JPH0524167A - Manufacture of thermoplastic resin decorative panel - Google Patents

Abstract

PURPOSE:To easily manufacture a decorative panel having desired characteristics by successively laminating impregnated paper formed by curing decorative paper having a pattern impregnated with a thermosetting resin and a synthetic resin film to the upper surface of a base material to cure the whole under heating and pressure. CONSTITUTION:For example, the solid printing 2 of a primer is applied to the chemically treated surface of an easy bonding PET film 1 by a gravure press to form a synthetic resin film A. As decorative paper B, for example, titanium paper 3 is used and a pattern 4 is applied to the surface thereof by gravure printing. The decorative paper B is impregnated with a thermosetting resin 5 to be dried to form resin impregnated decorative paper B. Further, as a base material 8, for example, an asbestos slate panel subjected to alkali sealing treatment is used. Then, the resin impregnated decorative paper B and the synthetic resin film A are successively laminated to the upper surface of the base material 8 and the whole is inserted in a hot press and heated and pressed from both surfaces thereof through respective mirror plates 9 to complete a thermosetting resin decorative panel.

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 thermosetting resin decorative board, and more particularly to a method for producing a thermosetting resin decorative board having improved surface physical and chemical properties.

[0002]

2. Description of the Related Art Conventionally, a thermosetting resin decorative plate has a printing pattern on a so-called titanium paper, which is a paper mainly mixed with an opaque pigment such as titanium oxide in order to have an impregnating property and a hiding property. After providing a decorative paper provided, melamine resin, diallyl phthalate resin, polyester resin, phenol resin and other thermosetting resin is impregnated to create a base material,
The impregnated paper and, if necessary, the overlay paper are laminated in this order, heated and pressed using a hot press, and cured to prepare.

The overlay paper is laminated as needed for the purpose of improving the physical and chemical properties of the surface of the thermosetting resin decorative plate, and a melamine resin-impregnated paper of about 30 to 150 μm is usually used.

[0004]

Decorative plates made of thermosetting resin have relatively stable surface characteristics, and even if water or hot water is spilled on the surface temporarily, the surface of the decorative plate is deteriorated. In particular, the melamine resin-impregnated paper laminated on the surface as an overlay paper has a considerably high surface strength and is effectively used as a wall material. However, a thermosetting resin decorative plate laid in a place that is in contact with water, hot water, or a high-humidity atmosphere close to saturation for a long time, such as a wall surface of a bath, may have a base material, impregnated paper, Peeling has occurred between laminated layers of overlay paper or the like, or water bubbles or molds have occurred on the surface.

In order to deal with such inconvenience, it has been practiced to laminate a thermosetting resin decorative board as a finished product with a synthetic resin film at the time of use, or such a coating operation requires a great labor. In addition, the adhesive force of the laminated synthetic resin film is not sufficient, and peeling or wrinkling occurs in a short time, which is not always a satisfactory solution.

An object of the present invention is to solve the above disadvantages of the conventional thermosetting resin decorative board.
More specifically, a method for producing a thermosetting resin decorative board capable of imparting characteristics such as moisture resistance, heat resistance, and gas barrier property to a synthetic resin decorative board without adding a special manufacturing process. The purpose is to get. Thereby,
It is possible to obtain a thermosetting resin decorative board that can be effectively used for a long time even in a hot and humid environment, and it is possible to further expand the application of the thermosetting resin decorative board.

[0007]

SUMMARY OF THE INVENTION In order to solve the above problems and achieve the object, the present invention prepares an impregnated paper by applying a desired pattern on a decorative paper and then impregnating and drying a thermosetting resin. Then, the impregnated paper is superposed on a base material, a synthetic resin film is placed on the base material, and then the laminated body is heated, pressed and cured to be integrated, which is a thermosetting property. A method for manufacturing a resin decorative board is disclosed.

As the substrate, a plurality of core papers, usually 4 to 6 sheets, which are impregnated with a thermosetting resin, for example, a phenol resin, are used in order to give a thickness and strength required for a decorative board, or
Depending on the type of decorative board, wood, plywood, particle board, metal plate, or the like is used. As the impregnated paper, it is preferable to use one in which a base material is impregnated with a colored thermosetting resin having a concealing property, and a so-called titanium paper obtained by mixing an opaque pigment such as titanium dioxide with a rice scale of 50 to 150 g / m ² is usually used. Is used, and a desired pattern is provided if necessary. The design may be prepared by kneading various known pigments such as red pattern, carbon black, ultramarine pearl ink, and the like.
The surface of the impregnated paper may be solid-printed with an ink having a concealing property. Further, titanium paper may be impregnated with a thermosetting resin and cured, and a pattern such as a tint block may be further printed on the surface. Or aluminum,
The metal vapor deposition film of chromium or the like may be formed entirely or partially. As the printing means, known printing methods such as gravure printing, gravure, offset printing, silk screen printing, letterpress printing, and offset printing can be appropriately selected and used.

