JPH05138847A - Thermosetting decorative sheet - Google Patents

Abstract

PURPOSE:To produce a melamine decorative panel having paper-to-paper strength not inferior to that of a conventional product at low cost by winding a thermosetting decorative sheet becoming a melamine decorative panel upon curing around a reel so as to make the same preservable and transportable and continuously bonding said sheet to a substrate without using a sheet fed system. CONSTITUTION:A thermosetting decorative sheet is constituted by successively laminating a sealer coat layer 2, a solid layer 3, a pattern layer 4 and a melamine resin coat layer 5 to base paper 5. This sheet is wound around a real before use and continuously bonded to a substrate through an adhesive to produce a decorative panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermosetting decorative sheet coated with a melamine resin and a method for producing a decorative board using the decorative sheet.

[0002]

2. Description of the Related Art Melamine resin decorative boards are excellent in various properties such as abrasion resistance, heat resistance and water resistance.
Widely used for horizontal surfaces such as counter tops, furniture materials such as storage furniture and cabinets, kitchen stands, etc.

By the way, the conventional melamine resin decorative board is
30 to 100 for backer paper and kraft paper, which are obtained by impregnating titanium paper with about 40 to 100% by weight of melamine resin and drying.
Dried core paper impregnated with wt% phenolic resin, decorative paper impregnated with patterned titanium paper with 100-150 wt% melamine resin, and rayon pulp or non-woven fabric with 40-300 wt% It is manufactured by sequentially stacking transparent overlay paper that has been impregnated with melamine resin and dried, and hot presses it by a hot cold method to cure it. The hardened melamine resin decorative board is secondarily bonded to a board such as plywood or particle board, and is used for horizontal surfaces such as desks and countertops, furniture materials such as storage furniture and cabinets, and kitchen stands. There is.

[0004]

However, since the conventional melamine resin decorative board is hardened before being bonded to a substrate such as a particle board, it cannot be wound on a reel and is not only used for storage and transportation. There is also a problem that it is necessary to carry out single-wafer bonding also when it is bonded to a substrate, which is not suitable for mass production and it is difficult to reduce the production cost.

The present invention is intended to solve the above-mentioned problems of the prior art, and enables a thermosetting decorative sheet, which is cured and becomes a melamine resin decorative sheet, to be wound and stored on a reel. Moreover, it is possible to manufacture a decorative plate having a sheet-to-paper strength comparable to that of a conventional product at a low cost by being able to continuously perform the bonding with a substrate such as a plywood or a particle board, instead of the single-wafer type. The purpose is to

[0006]

Means for Solving the Problems The present inventor has achieved the above-mentioned object by coating the printing paper with the melamine resin without impregnating the printing paper with the melamine resin, drying it to such an extent that it does not block, and winding the reel on a reel. The present invention has been completed by finding that the above can be achieved.

That is, the present invention provides a thermosetting decorative sheet in which a base paper, a sealer coat layer, a solid layer, a pattern layer and a melamine resin coat layer are sequentially laminated.

The present invention also provides a method for manufacturing a decorative board, which comprises bonding the thermosetting decorative sheet to a substrate via an adhesive and heating and pressing the same. In this case, it is preferable to wind the thermosetting decorative sheet on a reel and continuously bond it to the substrate.

The present invention will be described below in detail with reference to the drawings. In the drawings, the same numbers indicate the same or equivalent components.

FIG. 1 shows a thermosetting decorative sheet 1 according to the present invention.
0 shows a sectional view of 0. The decorative sheet 10 has a structure in which a base paper 1, a sealer coat layer 2, a solid layer 3, a pattern layer 4 and a melamine resin coat layer 5 are sequentially formed.

It is important that the entire decorative sheet 10 can be wound on a reel. Therefore, it is necessary to coat the melamine resin to form the melamine resin coat layer 5 and to dry the melamine resin coat layer 5 without completely curing it while maintaining a certain degree of flexibility and without blocking. For this purpose, it is generally 90 to 120 ° C., although it depends on the type of melamine resin used, the layer thickness, etc.
And dry for 120-240 seconds.

The melamine resin used for the melamine resin coating layer 5 can be appropriately selected from those conventionally used in thermosetting decorative boards, and is used at a relatively low pressure for a short time. The so-called melamine resin for short cycle, which is hardened at 1, and does not need to be cooled under pressure, is suitable for so-called short cycle melamine resin because it is suitable for mass production and the manufacturing cost can be reduced.

Regarding the coating amount of the melamine resin, when the conventional base paper is impregnated, it is 100 to 1 with respect to the base paper.
While 50% by weight was used, 100% was used in the present invention.
It is used in an amount of about 10% by weight, preferably 60 to 110% by weight.
If it is used excessively, it becomes too thick and difficult to dry, making it difficult to wind it on a reel.

The base paper 1 used in the present invention serves as a base material of the decorative sheet 10 of the present invention, and can be appropriately selected and used from those conventionally used in thermosetting decorative boards. For example, titanium paper having a basis weight of 30 to 50 g / m ^{2 and} the like containing a polyolefin-based resin to improve the inter-paper strength is more preferable.

The sealer coat layer 2 is for improving the inter-paper strength of the base paper. For such a sealer coat layer 2, synthetic resin such as urethane resin or melamine resin can be used. Generally, these resins are
Apply at 5 g (dry) / m ² .

