JPH07125135A - Melamine metal laminate sheet - Google Patents

Abstract

PURPOSE:To simplify the composition and process without lowering the superficial characteristics such as an abrasion resistance or the like of a melamine metal laminated sheet by using melamine resin-impregnating laminated paper as a surface layer and allowing crystal cellulose powder and amine powder to stay in melamine resin to be impregnated in decoration-laminated paper. CONSTITUTION:Thermosetting resin-impregnating paper 12 Is laminated on both sides of a metal sheet 11, and melamine resin-impregnating paper 13 is spread thereover, to then be entirely integrated by a heat-pressure forming process. By reason of a metal sheet that is lightweight and not liable to rust, an aluminum sheet is preferable to be used. The thickness is usually of the order of 0.8-1.6mm. Also, the surface is turned into roughness so as to enhance the adhesiveness. In the next place, the thermosetting resin-impregnating paper acts as an adhesive for the metal sheet and decoration-laminated sheet, and It is manufactured such that thermosetting resin such as phenol resin is impregnated and then dried in paper to be used ordinarily such as craft paper. As thermosetting resin, phenol or epoxy resin is preferably employed, which has excellent adhesiveness with a metal sheet and fine impregnation to paper.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a melamine metal decorative plate used for the interior of vehicles and the like.

[0002]

2. Description of the Related Art Since a melamine metal decorative plate is nonflammable, it has long been used as an interior material for railway vehicles and the like. As shown in FIG. 1, the conventional melamine metal decorative plate comprises a surface layer 1, a melamine resin decorative layer 2, a shielding layer 3, a phenol resin core material layer 4, an adhesive layer 5, and a metal plate 6 in order. . The surface layer 1 is an impregnated paper obtained by impregnating and drying a thin semi-transparent paper with a melamine resin, and becomes transparent after molding, and a material having good abrasion resistance is used. The melamine resin decorative layer 2 is
It is an impregnated paper obtained by impregnating a decorative paper or a pigment shaving paper with a predetermined amount of melamine resin by printing and drying. The phenol resin core agent layer 4 is an impregnated paper obtained by impregnating and drying an inexpensive paper with a phenol resin. Between the melamine resin decorative layer 2 and the phenolic resin core material layer 4, there is usually provided a shielding layer 3 made of a shielding impregnated paper obtained by impregnating a pigment-containing paper with a phenolic resin or a melamine resin.

As the metal plate 6, an aluminum plate is generally used, but a rustproof iron plate is also used. A melamine metal decorative plate is obtained by setting each impregnated paper on the metal plate 6 coated with the adhesive 5 as shown in FIG. 1 and heating and pressurizing it by a conventional method. The thickness of the layers excluding the metal plate is approximately 0.5 to 0.7 mm. In the case of a thin-layer melamine metal decorative plate obtained by thinning this, it is about 0.3 mm.

[0004]

DISCLOSURE OF THE INVENTION The present invention aims to simplify the structure of a decorative plate without lowering the surface properties such as abrasion resistance of the conventional melamine metal decorative plate, thus simplifying the manufacturing process. It was completed after various studies for the purpose.

[0005]

MEANS FOR SOLVING THE PROBLEMS The present invention is a melamine metal decorative plate obtained by stacking thermosetting resin-impregnated paper on the surface of a metal plate, melamine resin-impregnated decorative paper on the surface of the metal plate, and heat-pressing. In the above, the melamine resin-impregnated decorative paper is used as a surface layer, and the melamine metal decorative plate is characterized in that crystalline cellulose powder and alumina powder are present in the melamine resin impregnated in the decorative paper, and the surface decorative paper layer is crystallized. By containing the cellulose powder and the alumina powder, it is possible to obtain the surface characteristics such as abrasion resistance equivalent to the conventional one in a simplified process.