Printing can be done directly on red, titanium paper, etc.
Transfer printing may be performed using transfer paper.

An example of the overlay paper provided as required is melamine resin-impregnated paper having a thickness of about 30 to 150 μm. As the thermosetting impregnating resin, a melamine resin, a diallyl phthalate resin, a guanamine resin, a polyester resin, a phenol resin, or the like can be used, but when importance is attached to the design property, a melamine resin,
The use of diallyl phthalate resin is preferred.

The synthetic resin film laminated on the impregnated paper is
Any conventionally known synthetic resin film may be used, for example, polyethylene terephthalate, polybutylene terephthalate, and other polyester films, polyethylene films, polypropylene films, and other polyolefin films, polyvinyl chloride films, polyvinylidene chloride films, ethylene vinyl alcohol. A vinyl resin film such as a copolymer film, a polycarbonate film, a polyamide (nylon) film, a polystyrene film, an ethylene-vinyl acetate copolymer film or the like is used. Especially, the polyester film and the polycarbonate film are transparent, heat resistant, water resistant and gas barrier. It is preferable in terms of physical properties such as properties.

The synthetic resin film as described above may be a colored film or an uncolored film. Further, it may be partially colored, that is, it may have a printed pattern or a pattern, and such coloring, printing, etc. may be carried out according to the conventional technique. Further, the above synthetic resin film may be subjected to a primer treatment or a corona discharge treatment on the surface for the purpose of improving the adhesiveness of the surface thereof.

If the thickness of this synthetic resin film is too thin, it is disadvantageous in terms of strength and the like, and if it is too thick, it is uneconomical, and preferably about 10 to 100 μm. As a method for producing a decorative plate, a base material is impregnated with a thermosetting resin into a decorative base paper by an impregnation method using an ordinary impregnation machine, a solvent is dried, and a base material is provided between metal mirror surface plates interposed between upper and lower heating plates. After sandwiching the thermosetting resin-impregnated paper and the synthetic resin film and arranging them in this way, they are heated and pressed by the upper and lower heating plates. The conditions of the heating plate temperature, the pressing pressure, and the heating time for the heating and pressing are selected base material, resin type of thermosetting resin-impregnated paper, synthetic resin film, and core paper to be laminated together as necessary. , Overlaid paper, etc.

For example, when DPA (diallyl phthalate) resin-impregnated paper is used, thermosetting resin-impregnated paper is sequentially stacked on a plate-shaped substrate, and the temperature is 140 to 150 ° C. and 15 kg.
It is generally manufactured by heating and pressing under the conditions of / cm ² and about 10 minutes. When melamine resin impregnated paper is used, the core sheet is impregnated with the above impregnated sheet on 4 sheets of core paper, and overlay paper of about 35 g / m ² is impregnated with thermosetting resin under the same conditions as the printing paper and dried. Then, stack and sandwich between two mirror-finished metal plates, for example, 135 ℃, 100kg
It is generally manufactured by heating at a condition of / cm ² for about 20 minutes.

[0015]

As described above, in the present invention, the synthetic resin film is integrally laminated and laminated on the uppermost layer of the thermosetting decorative board during the heating and pressing in the manufacturing process. As a result, it becomes possible to effectively impart the physical and chemical properties of the synthetic resin film laminated on the uppermost layer to the thermosetting decorative board, for example, heat resistance, moisture resistance, gas barrier property. There is an effect that a thermosetting decorative board having desired characteristics such as the above can be easily obtained with a work amount almost equal to that for producing a normal thermosetting decorative board.

Further, the laminated synthetic resin film is integrally fused with the synthetic resin-impregnated paper and is not peeled off. Even when the laminated synthetic resin film is placed in a hot and humid environment for a long time, peeling between layers or There is an effect that blisters and mold are not generated on the surface. Therefore, the thermosetting decorative board manufactured by the present invention can be sufficiently used as a wall material for bathrooms, which has been difficult to use conventionally.