The solid layer 3 is provided in order to conceal the base paper 1 and the sealer coat layer 2 therebelow and to make the pattern layer 4 stand out clearly. Such a solid layer 3 can be formed by using an ink that has been conventionally used for producing a thermosetting decorative board, and preferably an opaque ink is used.

The pattern layer 4 is provided in order to enhance the design of the decorative sheet, and can be formed by using the ink which has been conventionally used for producing a thermosetting decorative board. The ink used may be transparent or opaque.

The decorative sheet 10 of the present invention can be manufactured by a conventional method. For example, first, a base paper 1 is coated with a urethane resin or the like dissolved in an organic solvent using, for example, a roll coater and dried to form a sealer coat layer 2, and a solid layer 3 and a pattern layer 4 are formed thereon by a gravure printing method or the like. Set up. Further, a melamine resin for short cycle is coated on it with a bar coater or the like, and dried to form the melamine resin coat layer 5, whereby the melamine resin coating layer 5 can be manufactured.

FIG. 2 is a thermosetting decorative sheet 1 of the present invention.
It is a figure explaining the aspect of a preferable line which manufactures the decorative board which has a hardened melamine resin layer on the surface by bonding 0 with a substrate such as a particle board.

In the figure, first, a substrate 21 such as a particle board is put into a production line, and a brush 22 first removes dirt on the surface.

Next, the adhesive is applied to the particle board 21 by the adhesive applicator 24 to which the adhesive 23 such as a two-component urethane adhesive is supplied to form the adhesive layer 25.

Then, the thermosetting decorative sheet 10 of the present invention is laminated on the adhesive layer 25 so that the melamine resin coat layer for short cycle is the upper surface. At this time, the thermosetting decorative sheet 10 of the present invention is wound on a reel 26, and the substrates 21 are continuously bonded to each other while preheating by the roller 27 and applying a desired tension.

Then, it is cut into a desired size with a knife 28, and is heated and pressed under a predetermined condition by a heat press 29 to cure the melamine resin coat layer. Thus
It is possible to manufacture a large number of decorative boards having a cured melamine resin layer on the surface at low cost.

Although the adhesive is applied to the substrate 21 in the embodiment shown in FIG. 2, it may be applied to the decorative sheet 10 side before the curable decorative sheet 10 is attached to the substrate 21 without being applied to the substrate 21. Good.

[0025]

The thermosetting decorative sheet of the present invention can be wound on a reel because the base paper is not impregnated with the melamine resin but is coated on it and dried to the extent that blocking is not caused. Therefore, when the thermosetting decorative sheet of the present invention and the substrate are attached to each other, it is possible to carry out continuously instead of the single-wafer type, and it is possible to manufacture a decorative board at a low cost that can correspond to mass production. Become.

[0026]

EXAMPLES The present invention will be described below in greater detail by giving Examples.

Example 1 Titanium oxide-containing inter-paper reinforced paper having a basis weight of 45 g / m ² (HPT
45, Tenma Special Paper Co., Ltd.), a urethane resin (manufactured by Dainichiseika Co., Ltd.) was applied as a sealer agent to a gravure solid plate having a plate depth of 60 μm, and dried to form a sealer coat layer.

Then, solid printing and pattern printing were performed on the sealer coat layer using a butyral type ink (D-2, manufactured by Dainichiseika) by a gravure printing method to provide a solid layer and a pattern printing layer.

A short cycle melamine resin (M-700, manufactured by Nissan Kagaku Co., Ltd.) was applied on the pattern layer by a reverse coater in an amount of 40 g / m ² (dry), and the line speed was 20 m / min at 110 ° C. It was passed through a drying oven for 2 minutes and dried to produce a thermosetting decorative sheet. After drying, this sheet could be wound on the reel without blocking and could be stably stored.

Example 2 The thermosetting decorative sheet of Example 1 was put into the apparatus shown in FIG. 2 and bonded with a particle board having a thickness of 15 mm by using a urea-vinyl acetate adhesive, at a temperature of 160 ° C. and pressure. A decorative plate was manufactured by performing a curing treatment at 30 kg / cm ² for 0.8 minutes.

The obtained decorative board had physical properties comparable to those of conventional decorative boards having a cured melamine resin layer on the surface, and the production cost was low.

[0032]

According to the present invention, a thermosetting sheet that hardens to become a melamine resin decorative board is wound on a reel for storage and storage.
A decorative plate that can be transported and can be continuously bonded to a substrate instead of a single-wafer type can be manufactured at low cost and with a paper-to-paper strength comparable to that of conventional products.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a thermosetting decorative sheet of the present invention.

FIG. 2 is a diagram for explaining an embodiment of a preferable line for producing a decorative board having a cured melamine resin layer on the surface by bonding the thermosetting decorative sheet of the present invention to a substrate.

[Explanation of symbols]

 1 substrate 2 sealer coat layer 3 solid layer 4 pattern layer 5 melamine resin layer 10 thermosetting decorative sheet 21 substrate 25 adhesive layer

Claims (3)

[Claims] 1. A thermosetting decorative sheet in which a base paper, a sealer coat layer, a solid layer, a pattern layer and a melamine resin coat layer are sequentially laminated. 2. The thermosetting decorative sheet according to claim 1,
A method for manufacturing a decorative board, which is characterized in that it is bonded to a substrate via an adhesive and heated and pressed. 3. The reel is wound with the thermosetting decorative sheet,
The method for manufacturing a decorative board according to claim 2, wherein the decorative board is continuously attached to the substrate.