FIG. 2 is a schematic cross-sectional view of a melamine decorative metal sheet according to the present invention, in which thermosetting resin-impregnated paper 12 is laminated on both sides of a metal plate 11, and a melamine resin-impregnated decorative paper 13 is further laminated.
Are laminated and the whole is integrated by heat and pressure molding. In the present invention, the metal plate is preferably an aluminum plate because it is lightweight and does not easily generate rust. Its thickness is usually about 0.8 to 1.6 mm. The surface is then usually roughened for good adhesion.

Next, the thermosetting resin-impregnated paper to be laminated on the surface of the metal plate acts as an adhesive between the metal plate and the decorative layer. The thermosetting resin is impregnated and dried.
The thermosetting resin used for the impregnated paper that is directly adhered to the metal plate is preferably a phenol resin or an epoxy resin, which has good adhesion to the metal plate and excellent impregnation property to the paper. Usually, a phenolic resin or a mixture of a phenolic resin and an epoxy resin is used for making the decorative board nonflammable. A water-soluble phenolic resin is preferably used because it has a particularly excellent impregnation property into paper.

Any kind of paper may be used as long as it is well impregnated with such a thermosetting resin liquid, but the basis weight is usually 3
The thing of 0-200g / m < ² > is used. In order to further improve the nonflammability of the decorative board, the basis weight is preferably 30 to 40.
Thin paper with g / m ² can be used. Further, as the paper directly bonded to the metal plate, thin paper of 20 to 50 g / m ² is preferable for improving the adhesive strength. For other papers, 1
The number of sheets used can be reduced by using a slightly thick one of 100 to 200 g / m ² .

Melamine resin-impregnated decorative paper is used for the decorative layer. The decorative paper contains titanium oxide and, if necessary, a coloring pigment, and a pattern is appropriately printed on the surface. Basis weight 50-15
0 g / m ² is suitable, but a smaller grammage is better for improving nonflammability. The content of titanium oxide is usually 5 to 5 of paper.
Although it is 50% by weight, when a coloring pigment is used, a relatively small amount may be sufficient, and in order to eliminate the shielding layer under the decorative paper, it may be increased.

In the decorative board of the present invention, the decorative layer is used as the surface layer, and in order to omit the overlay layer, crystalline cellulose powder and alumina powder are contained in the melamine resin varnish impregnating the decorative paper. The smaller the particle size of crystalline cellulose and alumina, the more preferable in terms of dispersibility in a varnish and surface smoothness of a decorative plate. Crystalline cellulose powder is 10
A particle size of 0 mesh pass is preferable, and further 200
A mesh pass is more preferable. The mixing ratio is 2 to 10 parts by weight, preferably 3 to 6 parts by weight, based on 100 parts by weight of the solid content of the melamine resin. If the amount is less than 2 parts by weight, the effect of improving wear resistance and the like is small, and if the amount is more than 10 parts by weight, the effect is not improved any more and the smoothness of the surface of the decorative plate decreases. The particle size of the alumina powder is preferably 100 mesh pass, more preferably 200 mesh pass. This blending ratio is 1% solid content of melamine resin.
0.1 to 5 parts by weight, preferably 0.00
It is 1 to 2 parts by weight. If it is less than 0.1 parts by weight, the abrasion resistance is insufficient, and if it is 5 parts by weight or more, the abrasion resistance is good, but the mirror surface plate is often damaged during molding.

The melamine resin to be impregnated into the decorative paper may be the one used in a usual melamine resin decorative board, and when post-forming after molding, a flexible type is preferable. In order to obtain the melamine decorative metal plate of the present invention, the thermosetting resin-impregnated paper and the melamine resin-impregnated decorative paper may be sequentially laminated on the surface of the metal plate and heat-pressed by a conventional method.

The total thickness of the decorative plate is about 1.0 to 1.8 mm. Since the thickness of the metal plate is usually 0.8 to 1.6 mm, the thickness of the resin-impregnated paper is about 0.2 to 0.3 mm. Moreover, since the decorative layer contains titanium oxide and alumina, and the resin is mainly melamine resin or phenol resin which is relatively incombustible, there is no problem in terms of noncombustibility.

