JPH05131476A - Manufacture of thermosetting resin decorative sheet and releasant therefor - Google Patents

Abstract

PURPOSE:To provide manufacturing method, by which productivity can be improved at the manufacturing of thermosetting resin decorative sheet, hence the production cost can be reduced. CONSTITUTION:In the method for simultaneously manufacturing a plurality of decorative sheets by forming a plurality of sets, each of which consists of thermosetting resin-impregnated pattern paper serving as decorative front surface layer and at least one layer of thermosetting resin-impregnated core paper laminating to the rear surface side of the pattern paper and serving as core material layer under heat and pressure, releasant mainly made of fluorine-based surface-active agent-containing polyelectrolytic metal. salt is applied on the outer surface side of the outermost layer core paper and dried before the lamination of at least one layer of the core paper to the pattern paper.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative board by heating and pressurizing a pattern paper impregnated with a thermosetting resin and at least one layer of core paper, and a separating sheet used for the same. It relates to a mold.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing a thermosetting resin decorative board, as shown in FIG.
After stacking a set of impregnated paper sets (a) and (b) and applying a mirror-finished stainless plate, applying a pressure of 50 to 100 Kg / cm ² and heating to a temperature of 120 to 160 ° C. for an appropriate time,
It has been generally practiced to obtain a plurality of thermosetting resin decorative plates by cooling to near room temperature, removing the mirror surface stainless plate after decompression, and removing the release paper.

As the release paper used in this conventional manufacturing method, glassine paper, a thermoplastic resin film or the like is generally used. The method of using release paper such as glassine paper or thermoplastic resin film has a drawback that productivity is poor because a step of inserting and removing the release paper is required before and after the heat and pressure molding.

Therefore, as another releasing method, for example, as disclosed in JP-A-52-146474, a metal salt of a polymer electrolyte (alginic acid) is formed on one side of the back surface of the core paper adjacent to the releasing paper of FIG. A method has been adopted in which a release paper containing sodium as a main component is applied to eliminate the release paper. In this case, a method of adding an inorganic powder is used for the purpose of sealing.

However, in the method of applying a release agent containing a metal salt of a polymer electrolyte as a main component and an inorganic powder, the releasability is inferior to that when a release paper is used. This is because the surface of the kraft paper, which is the core paper, is rough, so even if the release agent containing the metal salt of the polyelectrolyte as the main ingredient and the inorganic powder is applied, the bottom layer of the adjacent decorative board is This is because the fibers of the kraft paper in the core are entangled with each other, which makes it difficult to separate the adjacent decorative boards.

[0006] The present invention aims to improve the releasability of conventional release agents containing a metal salt of a polymer electrolyte as a main component.
It was made by newly discovering that releasability far superior to that of a release agent in which a metal salt of a polyelectrolyte containing a small amount of a fluorosurfactant as a main component is used and an inorganic powder is simply added is obtained. It is a thing.

[0007]

SUMMARY OF THE INVENTION The present invention has been made based on the above-mentioned background, and the problem to be solved is to obtain a plurality of thermosetting resin decorative boards.
It is to improve the productivity and reduce the manufacturing cost.

The first object of the invention according to claim 1 is to improve the productivity in manufacturing a thermosetting resin decorative board of this type, thereby reducing the manufacturing cost. It is to provide a manufacturing method that can be achieved. Another object of the invention of claim 2 is to provide a release agent suitable for carrying out the manufacturing method of claim 1.

