JPH0741701B2 - Endless melamine resin decorative board for vertical board - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an endless melamine decorative plate for vertical plates which is long in the longitudinal direction among thermosetting resin decorative plates mainly used for vertical inner layer surfaces such as wall surfaces.

[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]

The gist of the present invention is that a backer-impregnated paper is a fast-curing phenolic resin composition which cures within 60 seconds at a temperature of 140 ° C. or 60 at a temperature of 140 ° C.
The core-impregnated paper is impregnated with a fast-curing melamine-based resin composition that cures within 60 seconds and cures within 60 seconds at a temperature of 140 ° C.
It is fast curing impregnated phenolic resin composition that, pattern impregnated paper is impregnated with fast curing melamine resin compositions which cure within 60 seconds at a temperature 140 ° C., Bakker impregnation
It is an endless melamine resin decorative board for a vertical board, which is formed by laminating paper, core-impregnated paper and pattern-impregnated paper and integrally molding them by thermosetting, and which conforms to JISK6903.

The present invention uses a conventional production method of a batch type melamine resin decorative board by a multi-stage press, and has the same resin constitution as that of the melamine resin decorative board, that is, the melamine resin is a surface layer and the phenol resin is a core layer. The same quality with the above configuration, that is, JISK6903 (thermosetting resin decorative board)
It is possible to industrially produce an endless melamine decorative board for the first time by improving the curing speed of the melamine resin and the phenolic resin of the melamine resin decorative board of the quality that passes the requirement to the rapid curing property and using the continuous molding press machine. It was made possible. Further, in the present invention, since it is used for a vertical inner layer such as a wall surface, the overlay-impregnated paper is not required.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be specifically described below with reference to the drawings. FIG. 1 is a vertical cross-sectional view of an endless melamine resin decorative board according to the present invention. In this drawing, an endless melamine resin decorative board 1 for a vertical plate has a pattern 2 made of a melamine-based resin that is a fast-curing resin. A long roll-shaped makeup having a resin structure in which the core 3 of the layer is a fast-curing phenolic resin and the bucca-4 is a fast-curing phenolic resin or a fast-curing melamine resin. A plate is referred to, and its thickness varies depending on the number of cores 3 or the basis weight of the base papers that make up all the cores 3 and their resin impregnation amounts, and is preferably 0.2 mm to 0.8 mm, but is particularly limited. is not. Since these decorative plates are used for vertical plates, the overlay used for ordinary decorative plates is not necessary. In other words, the overlay plays a role of protecting the surface pattern when it is used on a work top such as a desk, a table, and a sink.
This is an essential layer for horizontal applications, but it is not necessary for abrasion resistance in vertical applications.

The above melamine resin contains melamine and formaldehyde as main components, and the fast-curing melamine-based resin used in the present invention is a temperature which is matched with the lamination curing with the phenol-based 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 having melamine and formaldehyde as main components, and partially alkyl etherified with alcohols or glycols or oxides, further depending on the application. It contains a modifier such as urea, benzoguanamine, acetoguanamine, or paratoluenesulfonic acid amide.

Next, the quick-setting 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 board 1 differs depending on the application and is not limited to a smooth surface or an embossed surface.

As described above, the endless melamine resin decorative plate for vertical plates according to the present invention is batch type 909 × 1818 mm (3 × 6 × 6) in a conventional multi-stage press machine.
(Length) or 1212 × 2424 (4 × 8), which is obtained by manufacturing a melamine resin decorative sheet, while it is a long endless scroll, so the size in the length direction is free. Therefore, there are many advantages in terms of application. That is, when used for a wall surface or the like, the conventional size melamine resin decorative board has a seam because the length is limited, but the endless melamine resin decorative board of the present invention becomes a seamless single piece, Is superior. When a thin melamine resin decorative board having a thickness of 0.6 mm or less is manufactured by a conventional multi-stage press, the thin melamine resin decorative board is often broken during handling work due to its thinness and the yield is reduced, so that it is not commercially available.

