JPH05202596A - Glossy artificial solid material - Google Patents

Abstract

PURPOSE:To enhance physical characteristics and secondary workability by impregnating glossy patterned paper of a specific constitutional component with thermosetting resin, and laminating a plurality of glossy patterned sheets of paper to make heat-pressure molding after it is dried. CONSTITUTION:Celluose pulp 20-80wt.%, artificial fiber 2-40wt.%, inorganic filler 10-70wt.% under an average particle size 10mum and gloss providing substance 1-30wt.% are dispersed into water to form a water dispersing element, and paper is made by a wet paper making method, etc., to obtain glossy patterned paper. After that, the obtained glossy patterned paper is impregnated with thermosetting resin so that an impregnation amount after the dry reaches 25-60wt.%, and after it is dried, a plurality of sheets of paper are laminated to obtain a gloss harmony artificial solid material by heat-pressure molding. According to the above constitution, workability, execution efficiency, strength, abrasion and wear resistance, and heat resistance can be enhanced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an artificial solid material having a glossy tone, and more particularly to an artificial solid material having a glossy feel such as metallic luster (metallic feel) and iris tone luster that is used for building materials and the like. is there.

[0002]

2. Description of the Related Art Conventionally, as a glossy artificial solid material,
Acrylic-based, polyester-based synthetic resin, metal powder,
There was a material that was formed by mixing shell pieces, pearl powder, etc., and used by processing it into buttons, figurines, etc.

[0003]

However, it is difficult to form a conventional glossy artificial solid material into a thin plate having workability, workability and physical properties (strength), and even if it can be formed, it is extremely fragile. Becomes In addition, if a certain amount of thickness is provided to prevent cracking, bending work and the like will be poor. For this reason, the conventional glossy artificial solid material cannot be used as a building material. Furthermore, since it is inferior in wear resistance and heat resistance, it has a drawback that there are restrictions on the construction target.

[0004]

Means for Solving the Problems As a result of extensive studies conducted by the present inventors in order to solve the drawbacks of the prior art, the texture,
The present invention has been accomplished by finding a glossy artificial solid material having both excellent aesthetics and high quality and excellent physical properties. That is, the present invention is a glossy pattern paper consisting of specific constituents,
More preferably, a thermosetting resin is impregnated into a glossy pattern paper consisting of specific constituents provided with an overlay layer on both sides,
The gist is an artificial solid material having a glossy tone, which is obtained by stacking a plurality of sheets to form an impregnated amount of 25 to 60% by weight, followed by thermocompression molding. The glossy pattern paper in the present invention means (A) cellulose pulp 20 to 80% by weight, (B) artificial fiber 2 to 40% by weight, (C) average particle size 1
10 to 70% by weight of an inorganic filler of less than 0 μ, and (D) 1 to 30% by weight of a gloss-imparting substance having a hue different from that of the inorganic filler in order to form a glossy pattern, a glossy pattern It is a paper, and more preferably, it is characterized in that the patterned paper is used as an intermediate and a three-layer paper is used which has front and back overlay layers containing no gloss-imparting substance on both surfaces thereof. The glossy pattern paper with the above-mentioned gloss-imparting substances internally added,
It is produced by a wet papermaking method or a method similar thereto.

In the present invention, cellulose pulp has an effect of imparting strength and an effect of supporting an inorganic filler, and one kind or two or more kinds is used in the range of 20 to 80% by weight. Two
If it is less than 0% by weight, the strength becomes too weak and breakage occurs during resin impregnation and thermocompression molding, which is not preferable. On the other hand, if it exceeds 80% by weight, the texture such as the inorganic texture is deteriorated, which is not preferable.

The cellulose pulp (A) used in the present invention is not particularly limited, but examples thereof include cotton linter pulp and bleached sulfite pulp (NBSP,
LBSP), bleached kraft pulp (NBKP, LBK)
P), dissolving pulp (DP) and the like.