[0009]

In order to solve the above-mentioned problems, the means adopted by the invention according to claim 1 is "a pattern paper impregnated with a thermosetting resin to form a decorative surface layer, and this pattern. A method for simultaneously producing a plurality of decorative boards by simultaneously heating and press-molding a plurality of sets of at least one core paper laminated on the back side of the paper and impregnated with a thermosetting resin to form a core material layer In, before laminating at least one layer of the core paper with respect to the pattern paper, on the outer surface side of the core paper, which is the outermost layer, a release agent containing a metal salt of a polymer electrolyte containing a fluorosurfactant as a main component A method for producing a thermosetting resin decorative board characterized by applying and drying a mold. "

That is, in the present invention, the decorative surface layer is made of pattern paper obtained by impregnating model paper with melamine resin, diallyl phthalate resin or polyester resin,
The core material layer is a method for producing a decorative board consisting of two layers of at least one core paper in which kraft paper is impregnated with melamine, phenol resin or polyester resin, and is obtained by heating and pressing a plurality of decorative boards at the same time. Therefore, the core paper on the bottom of each adjacent decorative sheet is coated with a release agent containing a metal salt of a polyelectrolyte containing a fluorosurfactant as the main agent on one side of the back surface of the core paper (12
The present invention relates to a method for producing a thermosetting resin decorative board, characterized in that the adjacent decorative board is released on the back surface of the core paper after being pressed (0 to 160 ° C.) (20 to 100 Kg / cm ² ) and molded.

In the invention according to claim 1, instead of the release film, a release agent containing a metal salt of a polymer electrolyte containing a fluorosurfactant as a main component is placed at the bottom of the adjacent decorative sheet. It is characterized in that it is applied to one side of the back surface of the core paper.

That is, in manufacturing a thermosetting resin decorative board, when a plurality of decorative boards are heated and pressed at the same time, production is performed by simplifying the insertion of a release paper in the step of incorporating the decorative boards before molding. It is intended to improve the productivity and reduce the manufacturing cost.

Further, the means adopted by the invention according to claim 2 suitable for use in the above-mentioned manufacturing method is "a pattern paper impregnated with a thermosetting resin to form a decorative surface layer, and this pattern paper. In the method of simultaneously manufacturing a plurality of decorative boards by simultaneously heating and press-molding a plurality of sets of at least one layer of core paper that is laminated on the back side of the sheet and is impregnated with a thermosetting resin to form a core layer. The release agent used is a release agent characterized in that a fluorine-based surfactant is added to a release agent containing a metal salt of a polymer electrolyte as a main component.

That is, in the invention of claim 2, first, as a metal salt of a polymer electrolyte, an aqueous solution of sodium alginate, sodium cellulose glycolate, sodium fibrin glycolate, sodium starch glycolate or the like is added to a fluorosurfactant. Add agents (perfluoroalkyl sulfonates, perfluoroalkyl carboxylates, perfluoroalkyl ethylene oxide adducts, perfluoroalkyl trimethyl ammonium salts, perfluoroalkyl amino sulfonates, perfluoroalkyl phosphates, etc.) It is a release agent composed of. Further, this release agent is one in which a core paper obtained by applying and drying a mixed solution thereof is heated and pressure-molded, and then adjacent decorative plates are released from each other on the back surfaces of the core papers. .. The amount of the fluorine-based surfactant added is 0.00 based on 1 part by weight of the metal salt of the polymer electrolyte.
5 to 0.2 parts by weight.

[0015]

In the manufacturing method of claim 1 configured as described above, since the release paper of FIG. 2 showing the prior art is completely unnecessary, the steps of inserting and removing it are not necessary at all. Improve the productivity of thermosetting resin decorative boards,
Therefore, the manufacturing cost of this type of decorative board is reduced.

Further, since the release agent according to claim 2 contains the fluorine-based surfactant therein, the leveling property is improved, and the entanglement of the fibers of the core paper which are the outermost layers to be released from each other. To prevent this. That is, even if the fibers are linearly exposed on the outer surface of the core paper to be released from each other, if the release agent is applied to the fibers and dried, the entanglement of the fibers is prevented. However, even if there is entanglement, the entanglement can be easily released by the action of the fluorochemical surfactant when the both decorative plates are peeled off.

That is, the mold release agent of claim 2 is most suitable for use in the method for producing a thermosetting resin decorative board as described in claim 1, and is used as the outermost layer of the core paper. It ensures the release.

