JPH0755506B2 - Method for manufacturing thermosetting resin decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION <Field of Industrial Application> Thermosetting resin decorative boards such as melamine resin decorative boards and diallyl phthalate resin decorative boards are widely used for furniture, desks, tables, architectural interiors, etc. There is. TECHNICAL FIELD The present invention relates to a method for producing a thermosetting resin decorative board having a pattern having a gloss difference on the surface of the surface of the thermosetting resin decorative board used for these, which has an improved design effect.

<Prior art> A thermosetting resin decorative board is a laminate of thermosetting resin-impregnated paper impregnated with a thermosetting resin and dried in a semi-cured state. In general, the material is installed and the resin is cured by heating and pressurizing it with a pair of hot plates to produce the resin. At that time, the surface gloss of the mirror surface plate is transferred to the surface of the decorative plate by placing the mirror surface plate on the thermosetting resin-impregnated paper which becomes the surface of the decorative plate and performing heat press molding. On the other hand, in order to form a pattern with a difference in gloss on the surface of the decorative plate, the surface of the specular plate is etched,
By using a method such as engraving or sandblasting to give a pattern or gloss difference and copy it on the surface of the decorative board, or instead of a mirror plate, use a resin plate with a different pattern or gloss in the same way, A method is used in which an embossed sheet is inserted between a hot platen and a thermosetting resin-impregnated paper, and heat and pressure molding is performed to copy the unevenness of the embossed sheet onto a decorative board.

In order to form the pattern with the difference in gloss, in the case of the mirror surface plate method, since it is in direct contact with the thermosetting resin, the reproducibility of the difference in gloss on the surface of the decorative plate is very good, but it is difficult to form a complicated pattern. However, it is necessary to prepare a mirror surface plate according to the number of stages at the time of molding, and it is difficult to support multi-product production such as cost of mirror surface plate production and preparation time when changing patterns. In addition, conventionally known embossed sheets include those obtained by embossing a resin film with an engraving roll or the like to give unevenness, and those obtained by printing on resin film paper or the like.

The embossed film embossed with an engraving roll or the like needs to be lined at the recesses with a synthetic resin or the like, and it is difficult to give the resin film a pattern having a fine gloss difference.
Since the embossed sheet printed on the rising surface has no releasability for the thermosetting resin in the embossed sheet itself, it is necessary to insert a release sheet or a metal foil between the embossed sheet and the thermosetting resin-impregnated paper. Therefore, the gloss on the surface of the decorative plate is the gloss of the release sheet or the metal foil, so that even if an uneven pattern is formed, almost no difference in gloss is felt.

Furthermore, when using a resin plate made of epoxy resin or phenol resin, insert a release sheet or metal foil between it and the thermosetting resin-impregnated paper to prevent adhesion with the thermosetting resin. However, even in this case, the surface of the decorative sheet had the surface gloss of the release sheet or the metal foil reflected, and even if there was a pattern with unevenness, almost no difference in gloss was felt.

<Problems to be Solved> It is an object of the present invention to provide a method for producing a thermosetting resin decorative board having a pattern with a difference in gloss on the surface, by compensating for the drawbacks of the conventionally known production methods as described above. It is intended.

<Means for solving the problem> In order to make a difference in gloss on the surface of the thermosetting resin decorative plate, a pattern with a difference in gloss is applied to the surface of the decorative plate to compensate for the defects of the resin plate and the conventional embossed sheet. When manufacturing a transfer paper that has, and when manufacturing a thermosetting resin decorative plate, insert it so that the surface with a pattern layer between the hot plate or mirror surface plate and the semi-cured thermosetting resin impregnated paper contacts the impregnated paper. The problem was solved by transferring the pattern with the difference in gloss of the transfer paper onto the thermosetting resin decorative board by heating and pressing to cure the resin.

Since the transfer paper can be easily manufactured by using an ordinary printing machine or an ordinary printing plate, there is no problem in dealing with various kinds.

The method of the present invention will be described in more detail with reference to the drawings.

FIG. 1 is a sectional view of a transfer paper used in the manufacturing method of the present invention. Reference numeral 1 is a base sheet of transfer paper, which uses a resin film, paper, or the like, or a sheet obtained by laminating them in multiple layers. The base sheet 1 must have a smooth surface and good printability, and must have heat resistance that can withstand the heat and pressure molding during the production of the thermosetting resin decorative board, and the thickness of the base sheet 1 is 6 to 6.
Polyester film, polypropylene film, cellophane, etc. of about 100μ are the most suitable. In the present invention, since the base sheet 1 has a release layer on the entire surface, it is an advantage that the releasability with the thermosetting resin does not have to be taken into consideration. Since paper is inferior in surface smoothness and density uniformity to a film, it is not suitable for forming a pattern having a fine gloss difference.
When using a thin resin film with a thickness of about 20μ or less, in handling during printing or heat and pressure molding,
It is also a good method to bond paper with good smoothness and back it.