Next, the artificial fiber of the above (B) is one type or two or more types in an amount of 2 to 40 in view of physical properties as a molded plate such as dimensional stability, abrasion resistance, impact resistance and heat resistance. weight%
Used in the range of. If it is less than 2% by weight, the physical properties are insufficient, and if it exceeds 40% by weight, the interlaminar strength of the paper becomes weak and breakage easily occurs during resin impregnation and thermocompression molding, which is not preferable. The artificial fibers used in the present invention include long glass fibers (chopped strands), short glass fibers (micro glass), alumina silica fibers (ceramic fibers), alumina fibers, mullite fibers, quartz fibers, silicate glass fibers, rock wool, titanium. Artificial inorganic fibers such as acid potassium fiber, zirconia fiber, calcium sulfate fiber, and polyester, nylon, vinylon, PVA,
Examples thereof include artificial organic fibers such as rayon, polyclar, PP, aramid, and kynol fibers. Among synthetic fibers, water dispersibility is good, it is colorless and transparent, and synthetic inorganic fibers that are effective in all physical properties such as dimensional stability, abrasion resistance, heat resistance and impact resistance are more preferable, and further, the average fiber diameter is 10
It is more preferable that the average fiber length is not more than μ and the average fiber length is 0.1 to 8 mm.

Next, the role of the above-mentioned inorganic filler (C) is to cancel out the plastic feeling (light, soft, no depth feeling) when formed into a molded plate, and to make a heavy, hard, deep inorganic texture uniform. In addition to imparting it, the background color is determined, and those having an average particle size of less than 10 μm are used in the range of 10 to 70 wt%. These inorganic textures are very important factors, and if they are not provided, they will simply be plastic plates and the commercial value will drop significantly. If the average particle size is 10 μm or more, the ground-colored portion of the granite-like artificial solid material becomes mottled, and the uniform inorganic texture of the ground-colored portion is insufficient, which is not preferable. Further, if the filling amount is less than 10% by weight, the inorganic texture is insufficient, and if the filling amount is more than 70% by weight, the strength of the paper becomes weak and the paper is apt to break at the time of resin impregnation, thermocompression molding, etc., which is not preferable. Further, the color of the inorganic filler is the ground color of the granite-like artificial solid material, and one or two or more kinds are appropriately selected and used according to the intended color tone of the granite-like solid material. Examples of the inorganic filler include silica stone, silica sand, diatomaceous earth, kaolin, halloysite, montmorillonite, bentonite, zeolite, phosphate rock, diaspore, gypsite, bauxite, acid clay, porcelain stone,
Wax, feldspar, limestone, wollastonite, plaster, dolomite,
Natural minerals such as magnesite and talc, water-insoluble metal hydroxides such as aluminum hydroxide, magnesium hydroxide and calcium hydroxide, calcium silicate hydrates such as tvermonite and xonotlite, calcium aluminate hydrate, calcium Hydrate of various oxides such as sulfoaluminate hydrate, alumina, silica, hydrous silicic acid, spherical silica, magnesia, zinc oxide, spinel, synthetic cordierite, synthetic mullite, synthetic zeolite, synthetic calcium carbonate, calcium phosphate, Examples thereof include powders of synthetic inorganic substances such as barium sulfate, magnesium carbonate, titanium oxide and potassium titanate, or fine fibrous substances having a length of less than about 10 μm. Note that whiskers, flakes, flakes and the like are also included.

If necessary, a paper-strengthening agent such as a water-soluble urea resin, melamine resin, cationized starch, CMC, polyamide polyamine epichlorohydrin resin, polyacrylamide resin, or a polymer flocculant, a sulfuric acid band,
Inorganic pigments such as molybdenum lettuce, red iron oxide, ultramarine blue as an auxiliary agent such as sodium aluminate, and a trace amount of colorant, or insoluble azo type, azo lake type, phthalocyanine type, triphenylmethane type, quinacridone type, thioindigo type, Dioxazine type, perinone perylene type,
Organic pigments such as isoindolinone type, fluorvin type, anthraquinone type, coupling type azo type, condensed type azo type and metal complex salt type may be internally added as long as the inorganic texture is not impaired. Since these pigments are ultrafine particles having a diameter of less than 1 μm, they do not form a spotted pattern and are uniformly colored in the background. Furthermore, the luster-imparting substance that imparts the luster pattern, the synthetic fibers, and the inorganic fillers may be previously treated with a silane coupling agent or the like.

