JPH072340B2 - Endless melamine resin decorative board manufacturing equipment - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is an endless melamine which is long in the longitudinal direction among thermosetting resin decorative plates mainly used for interior layers of buildings, vehicles, ships and the like and for makeup or base of furniture. The present invention relates to a decorative plate manufacturing apparatus.

[0002]

2. Description of the Related Art Conventionally, as a method for producing a long endless decorative board, for example, there is a method described in JP-A-56-144151. This method relates to a method for continuously producing a laminated sheet or a metal foil-clad laminated sheet, and when a thermosetting resin such as an unsaturated polyester resin or a diallyl phthalate resin is cured, condensed water or carbon dioxide is added. A method of continuously conveying a plurality of long impregnated papers impregnated with a thermosetting resin liquid that does not substantially generate a reaction by-product such as gas, and curing with a continuous molding press having an endless steel belt. Is. In this method, as described in the specification of the publication, the melamine resin and the phenol resin of the present invention are excluded.

Further, the specification of JP-B-51-15875 describes a method for producing a cosmetic sheet using a continuous molding machine having a steel belt. The purpose of this method is
As described in the specification, a flexible cosmetic sheet made of a synthetic rubber or a thermoplastic synthetic resin system, and in particular, is a permanent processing method due to its flexibility. Thus, a method for obtaining an endless melamine resin decorative board has not yet been established industrially.

[0004]

Therefore, in view of the above-mentioned prior art, the present inventor has conducted diligent research to make the curing speed of the melamine-based resin and the phenol-based resin fast, and as a result, in several tens of seconds. The melamine-based resin and the phenol-based resin that have been impregnated into the paper can be cured, significantly improving the productivity of the conventional melamine decorative board by the batch method and having the same quality as the batch method. The present invention has been newly discovered that endless can be continuously produced.

[0005]

Means for Solving the Problems The gist of the present invention, 140
Impregnated with a fast-curing melamine resin that cures at 60 ° C in 60 seconds or less
Impregnated paper to make up the surface layer, at 140 ℃ for less than 60 seconds
Form a core layer impregnated with a fast-curing phenolic resin that hardens
Impregnated paper to be formed, and the above-mentioned rapid hardening laminated as needed
-Impregnating melamine resin or quick-setting phenolic resin
Impregnated paper unwinding device for each impregnated paper forming the backing layer, a continuous molding press machine composed of a pair of endless steel belts that sequentially laminate these impregnated papers into a laminated body, and the obtained laminated body as a product processing portion for, and, in the manufacturing apparatus of an endless melamine resin decorative plate made from product take-up device for taking up the resulting product, in that a cooling device for cooling the laminate immediately after the continuous forming press It is an apparatus for producing a characteristic endless melamine resin decorative board. Impregnated paper that constitutes the surface layer is a surface pattern, etc.
Of the pattern impregnated paper, or in some cases, this pattern
Core impregnated paper and overlaid impregnated paper covering it, the core
The impregnated paper that forms the layer is the core that forms the center of the decorative board.
Refers to impregnated paper. And the impregnated paper forming the backing layer is
It is also called kka impregnated paper, but omit this.
You can In this manufacturing apparatus, the continuous molding press machine has four drums, or two drums above and below that are heating drums, and a pair of endless steel belts driven by the drums and the endless steel belts. It is preferable that the cooling device includes a pressurizing unit that pressurizes through a belt, and that the cooling device includes a plurality of cooling rolls.

The present invention uses the conventional production method of a batch type melamine resin decorative board by a multi-stage press, and has the same resin constitution as this melamine resin decorative board, that is, the melamine resin is the surface layer and the phenol resin is the core layer. With the constitution described above, a melamine resin decorative board having the same quality, that is, a quality that passes JIS K6903 (thermosetting resin decorative board), has been improved in the curing speed of the melamine resin and the phenol resin to a rapid curing property and continuous molding. The use of a press machine made it possible to industrially manufacture an endless melamine decorative board.