[0018]

EXAMPLES Next, examples of each invention will be described.
Since the mold release agent according to claim 2 is substantially used in the manufacturing method according to claim 1, the following examples will be described focusing on the manufacturing method according to claim 1.

Example 1 30 g of sodium alginate was mixed with 30 g of mica having an average particle size of 100 μ. A solution of 1 g of perfluoroalkyl phosphate ester dissolved in 30 g of isopropyl alcohol is mixed with this powder to obtain a clay-like release agent. This mold release material is dissolved in 2 kg of water to prepare a mold release agent solution.

As the core material layer, kraft paper of 200 g / m ² was impregnated with 50% of phenol resin to prepare core paper,
On the back surface of this core paper, 30 g / m ² of the above releasing agent solution was applied.
Is applied by a roll coater at a ratio of 1 to 120 ° C. and dried for 1 minute to form a release coating.

As the decorative surface layer, a pattern paper having 120 g / m ² of pattern paper impregnated with a melamine resin was prepared, and as shown in FIG. 1, two sets of the core paper and the release agent-coated surfaces were in contact with each other. Combine, place mirror-finished stainless steel plates on the top and bottom, apply a pressure of 80 kg / cm ² , and apply 30 ° C at 150 ° C.
After heating for a minute, cool to room temperature, decompress and remove the mirror-finished stainless steel plate to easily set the impregnated paper in Fig. 1 (a).
Two melamine decorative boards consisting of and (b) are completed,
These could be released easily. In this embodiment, as shown in FIG. 1, a total of four layers of core paper and one layer of pattern paper are adopted to complete one decorative plate.

Example 2 30 g of sodium alginate was mixed with a solution of 1 g of perfluoroalkyl phosphate ester in 30 g of isopropyl alcohol to prepare a clay-like release agent. Example 1
By molding the decorative board in the same manner as in (2), the two melamine decorative boards could be easily released.

[0023]

As described above, in the invention according to claim 1, as illustrated in the above embodiment, "a pattern paper impregnated with a thermosetting resin to form a decorative surface layer, and In a method for simultaneously manufacturing a plurality of decorative boards by simultaneously heating and pressing a plurality of sets laminated on the back side and impregnated with a thermosetting resin to form a core material layer and at least one layer of core paper, Before laminating at least one layer of the core paper to the pattern paper, a release agent containing a metal salt of a polymer electrolyte containing a fluorosurfactant as a main component on the outer surface side of the core paper which is the outermost layer. It is possible to easily and surely release the molded thermosetting resin decorative board, resulting in high productivity and after molding. Manufacture of veneer It is possible to reduce the door.

Further, according to the mold release agent of the second aspect, the above-mentioned manufacturing method can be surely carried out, and the mold release of the thermosetting resin decorative plate is facilitated to improve its productivity. As a result, the cost of the thermosetting resin decorative board can be reduced.

[Brief description of drawings]

FIG. 1 is a cross-sectional view schematically showing a manufacturing method of the present invention.

FIG. 2 is a cross-sectional view schematically showing a conventional manufacturing method.

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Claims (2)

[Claims] 1. A pattern paper impregnated with a thermosetting resin to form a decorative surface layer, and at least one core paper laminated on the back side of the pattern paper and impregnated with a thermosetting resin to form a core material layer. In the method for simultaneously producing a plurality of decorative boards by simultaneously heating and press-molding a plurality of sets of the core sheet and the core sheet, at least one layer of the core sheet is laminated on the pattern sheet before forming the outermost layer. A method for producing a thermosetting resin decorative board, which comprises coating and drying a release agent containing a metal salt of a polymer electrolyte containing a fluorine-based surfactant as a main component on the outer surface side of paper. 2. A pattern paper which is impregnated with a thermosetting resin to form a decorative surface layer, and at least one core paper which is laminated on the back side of the pattern paper and is impregnated with a thermosetting resin to form a core material layer. A mold release agent used in the method of simultaneously manufacturing multiple decorative boards by simultaneously heating and pressing multiple sets of and a fluorine-based interface A release agent comprising an activator added.