Next, as a method for imparting a glossy pattern, there is an internal addition method in which a gloss-imparting substance is internally added, and the gloss having a hue different from that of the inorganic filler is selected according to the intended glossy solid material. One or more of the imparting substances are mixed with the above-mentioned constituents to form an aqueous dispersion and papermaking. In order to obtain a glossy tone, it is desirable that the mixing ratio of the gloss-imparting substance be in the range of approximately 1 to 30% by weight. If it is less than 1% by weight, the glossy pattern becomes too sparse, which is not preferable, and if it exceeds 30% by weight, the patterns become too dense and overlap each other, which is not preferable. The (D) gloss-imparting substance may be inorganic or organic as long as it has a sense of brightness, but one or more may be appropriately selected depending on the intended design. For example, metal pieces, natural pearl pieces, synthetic pearl pieces, trade name Rainbow Flake No 501 (manufactured by Diamond Industry), trade name Rainbow Flake No 530 (manufactured by Diamond Industry), trade name LJ Silver (manufactured by Oike Kogyo), trade name Opal (kyo Sakae Calcium), trade name Opal S (Kyoei Calcium), trade name Chemical Foil (Fukuda Metal Co., Ltd.) and the like, but are not limited thereto. The shape of the gloss-imparting substance may be spherical, scale-like, whisker-like, polyhedral, cylindrical or strip-like, but since the molded plate is a solid material, it is desirable that the cross-section has a glossy pattern.

The glossy pattern paper by the internal addition method as described above is dispersed in water to form an aqueous dispersion, and the paper is made by a wet papermaking method or a method similar thereto. The wet papermaking method or a method similar thereto means, for example, a strip shape, a cylindrical shape,
After the above-mentioned aqueous dispersion is flown on a filter medium such as a square-shaped filter net, a filter cloth, or a filter plate, or after being sandwiched between these filter media, for example, natural filtration, or Is a general term for a method of filtering into a sheet by an operation such as vacuum filtration.

When only one layer of this pattern paper is used, it is dried as it is to form a glossy pattern paper. On the other hand, when this glossy patterned paper is used as an intermediate layer and an overlay layer containing no gloss-imparting substance is laminated on both front and back sides to form three layers, the constituent elements of the overlay layer are the components of the glossy patterned paper of the intermediate layer. It is also possible to exclude only the gloss-imparting substance from. Since the main purpose of the front and back overlay layers is to prevent the gloss-giving substance from falling off from the glossy pattern paper, and it is desirable that it becomes transparent when molded, it is preferable that it is as thin as possible.
A suitable basis weight is approximately 5 to 30 g / m ² .
Further, it is possible to print on the surface overlay layer as long as the glossiness is not impaired. In order to make a three-layer paper having an intermediate layer containing these gloss-imparting substances, a known paper-making method may be applied.
P295-307 (August 1, 1985 (existing) Chugai Industrial Research Board) published multi-layer papermaking method, 3-layer papermaking, such as round-net, long-net, short-net former, etc. May be used. By making three layers, the gloss-imparting substance is less likely to fall off during the papermaking process and the subsequent impregnation process.

The thus obtained glossy pattern paper is impregnated with a thermosetting resin in an amount of 25 to 60% by weight (see Formula 1), dried, and then laminated with a plurality of sheets to form a solid material. obtain. The impregnated amount is preferably about 25 to 60% by weight. If it is less than 25% by weight, the flow of the resin is insufficient and fogging easily occurs, and if it exceeds 60% by weight, the resin flows too much, which is not preferable.