Since the laminated body heated and pressed between the endless steel belts is not completely cooled, sanding with a sand paper or the like as it is tends to cause clogging of the sander. Further, when the edges of the continuous laminate are cut off, if they are not completely cooled, the surface of the laminate is apt to be scratched by the pressing roll of the edge cutter, etc. By installing a cooling device immediately after the press machine, the laminate is cooled before processing to make products such as sanding or edge cutting, so clogging of the sander is prevented and scratches at the time of edge cutting are prevented. Can also be prevented. Further, since the product obtained by the present invention is a laminate of foreign substances, warping occurs only by natural cooling, but the laminate is cooled after being heated and pressed by a cooling device to eliminate warpage.

The detailed contents and examples of the present invention will be described below.
It will be specifically described with reference to the drawings. FIG. 1 shows the present invention.
Longitudinal section of endless melamine resin decorative board obtained by
In this figure, an endless melamine tree
The oil decorative plate 11 has the overlay 1 and the pattern 2 on the surface layer.1
Cures at 40 ° C in 60 seconds or lessFast curing melamine tree
It ’s fat, and the core 3 below it is60 seconds or less at 140 ° C
Cure withFast curing phenolic resin, bacca-4
Hardens in less than 60 seconds at 140 ° CFast curing phenol
Composition of resin or quick-setting melamine resin
Made of longofIt refers to a scroll-shaped decorative plate.
The thickness is the number of cores 3 or the raw materials that make up all of them.
0.2m depending on the basis weight of paper and the amount of resin impregnation
The range from m to 0.8 mm is preferable, but it is not particularly limited.
There is no. And these decorative plates are flat plates according to their use.
Used for general use, vertical use, vehicle use and curved surface
It is broadly divided into post-forming for use. For vertical
In some cases, overlay 1 may or may not be present. Tsuma
Rio Overlay is a work top plate for desks, dining tables, sinks, etc.
Played a role of protecting the surface pattern when used for
And is an essential layer for horizontal applications, but vertical applications
This is because in the case of, there is no need for abrasion resistance.

The above-mentioned melamine resin contains melamine and formaldehyde as main components, and the fast-curing melamine resin used in the present invention is a temperature which is matched to the lamination curing with the phenol resin used for the core. 6 hours at 140 ° C
It is a resin adjusted to the condition of being hardened in 0 seconds or less. In general, melamine resins have fast curing properties among condensed resins, but under the above curing conditions, a satisfactory surface condition cannot be obtained due to insufficient resin flow and gas generated by condensation.

In the present invention, the above-mentioned drawbacks are improved, and it is a melamine resin which is composed mainly of melamine and formaldehyde and is partially alkyl etherified by alcohols, glycols or oxides, and is further used. Depending on the conditions, urea, benzoguanamine, acetoguanamine, paratoluenesulfonic acid amide and the like modifiers are included.

Next, the fast-curing phenolic resin is
Similar to the melamine-based resin, it satisfies the curing conditions of a temperature of 140 ° C. and a time of 60 seconds or less, and is obtained by a limited compounding ratio of phenol, alkylphenol and formaldehyde as main components and a limited reaction method. It is a thing. The curing conditions of the phenol resin used in the conventional batch-type melamine resin decorative board are temperature 14
When the temperature is 0 ° C., it takes 3 minutes or more and usually 4 to 5 minutes. The surface finish of the endless melamine resin decorative plate 11 differs depending on the application and is not limited to a smooth one or an embossed one.

As described above, the endless melamine resin decorative board obtained by the apparatus of the present invention is batch type 909 × 1818 mm by a conventional multi-stage press machine.
(3 x 6) or 1212 x 2424 (4 x 8)
While it is obtained by manufacturing a melamine resin decorative plate of the same size, since it is a long endless scroll, the size in the length direction is free and there are many advantages in terms of application. That is, when used for a long counter, desk, etc., the melamine resin decorative board of the conventional size has a seam because the length is limited, but the endless melamine resin decorative board obtained by the device of the present invention has a seam. It is a single piece that does not have, and is excellent in design. And 0.6
When a thin melamine resin decorative sheet having a thickness of less than or equal to mm is manufactured by a conventional multi-stage press, the thin melamine resin decorative sheet is not commercially available because it is often damaged due to its thinness and the yield is lowered.

