention is to provide a sense of luxury that can be enjoyed by real materials such as veneers, textiles, and Japanese paper that are not printed decorative paper. The object of the present invention is to provide a method for manufacturing a high-quality decorative board that has both the excellent surface properties of a thermosetting resin decorative board and the excellent surface properties of a thermosetting resin decorative board.

[0005]

[Means for Solving the Problems] The method for manufacturing a decorative laminate according to the present invention is to manufacture a thermosetting resin decorative laminate using a decorative material having fine irregularities on the surface. After the materials are layered, a thermoplastic synthetic resin film that undergoes thermal deformation under hot-pressing molding conditions but does not adhere to the surface of the laminate is placed on top of it, and hot-press molding is performed. The method is characterized in that the above-mentioned thermoplastic synthetic resin film is peeled off.

[0006]

[Operation] In the decorative laminate manufacturing method of the present invention as described above, the softened thermoplastic synthetic resin film is pushed into the recesses on the surface of the decorative material by the molding pressure at an early stage of the hot-press molding process. Therefore, the uncured thermosetting resin that was in the recess is removed from the recess and permeates into another location in the decorative material. Since the thermosetting resin is then cured, the recesses are not filled with the thermosetting resin, and a thermosetting resin decorative board with preserved surface irregularities is formed. The decorative laminate manufacturing method of the present invention can be implemented in various ways, but the main ones are as follows.

[0007] ■ A thermosetting resin-impregnated decorative material is placed on the base material, a thermoplastic synthetic resin film is placed on the decorative resin-impregnated material, and hot pressure molding is performed. Peel off the adhering thermoplastic synthetic resin film. ■ The base material, the thermosetting resin-impregnated decorative material, and the thermosetting resin-impregnated transparent overlay paper (transparent sheet for surface reinforcement) are layered one after another, and the thermoplastic synthetic resin film is placed on top of the transparent overlay paper. After that, the thermoplastic synthetic resin film adhering to the surface of the laminate is peeled off. ■ The base material, thermosetting resin-impregnated underlay sheet (non-impregnated decorative adhesive sheet), decorative material, and thermosetting resin-impregnated transparent overlay paper are layered one after another, and the thermoplastic synthetic resin film is transparent. It is placed on overlay paper and subjected to hot pressure molding, and then the thermoplastic synthetic resin film adhering to the surface of the laminate is peeled off.

[0008] In both manufacturing methods, a decorative material with fine irregularities on its surface is used, and these irregularities include the openings of wood conduits in wood veneers, the mesh-like irregularities between threads in textiles, and the irregularities in Japanese paper. It refers to minute irregularities caused by mixed paper fibers, which are closely related to the texture of the material, and is different from mere scratches or irregularities due to poor finishing. When impregnating a decorative material with a thermosetting resin, examples of thermosetting resins include diallylphthalate resins, polyester resins, melamine resins, benzoguanamine resins, phenolic resins, urea resins, etc. Those commonly used for manufacturing resin decorative boards can be used. These resins can also be used as resins for impregnating transparent overlay papers and adhesive underlay papers.

[0009] The thermoplastic synthetic resin film used in the hot-pressing molding process must have temperature characteristics that ensure that it becomes soft and deformable when pressure is applied at the hot-pressing molding temperature. Moreover, it must not be irremovably adhered to the surface of the laminate. Therefore, the optimal film must be selected depending on the type of impregnated resin, and should be selected at a temperature of about 100-200℃ and a pressure of 10-3℃.
Examples of films that can be used in general hot-pressure molding performed at about 0 kgf/cm2 include films of polyethylene, polypropylene, polyvinyl chloride, polyester, polystyrene, polycarbonate, nylon, polyvinylidene chloride, vinylon, and the like. The film may be a matte film by surface treatment or pigment kneading, or a film treated with a release agent.

[0010] When a film that softens under these hot-pressing molding conditions is used in the manufacturing method of the present invention, it may become fused to the press mirror plate and become difficult to peel off. To prevent this, a film with a relatively high melting point that is not likely to fuse to the mirror plate (
For example, films of polyester, polystyrene, polycarbonate, polyamide, polyvinylidene chloride, polytetrafluoroethylene, polysulfone, etc.) may be further superimposed and hot-press molded. As the base material, any material such as particle board, plywood, hollow fiberboard, etc. can be used.

[0011] Except for placing a thermoplastic synthetic resin film on the top of the laminated material and, if necessary, further placing a film for preventing fusion, hot-pressing molding is performed using ordinary thermosetting resin. It can be performed in the same manner as hot pressure molding in the production of resin decorative boards. In hot pressure molding, a thermoplastic synthetic resin film with a low softening temperature is plasticized before the thermosetting resin in the laminated material begins to harden. Then, due to the strong pressure being applied, the film is strongly pressed against the decorative material directly below it, and it also penetrates into minute dents on the surface of the decorative material. At this time, the thermosetting resin in the depression still maintains fluidity and has low viscosity, so it passes through the decorative material and flows to other unimpregnated areas. Thereafter, the temperature is further increased and the thermosetting resin is cured.