[Formula 1] The thermosetting resin may be any of a water-soluble type, a water-dispersed type, an organic solvent solution type, and the like, as long as it can be finally formed into a solid material by thermocompression molding. For example, phenol, melamine, urea, unsaturated polyester,
Examples thereof include epoxy, diallyl phthalate, alkyd, polyimide, polyamide, imide and furan. In this way, a plurality of sheets that have been impregnated with a thermosetting resin and dried are laminated, and then thermocompression molding is performed. The temperature, pressure, time, etc. at the time of thermocompression molding are appropriately set depending on the properties of the resin used. Also, the number of sheets to be laminated can be laminated as required according to the required thickness of the forming plate.

[0014]

EXAMPLES The present invention will now be specifically described with reference to examples, but the present invention is not limited to these examples.
The evaluation methods used in the examples are as follows. (1) Texture: Overall feeling of inorganic texture and glossiness ◎: Very good, ◯: Good, Δ: Slightly inferior, ×: Inferior. (2) Impact resistance The surface condition when a steel ball weighing 500 g is dropped from a height of 30 cm. ◎: Almost no cracks, ○: Some cracks, Δ: Quite many cracks, ×: Shattered and shattered. (3) Abrasion resistance Abrasion rate (%) after 1000 rotations of the Taber abrasion test material under a load of 1 kg ◎: 10% or less, ◯: 10 to 30%, Δ: 30 to 50
%, X: 50% or more. (4) Heat resistance Surface condition after putting an oil bath at 200 ° C. for 10 minutes ◎: No change, ○: slightly discolored, Δ: considerably discolored, ×: significantly discolored. (5) Dimensional stability Dimensional change rate after immersion in water for 24 hours ⊚: None, ∘: 0.5% or less, Δ: 0.5 to 1.0
%, X: 1.0% or more. (6) Secondary workability Comprehensive evaluation of machinability, bending workability, drill suitability, and adhesion ◎: Very good, ◯: Good, Δ: Slightly inferior, ×: Inferior. (7) Dropping in process Evaluation of the degree of drop of gloss-giving substance from the paper layer.

Example 1 55 parts by weight of cotton linter pulp as cellulose pulp, 10 parts by weight of glass long fiber chopped strand (average fiber diameter 6 μ, average fiber length 6 mm) as artificial fiber,
Aluminum hydroxide as an inorganic filler (Showa Denko,
Heidilide H-32, 25 parts by weight of average particle diameter 3.2μ and titanium oxide (manufactured by Ishihara Sangyo, Taipaque R-820,
2 parts by weight of an average particle size of 0.3 μ, 8 parts by weight of Rainbow Flake No 501 (manufactured by Diamond Industry Co., Ltd.) as a gloss-imparting substance are dispersed in 1100 parts by weight of water, and 1.5 parts of a melamine resin-based paper-strengthening agent is further dispersed. After adding 1 part by weight, the pH was adjusted to 5.5 with a sulfuric acid band and sodium aluminate, and the basis weight was 1 using a tapping sheet machine (round papermaking machine for handmaking).
A 20 g / m ² sheet was made into paper. Next, a water-soluble melamine resin having a liquid concentration of 50% by weight (manufactured by Nippon Carbide Co., trade name Nikaresin) was impregnated in an amount of 52% (after impregnation, basis weight was 250 g /
It was impregnated with m ² ), dried, and 16 sheets of the same type were laminated and pressed at a temperature of 130 ° C. and a pressure of 80 kg / cm ² for 30 minutes. The finished molded plate had a thickness of 3 mm. Table 1 shows the evaluation of the obtained molded plate.