However, since the endless melamine resin decorative board obtained by the device of the present invention is a rolled material, it is advantageous in the manufacturing method, and it is industrially possible to be thin, and the material cost is low. There is no difference with the board. That is, it has many excellent features such as physical properties that sufficiently pass JIS K6903 (thermosetting resin decorative board).

Next, the endless melamine resin of the present invention
The decorative board manufacturing apparatus will be described with reference to the drawings. Figure
2 is a manufacturing process of the endless melamine resin decorative board of the present invention
It is an explanatory view showing the main part of, in this drawing,14
A fast-curing melamine resin that cures at 0 ° C in 60 seconds or less
Impregnated Overlay impregnated paper 1 and the fast-curing melamine
Pattern-impregnated paper 2 impregnated with a base resin at 140 ° C for 60 seconds or less
Core impregnated with fast-curing phenolic resin that cures under
Impregnated paper and fast-curing paper that cures at 140 ° C in 60 seconds or less
Bucker-impregnated paper impregnated with a phenolic resinEach volume of 4
Items can be sequentially stacked on the impregnated paper unwinding device A from above.
Installation,By a pair of endless steel beltsContinuous formation
It is inserted into the press machine B. Continuous forming press B is heated
Drum 5, endless steel belts 6, 7 and pressurizing section 8
The endless steel belt drive is heated.
Done on drums. And then inserted into the continuous forming press
Of the impregnated paper is a mirrored steel bell that contacts the front side.
It is sandwiched between the steel belt 7 and the steel belt 7 that contacts the back side.
It The upper and lower endless steel belts are heated
Receive heat from the mu.

The four heating drums may be all four heating drums or two heating drums above and below. The heat is conducted by the upper and lower steel belts by driving the heating drum. The surface temperature of these steel belts is 140 to 1
The temperature is preferably 60 ° C., and this temperature depends on the grade of the obtained endless melamine resin decorative board. That is, in the case of producing an endless melamine resin decorative board for post forming, 140 to 150 ° C. is particularly preferable, and in the case of producing an endless melamine decorative board for general or vertical use, vehicle is 150 to 160 ° C. preferable. Next, the applied pressure is the tension applied to the endless steel belt and the pressing portion 8
It is advisable to pressurize with a fluid of 10 to 30 kg / cm ² .

The material of the endless steel belt is made of hard stainless steel (SUS304) and has a thickness of 1.2 mm. The surface condition of the mirror-finished steel belt 6 for the surface depends on the surface finish of the endless melamine resin decorative plate to be obtained.
That is, a mirror-finished steel belt 6 for obtaining a matte product
The surface condition of is a matte, and in the case of a glossy product, the surface condition of the mirror-finished steel belt is glossy. The surface finish of the steel belt on the back side is not particularly limited.

The laminate obtained by heating and pressurizing the impregnated paper with the continuous molding press B is not completely cooled. Therefore, this laminated body is cooled by the cooling device C. The cooling device C is preferably a cooling device including a plurality of cooling rolls 9, and the cooling roll 9 is preferably cooled by cooling water.

Thereafter, the back surface is continuously sanded by the sander device D using the belt sander 10 and the endless melamine resin decorative plate 11 is wound by the product winding device E. It should be noted that it is preferable that the edges are cut by edge cutting before being wound by the winding device E. Here, a cutting machine such as a guillotine cutter, a rotary knife, or a tip saw may be inserted in the preceding step of the product winding device E to cut it to an arbitrary length. That is, when the thickness of the decorative plate is 1.0 mm or more, it becomes difficult to wind it, and therefore the product is cut into a length according to the order of the market, loaded, packed and shipped. In the case of a scroll, the product is packed and shipped in a length that meets the market order.

As described above, in the apparatus for producing the endless melamine resin decorative board of the present invention, the melamine resin and the phenol resin are cured in several tens of seconds, and immediately after the continuous molding press machine. By using the cooling device, the productivity is significantly improved compared to the conventional method for producing a melamine resin decorative board, and a thin melamine resin decorative board can be produced with high yield. Therefore, it is an article that has extremely excellent effects such as being arbitrary.

Next, examples of the present invention will be described.