A pattern layer 2 forms a pattern by printing. The printing ink is, for example, an amino alkyd-based, polyester-based, urethane-based, etc. one or more selected base sheets, each type of base sheet having good adhesion to each other, and a silica having a particle size of about 1 to 20 μm as a gloss adjusting agent. Calcium carbonate,
A pattern is printed by a printing method such as a gravure printing method, an offset printing method, a silk screen printing method using an ink in which an extender pigment such as barium sulfate or alumina is added and adjusted. By heat-drying after printing, fine irregularities are formed on the surface of the printed pattern layer 2 due to the difference in particle size of the extender pigment and the addition amount / application amount, and the glossiness disappears. Further, when printing is performed by using a gradation plate by the gravure printing method, a fine gloss difference can be expressed by the difference in the applied amount depending on the gradation. Note that if the ink is an extender pigment, it is achromatic, so it is colored with an organic pigment or inorganic pigment, etc., whose particle size and addition amount are selected within the range that does not affect the surface gloss of the pattern layer to confirm the printed pattern. It's also a good way to do it.

A release layer 3 is coated on the entire surface of the base sheet 1 and the pattern layer 2. Silicone resins, waxes and the like can be used as the release agent used in the release layer 3, and there are a method of diluting the release agent in a solvent and coating, and a method of adding a small amount to the vehicle and coating. When added to the vehicle, the vehicle is the same as the pattern layer 2, for example, one kind of aminoalkyd series, polyester series, urethane series or the like, or a mixture of two or more kinds of the selected base sheets. By adding 0.2 to 2.0 parts of and coating and baking, a very good releasability from the thermosetting resin can be obtained. The most suitable coating method is a gravure coating method or a roll coater coating method. Particularly, in the case of the gravure coating method, a gravure printing machine having a unit of two-color printing or more is used to print the pattern of the pattern layer 2 and online. Coating is very advantageous in terms of process cost and production loss. The coating thickness of the release layer 3 is preferably 0.2 μm or more, and is preferably less than the recess thickness of the pattern layer 2.
(A good release property to the thermosetting resin and a release layer which did not affect the surface irregularities or surface gloss of the pattern layer 2 were obtained.)
By selecting a resin with a very high surface gloss value such as an epoxy type, amino alkyd type, polyester type, etc. that can form a smooth coating film as a vehicle, the gloss of the non-patterned part becomes extremely high. In contrast to the loss of gloss on the part, the difference in gloss is very large and a vivid design effect can be obtained. It is also possible to adjust the amount of the gloss adjusting agent added to the release layer 3 in the same manner as that for the pattern layer 2 so that the rate of gloss loss becomes smaller than that of the pattern layer 2.

FIG. 2 is a cross-sectional view of a structure when a typical melamine resin decorative board, which is a thermosetting resin decorative board, is molded using the transfer paper manufactured above. The following items are laminated in order from the top between the upper and lower heating plates 12. 11 is a heat-resistant cushion sheet. Ten
Is a mirror plate, but the lower surface does not come into direct contact with the melamine resin, and the base sheet 1 of the transfer paper 4 is between the melamine resin-impregnated paper, so it does not have to be sufficiently polished. I don't care. Reference numeral 4 denotes a transfer paper, which is installed such that the pattern layer 2 printed and coated on the base sheet 1 and the release layer 3 face downward. Numeral 5 is an overlay paper, which is obtained by impregnating rayon pulp or non-woven fabric having a basis weight of 25 to 45 g / m ² with 40 to 100% of melamine resin and drying it to obtain a semi-cured state. In some cases, the overlay paper may be omitted.
6 is a melamine resin-impregnated paper obtained by printing a pattern on titanium paper having a basis weight of 55 to 160 g / m ² , optionally impregnating the melamine resin with 40 to 100%, and drying to a semi-cured state. The pattern print side should be set up. As the thermosetting resin decorative plate having a pattern with a difference in gloss in the present invention, the design effect is sufficiently obtained without pattern printing on titanium paper,
By printing a pattern pattern on titanium paper, a high design effect can be expressed synergistically, although it does not match the pattern with a difference in gloss. Reference numeral 7 is a core paper, which is obtained by impregnating a paper having a basis weight of 140 to 180 g / m ^{2 with} a phenol resin in an amount of 30 to 60% and drying the paper to a semi-cured state. Maintains the dimensional stability of the melamine resin decorative board,
It determines the thickness of the decorative plate and is used by stacking 4 to 5 layers. Reference numeral 8 is a backer paper, which is a titanium paper having a basis weight of 55 to 160 g / m ² impregnated with melamine resin in an amount of 40 to 100% and dried to be a semi-cured state.
It balances with the overlay paper 5 and plays the role of preventing warping of the decorative board. A release sheet 9 prevents the melamine resin from adhering to the lower heat-resistant cushion 11.

Stacked in the state shown in Fig. 2, maximum temperature 140-150 ℃, pressure 80-
After heat and pressure molding at 100 kg / cm ² for 15 to 30 minutes, the semi-cured resin of the impregnated paper is cured and integrated, and the thermosetting resin decorative plate 13 shown in FIG. 3 is manufactured and heated. Cool with cold water for 15 to 30 minutes while applying pressure.