[0013]

In the present invention, in order to maintain and improve the surface properties such as abrasion resistance by omitting the overlay layer and using the decorative layer as the surface layer, crystalline cellulose powder and alumina powder are added to the melamine resin impregnated into the decorative paper. Include. Alumina powder is effective for improving the wear resistance, but if it is present in a certain amount or more, it will damage the mirror surface plate at the time of molding, so the amount used is limited. If the amount of alumina powder is reduced and a suitable amount of crystalline cellulose powder is added thereto, the same wear resistance as that of the alumina powder alone can be obtained. In addition, the effect of improving the wear resistance is small when the crystalline cellulose is used alone.

[0014]

Example The surface of an aluminum plate having a thickness of 1.2 mm was roughened by sanding. Kraft paper having a basis weight of 40 g / m ² as an adhesive layer was impregnated with a mixed resin of a phenol resin and an epoxy resin on the surface, and dried to obtain one sheet of impregnated paper having a resin content of 50% and a core layer having a basis weight of 100 g / m ^2. 130 g of gram paper containing 20% titanium oxide as a decorative layer on the surface of two sheets of m ² kraft paper impregnated with a water-soluble phenolic resin and laminated with two sheets of impregnated paper with a resin content of 50%.
5% of 200-mesh pass crystalline cellulose powder and 200-mesh pass alumina powder 0.5% / m ² of decorative paper
% Resin content obtained by impregnating and drying a melamine resin containing 5%
Overlaid with 0% impregnated paper, 160 ℃, 100kg / c
It was heated and pressed under the condition of m ² to obtain a melamine resin aluminum decorative plate having a thickness of 1.5 mm.

For comparison, as a decorative layer, a melamine resin containing neither crystalline cellulose powder nor alumina powder was impregnated and dried, and an impregnated paper having a resin content of 50% was used, and as an overlay layer, kraft paper having a basis weight of 30 g / m ² was used. A melamine resin aluminum decorative board was obtained in the same manner as in Example except that an overlay paper having a resin content of 60% impregnated with the same melamine resin was used. With respect to each of the obtained decorative plates, the abrasion test and the nonflammability were measured, and the results shown in Table 1 were obtained.

[0016]

[Table 1]

(Measurement method) Abrasion test: Nonflammability according to JIS K 6902: According to Ministry of Transport regulations

[0018]

EFFECTS OF THE INVENTION The melamine metal decorative plate of the present invention can maintain the characteristics of the conventional decorative plate and can be simplified in the layer structure to reduce the number of steps in the laminating process and reduce the cost. .

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of a conventional melamine decorative metal plate.

FIG. 2 is a schematic sectional view of a melamine decorative metal plate of the present invention.

[Explanation of symbols]

 1 Surface Layer 2 Decorative Layer 3 Shielding Layer 4 Core Material Layer 5 Adhesive 6 Metal Plate 11 Metal Plate 12 Thermosetting Resin Impregnated Paper 13 Melamine Resin Impregnated Decorative Paper

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical display area C08L 61/28 LNL C08L 1:02

Claims (2)

[Claims] 1. A melamine metal decorative plate obtained by stacking thermosetting resin-impregnated paper on the surface of a metal plate, further stacking melamine resin-impregnated decorative paper on the surface thereof, and heat-pressing the melamine resin-impregnated decorative paper. A melamine metal decorative board characterized in that crystalline cellulose powder and alumina powder are present in the melamine resin impregnated into this decorative paper. 2. The blending amount of crystalline cellulose and alumina powder to melamine resin is 10% melamine resin (solid content).
The melamine decorative metal sheet according to claim 1, wherein the crystalline cellulose is 2 to 10 parts by weight and the alumina powder is 0.1 to 5 parts by weight with respect to 0 parts by weight.