However, since the endless melamine resin decorative board 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. In terms of quality, it is somewhat different from the conventional melamine resin decorative board. Absent. That is, JISK69
It has many excellent features such as physical properties that sufficiently pass 03 (thermosetting resin decorative board).

Next, a method for manufacturing the endless melamine resin decorative board of the present invention will be described with reference to the drawings. FIG. 2 is an explanatory view showing a main part of a manufacturing process of the endless melamine resin decorative board of the present invention. In this drawing, a pattern-impregnated paper 2 impregnated with a fast-curing melamine resin, a fast-curing phenol resin. Each roll of the core-impregnated paper 3 impregnated with and the packer-impregnated paper 4 impregnated with the fast-curing phenol resin or the fast-curing melamine resin can be sequentially laminated on the impregnated paper unwinding device A from above. The continuous molding press B is attached to the mounting continuous molding press B. The continuous molding press B is composed of a heating drum 5, endless steel belts 6 and 7, and a pressurizing unit 8, and the endless steel belt is driven by the heating drum. Then, the impregnated paper integrated into the continuous molding press is sandwiched between the mirror-like steel belt 6 contacting the front surface side and the steel belt 7 contacting the rear surface side. The upper and lower endless steel belts receive heat from the heating drum.

All four heating drums may be heating drums, or two heating drums may be provided. 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, when producing an endless melamine resin decorative board for post forming, 140 to 150 ° C. is particularly preferable, and when producing an endless melamine decorative board for a vertical plate, 150 to 150 ° C.
160 ° C. is preferred. Next, the applied pressure may be 10 to 30 kg / cm ² by the tension applied to the endless steel belt and the pressure applied by the fluid in the pressurizing section 8. The material of the endless steel belt is hard stainless steel (SUS
In 304), the surface condition of the mirror-finished steel belt 6 having a thickness of 1.2 mm depends on the surface finish of the endless melamine resin decorative plate to be obtained. That is, when the matte product is obtained, the surface state of the mirror-finished steel belt 6 is matte, and when the product is glossy, 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 impregnated paper is heated and pressed by such a continuous forming press machine B and then cooled by a cooling device C comprising a cooling roll 9 with cooling water. After that, the back surface is continuously sanded by the sander device D using the belt sander 10, and the endless melamine resin decorative board 1 is wound by the product 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.

[0015]

As described above, the endless melamine resin decorative board for vertical plates of the present invention is characterized in that the melamine-based resin and the phenol-based resin are rapidly cured in a few tens of seconds. Since it is longer than the resin decorative board, the dimensional application is expanded, and at the same time the productivity is significantly improved.
A thin melamine resin decorative board conforms to JIS and can be produced at a high yield, which is an extremely excellent effect.

[0016]

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view of an endless melamine resin decorative plate for vertical plates according to the present invention.

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

[Explanation of symbols]

 1 Endless melamine resin decorative board 2 Pattern-impregnated paper made of melamine-based resin 3 Core-impregnated paper made of phenol-impregnated paper 4 Bucker-impregnated paper made of phenol-impregnated paper 5 Heating drum 6 Mirror surface side of surface Rubelt 7 Steel belt on the back side 8 Pressurizing section 9 Cooling roll 10 Belt sander A Impregnated paper unwinding device B Continuous forming press C Cooling device D Sanding device E Product winding device

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Claims (1)

[Claims] 1. The backer-impregnated paper is kept at a temperature of 140 ° C. for 60 seconds.
Fast curing phenolic resin composition, or temperature cures within
The core-impregnated paper is impregnated with a fast-curing melamine resin composition that cures at a temperature of 140 ° C within 60 seconds ,
The pattern-impregnated paper is impregnated with a fast-curing phenolic resin composition that cures within 0 seconds and the temperature is 140 ° C. within 60 seconds.
JIS K69, which is impregnated with a fast-curing melamine-based resin composition that cures, and is formed by stacking backer-impregnated paper, core-impregnated paper, and pattern-impregnated paper and integrally molding them by thermosetting.
Endless melamine resin decorative board for vertical boards that is compatible with 03.