[0017]

The present invention will be described in more detail with reference to the following examples. [Example 1] Easy-adhesion PET (polyethylene terephthalate) film (manufactured by Toyobo Co., Ltd., A4100, 75μ)
m) 1 Chemically treated surface of ordinary gravure printing machine (54L4
In 0), solid printing 2 of a primer was performed to obtain a synthetic resin film A.

Titanium paper (KW-1000P, manufactured by Kojin Co., Ltd.) 3 was used as the decorative paper B, and a pattern 4 was formed on the surface thereof.
Was prepared by gravure printing. The decorative paper was replaced with diallyl phthalate resin (manufactured by Daiso). Impregnation with C = 100% 5
Then, it was dried at 80 ° C. for 5 minutes by a dryer to prepare a resin-impregnated decorative paper B. As the base material 8, an asbestos slate plate manufactured by Nikko Kasei Co., Ltd. that has been treated with an alkali sealer is used.
The resin-impregnated decorative paper B is overlaid thereon, and the resin film A having the above-mentioned constitution is further laminated thereon, which is then inserted into a heating press, and through a mirror plate 9, 9, 150 ° C., 15 kg
It was thickened by heating on both sides for 15 minutes at / cm ² .

Example 2 The same easy-adhesion PET as in Example 1
An ordinary gravure printing machine (54
L40) prints one picture pattern 10 and
Solid printing 2 of the primer was performed to obtain a synthetic resin film A. White titanium paper as makeup paper (made by Kojin Co., Ltd., K
W-1000P) 3 and a diallyl phthalate resin (manufactured by Daiso) was used. C = 100% was used for impregnation 5, and the resin-impregnated decorative paper B was prepared by drying at 80 ° C. for 5 minutes with a drier.

As a base material 8, an asbestos slate plate manufactured by Nikko Kasei Co., Ltd., which has been subjected to an alkali sealer treatment, is laminated with the above resin-impregnated decorative paper B, and further, the resin film having the above-mentioned constitution. A is laminated, inserted into a heating press, and through a mirror plate 9 at 150 ° C. and 15 kg / cm ² 10
Thickened by heating on both sides for a minute. [Example 3] The same gravure printing machine (54L40) was used to print a plurality of patterns 10 'on the chemically treated surface of the same easy-adhesion PET film 1 as in Example 1, and the solid printing 2 of the primer was performed. A synthetic resin film A was obtained.

White titanium paper (KW-1000P, manufactured by Kojin Co., Ltd.) 3 was used as a decorative paper, and a plurality of pictorial patterns 4'was provided on the surface by gravure printing. The decorative paper was replaced with diallyl phthalate resin (manufactured by Daiso). C = 100
% Impregnation 5% and dried in a dryer at 80 ° C. for 5 minutes,
A resin-impregnated decorative paper B was prepared. As the base material 8, an asbestos slate plate manufactured by Nikko Kasei Co., Ltd., which has been treated with an alkali sealer, is used, and the above-mentioned resin-impregnated decorative paper B is superposed on it.
Further, the resin film A having the above-mentioned structure is laminated thereon, and the resin film A is inserted into a heating press, and then, through the mirror plate 9, 150
It was thickened by heating both sides at 10 ° C. and 15 kg / cm ² for 10 minutes.

In any of the Examples, the obtained decorative board has the physical properties of the PET (polyethylene terephthalate) film laminated on the surface thereof, such as water resistance, moisture resistance, heat resistance, gas barrier property, transparency and heat resistance. It had shrinkability and scratch resistance.

[Brief description of drawings]

FIG. 1 is a schematic view showing a cross section of a laminated structure of an embodiment of a thermosetting resin decorative board manufactured by the method of the present invention.

FIG. 2 is a schematic view showing a cross section of a laminated structure of another example of the thermosetting resin decorative board manufactured by the method of the present invention.

FIG. 3 is a schematic view showing a cross section of a laminated structure of still another embodiment of a thermosetting resin decorative plate manufactured by the method of the present invention.

[Explanation of symbols]

1-synthetic resin film, 2-primer layer, 3-decorative paper, 4-pattern, 5-thermosetting resin, B-thermosetting resin-impregnated paper, 8-base material

Claims (1)

Claims: 1. A decorative paper is provided with a desired pattern, impregnated with a thermosetting resin and dried to prepare an impregnated paper, which is then laminated on a substrate, A method for producing a thermosetting resin decorative board, which comprises placing a synthetic resin film thereon and then heating, pressing and curing the laminate.