JPH0464413A - Manufacture of template for forming laminate - Google Patents

Abstract

PURPOSE:To give the remarkable durability for scuff mark, beat mark and abrasion to a template by providing the layer to which alumina is added on at least surface layer of the template. CONSTITUTION:The prepregs 1, 2 in which porous base material is impregnated with thermosetting resin and is dried are mutually laminated, and emboss- imparting material 4 is press-formed under heating thereon, whereby the template for forming a laminate is produced. Then, the layer to which alumina is added is provided on at least surface layer of the template. Consequently, the template for forming a laminate wherein scuff marks or beat marks etc., are not easily made on its surface and which is light weight and easy in handling and further is excellent in abrasion resistance and durability, may be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for manufacturing a template for forming a laminate having excellent wear resistance.

<Prior art and problems> When manufacturing melamine resin decorative boards and diallyl phthalate resin decorative boards, methods for adding embossing to the surface for the purpose of improving design, scratch resistance, and heat resistance include A) etching board or A method in which impregnated paper for decorative laminates is directly hot-pressed onto a surface-embossed metal plate such as a cast plate. B) A method of simultaneously laminating an embossed film with irregularities made of resin or the like on a sheet-like base material such as paper, polyethylene phthalate, or metal foil. C) An embossed metal plate or film used in A) and B) above, or a natural material, by laminating Gripreg impregnated with a thermosetting resin such as phenolic resin and dried on a porous substrate such as kraft paper. etc., and heat-press molded onto the embossed material directly or with a film such as polypropylene or polyester, or a sheet material with mold releasability such as aluminum foil interposed therebetween, and use a molding template in which the emboss is formed. There was a way.

However, regarding A), the weight of the template is heavy,
The drawback is that it is easy to sing while working.

Regarding B), since it is disposable, the cost of the product tends to be high. Regarding C), although it is light in weight, it has the disadvantage that it is more likely to be scratched or dented on the surface during work, and is inferior in durability.

<Objective of the Invention> The present invention provides a method for manufacturing a template for forming a laminate, which is lightweight and easy to handle, has no scratches or dents on the surface, and has excellent wear resistance and durability.

<Disclosure of the Invention> In the present invention, a porous base material is impregnated with a thermosetting resin, dried prepregs are laminated, and the embossed material is hot-pressed to form a template for forming a laminate. Alumina is added to at least the surface layer of the template. This is a method for manufacturing a template for molding a laminate, characterized in that the first feature is that a sound is provided.

Next, it will be explained in detail with illustrations.

FIG. 1 shows a cross-sectional view of the structure.

Thermosetting resins used in the present invention include phenolic resins, melamine resins, epoxy resins, unsaturated polyester resins,
Known thermosetting resins used for decorative boards or laminates, such as diallyl phthalate resin, can be used.

Examples of porous substrates include papers such as kraft paper, linter, cellulose, polyester, nylon, and rayon #! Known porous base materials conveniently used as steel materials for laminated boards, such as non-woven fabrics and woven fabrics made of fibers such as synthetic fibers, vinylon fibers, natural fibers, glass fibers, and alumina fibers. applies. The prepreg can be produced by impregnating the porous base material with the above resin and drying it6, but from the viewpoint of durability and cost, phenolic resin or melamine resin is used. Gripreg impregnated and dried in kraft paper of 100 to 2 sO9/M was used as Gripreg for the same layer (1), and α-cellulose abrasive of 20 to 1 sO/M was used as prepreg for the surface layer (2). It is best to use impregnated and dried prepreg. Alumina may be added to all layers including the surface layer laminated to produce a molding template, but from the viewpoint of cost and effectiveness, it is added only to the surface layer prepreg (2). A method for adding alumina, which may be in the form of a plate, is to add and mix 1 to 80% by weight of impregnating resin K such as phenol resin or melamine resin, and alumina with a particle size of 0.01 to 200μ, preferably 10 to 100μ. A method of adhering to the base material during impregnation. Alternatively, when manufacturing an impregnated base material, for example, when making paper whose main component is α-cellulose, alumina is mixed and dispersed in the valve raw material every other time, and alumina is mixed into the paper as a mixed paper of valve and alumina. There is a method of impregnating this mixed paper with ordinary phenol resin or melamine resin. The resin impregnation rate in prepreg (i) t2i is 20 to 40
0%, preferably 640-300%. Embossing materials (41 include surface-embossed metal plates such as etched plates and electroformed plates, embossed films, natural materials such as natural wood, etc., as well as molds that have been transferred to the main building, etc.). Next, for hot-press molding, a release film (3) is placed between the embossing material (4) and the Nolipreg for surface layer (2).
It is normal to use prepreg for surface coral (2
) and the inner layer prepreg (1) are combined together, matched with the embossing material (4), and the temperature and pressing pressure required to transfer the embossed surface and simultaneously perform one curing molding is required. d To hot-press a prepreg made of paper impregnated with phenolic resin, the temperature is 130-160°C, 5°C.
After molding under hot-cold conditions at 9/d from 0 to 100, the mold plate is taken out from the press, cut to the required size, and used as a mold plate for forming a laminate.

<Operations and Effects of the Invention> Compared to conventional templates, the template for forming laminates obtained by the present invention has alumina added to the surface layer, so the template is less susceptible to scratches, dents, and wear. It is extremely durable. Therefore, the number of times of use increases, resulting in a reduction in the product cost of the embossed decorative board.

Next, an example will be explained.

Example 1 185g/Wl kraft paper impregnated with phenolic resin $
It was impregnated to 60% and dried to obtain a prepreg for the inner layer. front,
Alumina with an average particle size of 74μ was mixed into paper to make it 25% by weight, and as a base material for the surface layer with a basis weight of 40 f/fll, melamine resin was impregnated and dried to give an impregnation rate of 200%. It was made into a Gripreg for surface layer. Next, 14 pieces of Gripreg for the inner layer and one Gripreg for the surface layer are laminated on the front and back sides, a release film of 50μ polypropylene film is interposed, and a metal etching plate with a wood grain pattern is embossed. As a material, it is placed on the front and back sides, and then as a molding material, 185
10 sheets of kraft paper of g/m were placed on the outside of the embossing material and hot-pressed at 150°C and 280 kq/d for 30 minutes, and then cooled for 15 minutes to obtain a template for molding a laminate with a thickness of 3M. .

Comparative Example 1 In Example 1, without using prepreg for the surface layer,
A template for forming a laminate was obtained in the same manner except that only the inner layer prepreg was laminated.

Next, the abrasion resistance of the templates obtained in Example 1 and Comparative Example 1 was determined by J
Wear amount (f/100 revolutions) and surface hardness according to IS K 6902 r Thermosetting resin decorative board test method” JIS
Percoll hardness and usage durability according to "K 6911r General Test Method for Thermosetting Plastics"
sf/rf kraft paper with 60% phenolic resin
150'C, 804 /
aI! The number of uses until the acute angle of the embossing on the surface of the template disappears was measured under molding conditions for 30 minutes.

The measured values are shown in Table 1.

Table 1 Example 11 Comparative example 1

[Brief explanation of drawings]

FIG. 1 shows a sectional view of the structure according to the present invention. 1... Inner layer prepreg 2...Prepreg for surface layer 3...Release film 4. Embossing material Patent applicant: Aikanigyo Co., Ltd.

Claims (1)

[Claims] When manufacturing a laminate molding template by impregnating a porous base material with a thermosetting resin and laminating dried prepregs and then hot-pressing the embossed material, alumina is added to at least the surface layer of the template. A method for producing a template for forming a laminate, the method comprising providing a layer containing additives.