Example 2 The surface overlay layer was formed by a gauze paper machine, the intermediate layer of the glossy patterned paper component was formed by a short net type wet paper machine, and the back overlay layer was formed by a gauze former type paper machine. A three-layer papermaking paper was produced by a conventional method using a combination of short-mesh → circle-mesh former. The surface overlay layer was composed of 85 parts by weight of bleached sulfite pulp (NBSP), chopped strands of long glass fiber (average fiber diameter 6 μ, average fiber length 6 mm) 1
5 parts by weight and 1.0 part by weight of a polyamine epichlorohydrin resin as a paper-strengthening agent were used to form a paper having a basis weight of 15 g / m ² with an aqueous dispersion and a circular net-type paper machine. Further, the intermediate layer of the glossy patterned paper component is 80 parts by weight of bleached sulfite pulp (NBSP) as cellulose pulp, 5 parts by weight of chopped strands of glass long fibers (average fiber diameter 6 μ, average fiber length 6 mm) as artificial fibers and cut. 5 parts by weight of rayon fiber (2 denier x 5 mm long), 50 parts by weight of aluminum hydroxide (manufactured by Showa Denko, Hijilide H-32, average particle size 3.2μ) as an inorganic filler, silica powder (average particle size 3
μ) 10 parts by weight and titanium oxide (manufactured by Ishihara Sangyo Co., Ltd., Taipaque R-820, average particle size 0.3 μ) 5 parts by weight, as a gloss-giving substance, trade name Rainbow Flake No 530 (manufactured by Diamond Industrial Co., Ltd.) 30 parts by weight, and a very small amount. The condensed azo pigment of Example 1 was dispersed in 1600 parts by weight of water, and before the papermaking, Example 1
Add a paper strength enhancer and a pH adjuster similar to the above to adjust the pH to 5.5.
Adjusted to a short-net wet paper machine with a basis weight of 120 g
/ M ² minutes papermaking. This interlayer was a light ivory color. For the back overlay layer, the same components as those of the front overlay layer were prepared by using a water-dispersed and non-reticulated former paper machine to produce a basis weight of 15 g / m ² . 3 at this time
The total basis weight of the layered paper was 150 g / m ² . The thus-obtained 3-layer glossy patterned paper was impregnated with the same melamine resin as in Example 1 and dried to form an impregnated sheet having a basis weight of 300 g / m ² , and 8 sheets were stacked to form the same sheet as in Example 1. Was subjected to thermocompression molding. The thickness of this molded plate is 1.5 mm
Met. This patterned paper was good with no loss of the gloss-imparting substance observed in the papermaking process, impregnation process, and molding process. Also, the overlay layer became transparent and the glossiness was not impeded at all. Table 1 shows the evaluation of the obtained molded plate.

[0017]

[Table 1]

As is clear from the results shown in Table 1, the solid materials obtained in Examples 1 and 2 were excellent overall. Further, when the solid agent obtained from Examples 1 and 2 was made into a 30 cm square plate and the minimum thickness which can be used as a building material having bending workability and impact resistance was evaluated, both Examples 1 and 2 were 1 It was possible up to 0.2 mm.

[0019]

EFFECTS OF THE INVENTION The glossy artificial solid material obtained as described above is excellent in glossiness such as metallic long gloss (metallic feeling) and iris tone gloss, and further has physical properties and secondary processability. Is a completely new type of building interior and exterior material, such as furniture, system kitchen, interior,
Applicable to a wide range of applications such as exterior materials.

Claims (2)

[Claims] 1. (A) Cellulose pulp 20 to 80% by weight, (B) Artificial fiber 2 to 40% by weight, (C) Average particle size 1
Inorganic filler of less than 0 μ, 10 to 70% by weight, (D) Gloss imparting substance 1 to 30% by weight, gloss-patterned paper is used, and impregnation amount after drying the thermosetting resin is 25 to 60% by weight. A glossy artificial solid material, characterized in that it is formed by impregnating so as to be dried, drying, and then laminating a plurality of sheets and thermoforming. 2. A glossy artificial solid according to claim 1, wherein the glossy patterned paper is used as an intermediate, and a three-layer paper having an overlay layer containing no gloss-imparting substance on both surfaces thereof is used. Material.