When taken out from the press, the thermoplastic synthetic resin film is in close contact with the surface of the laminate formed by the hardening of the thermosetting resin. (The fine irregularities on the surface of the decorative material are transferred.) The resulting decorative board has a hard surface layer in which the decorative material and the thermosetting resin are integrated, with most of the original unevenness of the decorative material remaining intact.

[0013]

【Example】

Example 1 Short cycle melamine resin M was applied to a transparent overlay paper with a basis weight of 18 g/m2 and a veneer sheet (the back side of a veneer sheet with a basis weight of about 200 g/m2 was reinforced with a thin non-woven fabric).
-700 (product of Nissan Chemical Co., Ltd.) was impregnated. The amount of resin attached is 250% by weight (45% by weight) for overlay paper.
g/m2), and 70 g/m2 in the case of a veneer sheet. The above-mentioned impregnated veneer sheet and overlay paper were stacked one after another on the particle board (15 mm thick) used as a base material, and set in a hot pressure molding press, and a polypropylene film (25 μm thick) was placed on top of the overlay paper. Furthermore, in order to prevent the polypropylene film from being fused to the press mirror plate, a polyester film (thickness 75 mm) was used.
μ) was mounted, and hot-press molding was performed using a smooth mirror plate using a conventional method (hot plate setting temperature 160°C, press pressure 25 kg).
f/cm2, press time 6 minutes). After pressing, the polypropylene film adhered to the surface of the laminate, but could be easily peeled off. On the surface of the laminate after the film was peeled off, most of the dents in the conduit part of the veneer used as a decorative material remained as dents, and the other parts were glossy surfaces to which the glossy surface of the polypropylene film had been transferred. As a result, a luxurious melamine resin decorative board with the appearance and feel of natural wood and excellent surface properties was obtained.

Example 2 The same veneer sheet used in Example 1 was impregnated with diallyl phthalate/polyester mixed type impregnating resin to obtain a decorative material impregnated with about 100 g/m2 of resin in terms of solid content. I got it. When laminating this on particle board through hot pressure molding, a 25μ thick polypropylene film was placed on top of the impregnated decorative material, and then a uniaxially stretched polypropylene film (thickness 50μ) was placed on top of the impregnated decorative material at 160°C. Hot pressure molding was carried out at 25 kgf/cm2 for 3 minutes. When we peeled off the film that had adhered to the surface and observed the surface of the laminate, we found that the conduit portion of the veneer remained unfilled with thermosetting resin, giving it the natural appearance of natural wood.

Example 3 Underlay impregnated paper (basis weight 8
0g/m2 white titanium paper impregnated with resin for the purpose of adhering decorative materials and replenishing resin to the decorative material layer), fabric roughly woven with yarn mainly composed of cotton fibers ( 110g/m2), transparent overlay impregnated paper (25
g/m2), a polypropylene film for recess filling (thickness: 25 μm), and a polyester film for preventing fusion (thickness: 75 μm) were stacked on each other in the order listed, and hot-press molding was performed under the same conditions as in Example 1. In addition, Example 1 was used for resin impregnation.
The same melamine resin used in was used. After the film is peeled off, the surface of the laminate is reinforced with strong melamine resin,
Moreover, it had fine lattice-like irregularities similar to the irregularities of the fabric used as a decorative material.

[0016]

[Effect of the invention] A book in which all laminated materials for manufacturing decorative laminates are laminated together and then a thermoplastic synthetic resin film that undergoes thermal deformation under hot pressure molding conditions but does not adhere to the surface of the laminate is placed and hot pressure molded. According to the invention, as mentioned above, the characteristic surface irregularities inherent in the decorative material are not flattened by the thermosetting resin and are left as they are on the product, so the veneer,
To easily produce a high-quality decorative board that has both the luxury of real decorative materials such as textiles and Japanese paper and the durability of thermosetting resin decorative boards.

Claims (2)

[Claims] Claim 1: When manufacturing a thermosetting resin decorative board using a decorative material having fine irregularities on the surface, after overlapping all the laminated materials for manufacturing the decorative board, thermo-pressure molding is performed on top of the laminated materials. A thermoplastic synthetic resin film that undergoes thermal deformation under certain conditions but does not adhere to the surface of the laminate is placed and hot-press molded, and then the thermoplastic synthetic resin film that is in close contact with the surface of the laminate is peeled off. A method for manufacturing decorative laminates. 2. The manufacturing method according to claim 1, wherein the decorative material having fine irregularities on the surface is veneer, textile, or paper.