【Example】

Example 1 0.2 mol of aliphatic alcohol to 1 mol of melamine,
Overlay paper and pattern paper were impregnated with a resin solution prepared by adding 0.3% of KATANIT A (manufactured by Nitto Kagaku Co., Ltd.), which is a latent curing catalyst, to a melamine resin condensate synthesized with 1.3 mol of formaldehyde and dried. After that, the roll was wound to obtain a roll of Overlay impregnated paper and pattern impregnated paper. At this time, the resin impregnation rate for each base paper was 20% for the overlay.
It was 0% and the pattern was 120%. Next, a core resin made of kraft paper and a backer paper were impregnated with a phenol resin condensate synthesized by 0.7 mol of phenol and 0.3 mol of alkylphenol with 1.5 mol of formaldehyde, respectively. Then, it was dried and wound to obtain a roll of core-impregnated paper and bucker-impregnated paper. At this time, the impregnation rate of each base paper was 60% for the core and 70% for the backer.

The rolls of impregnated paper thus obtained were attached to an impregnated paper unwinding device in the form of an overlay, a pattern, a core and a backer. Then, they were inserted so as to be sequentially stacked between the steel belts of the continuous molding press. At this time, the temperature of the upper and lower endless steel belts is 160 ° C. and the applied pressure is 20 kg / cm ² . Then, after heating and pressurizing for 20 seconds, cool with a cooling roll #
The back surface was sanded with a sandpaper of 60 and wound up to obtain a 0.6 mm endless melamine resin decorative board.
At this time, the impregnated paper feed speed and the speed of the steel belt were synchronized, and the production speed was 10 m / min.

[0022]

As described above, with the apparatus of the present invention, a fast-curing phenotype which cures at 140 ° C. for 60 seconds or less.
It is possible to continuously manufacture an endless melamine resin decorative board by laminating an impregnated paper impregnated with a resin composition and a fast-curing melamine resin composition that cures at 140 ° C. for 60 seconds or less. In particular, since the laminate is cooled before being processed into a product such as sanding or edge cutting by providing a cooling device immediately after the continuous forming press machine using a pair of steel belts, clogging of the sander is prevented. It also prevents scratches when cutting edges,
Continuous molding proceeds smoothly. The obtained product has no warp, and a good endless melamine resin decorative board can be manufactured.

[0023]

[Brief description of drawings]

FIG. 1 is a vertical sectional view of an endless melamine resin decorative board obtained by the present invention.

FIG. 2 is a schematic explanatory view of an endless melamine resin decorative board manufacturing apparatus of the present invention.

[Explanation of symbols]

 1 Overlay impregnated paper consisting of melamine resin 2 Pattern impregnated paper consisting of melamine resin 3 Core impregnated paper consisting of phenolic impregnated paper 4 Bucker impregnated paper consisting of phenolic impregnated paper 5 Heating drum 6 Surface Side mirror belt 7 Belt on the back side 8 Belt 8 Pressurizing part 9 Cooling roll 10 Belt sander 11 Endless melamine resin decorative board A Impregnated paper unwinding device B Continuous molding press C Cooling device D Sanding device E Product Winding device

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Claims (3)

[Claims] 1. A quick-hardening material which cures at 140 ° C. in 60 seconds or less.
Impregnated paper that forms the surface layer impregnated with melamine resin,
And fast-curing phenol that cures at 140 ° C in 60 seconds or less
Impregnated paper forming a core layer impregnated with a system resin, respective impregnated paper unwinding devices, and a pair of endless steel belts that are sequentially laminated and integrated into a laminated body
A continuous molding press machine, a processing unit for making the obtained laminated product into a product, and an apparatus for manufacturing an endless melamine resin decorative plate, which comprises a product winding device that winds the obtained product. An apparatus for manufacturing an endless melamine resin decorative board, characterized in that a cooling device for cooling the laminate is provided immediately after. 2. The continuous molding press machine comprises all four drums, or the upper and lower two drums of which are heating drums, and a pair of endless steel belts driven by the drums and the endless steel belts are provided. The manufacturing device for an endless melamine resin decorative board according to claim 1, which comprises a pressurizing section for pressurizing through. 3. The apparatus for manufacturing an endless melamine resin decorative board according to claim 1, wherein the cooling device comprises a plurality of cooling rolls.