The above is the method for producing what is called a high-pressure melamine decorative board among the melamine resin decorative boards. In addition to the above, a thermosetting resin decorative board using a diallyl phthalate resin or a benzoguanamine resin as a decorative board, or a decorative board using plywood or particle board instead of the core paper 7 as a base material has a heat and pressure condition. It can be manufactured by a similar method by changing it.

FIG. 3 is a cross-sectional view of the thermosetting resin decorative plate taken out after being heated and pressed, cooled under pressure. Since the transfer paper 4 has a releasing property on the surface, it can be easily peeled off, and when peeled off, the transfer paper is in the same state as before molding and the pattern layer 2 is formed on the base sheet 1.
Although the release layer 3 remains, a pattern with a difference in gloss of the transfer paper 4 is copied on the surface of the molded thermosetting resin decorative plate, and a pattern with a difference in gloss having a very high design effect is obtained. A thermosetting resin decorative board can be manufactured. Since the transfer paper 4 can be peeled off at any time, it can be used as a protector sheet for preventing scratches and stains on the decorative plate in the manufacturing process.

Although the silicon of the release layer 3 of the transfer paper 4 is slightly transferred to the surface of the manufactured thermosetting resin decorative plate, it does not cause deterioration of the surface physical properties and the thermosetting resin decorative plate does not use the transfer paper. Compared with the above, since the surface resin layer does not change at all, the physical properties of the decorative board are also the same.

Example 1 A polyester film having a thickness of 25 μm was used as the base sheet 1, and the depth was measured by the first unit of a 4-color gravure printing machine.
A pattern layer 2 having a gradation of 45 μm and having a gradation pattern was printed by a gravure printing method to form a pattern layer 2, and then the release layer 3 was coated online with a solid plate having a depth of 28 μm in a fourth unit. The pattern layer 2 was printed by adding 9 parts of paratoluenesulfonic acid as a curing catalyst at the time of printing to an ink prepared by mixing 20 parts of silica having an average particle size of 4 μ with 100 parts of an alkyd melamine resin and adding a solvent. Then, it was thermally dried at 120 ° C. for 5 seconds. The release layer 3 is formed by coating a paint in which 0.5 part of a silicone resin is added as a release agent by adding a solvent to an epoxy melamine-based resin, and baking it at 170 ° C for 10 seconds to form a portion where the stone pattern is not printed. Has a very high gloss, the portion where the stone pattern is printed loses the gloss, and since it is printed with a gradation plate, a transfer paper 4 having a difference in gloss even in the stone pattern was obtained. .

Next, 60% of melamine resin was impregnated into a pattern paper made by printing a stone pattern of three colors on white titanium paper with a basis weight of 100 g / m ² , and then dried in a semi-cured state, impregnated paper, melamine resin on rayon pulp. An overlay paper impregnated with, a phenol core paper in which paper was impregnated with phenol resin, and a backer paper in which titanium paper was impregnated with melamine resin were prepared.

Next, as shown in FIG. 2, between the upper and lower heating plates 12, the upper cushion 11, the mirror plate 10, and the pattern printing surface of the transfer paper 4 manufactured above are directed downward, and the overlay paper 5 and the pattern paper 6 are patterned. After the printing surface is placed vertically, the phenol core paper 7, the backer paper 8, the release sheet 9 and the lower cushion 11 are laminated in this order, and then the maximum temperature is 145 ° C., the pressure is 80 kg / cm ² , and the heat and pressure molding is performed for 25 minutes. , Water-cool for 20 minutes with pressure applied,
A melamine resin decorative board in which the melamine resin and the phenol resin were cured and integrated was obtained.

After molding, when the transfer paper 4 was peeled off, it had a stone pattern with a difference in gloss on the surface, and although it was out of sync with the stone pattern with a difference in gloss, it had a stone pattern printed in three colors on the base. Due to the synergistic design effect, a melamine resin decorative board with a slight difference in gloss and a natural stone pattern was obtained.

In the peeled transfer paper 4, the pattern layer 2 and the release layer 3 remained on the base sheet 1, but only part of the silicon was transferred to the surface of the decorative sheet. Therefore, the surface of the decorative sheet feels slightly slippery, but the results are better than those of ordinary melamine decorative sheets in terms of abrasion resistance and stain resistance. The other physical properties of the decorative board were the same as those of the ordinary melamine decorative board, because only gloss was transferred.

<Example 2> As the base sheet 1, a polyester film having a thickness of 9μ and a high-quality paper having a basis weight of 40 g / m ² which is dry-laminated with a urethane two-component adhesive are used, and the polyester film surface has four colors. The first unit of the gravure printing machine prints the pattern layer 2 by the gravure printing method using the wood grain pattern plate with a depth of 38μ, and then forms the pattern layer 2 online in the fourth unit with the solid plate with a depth of 28μ. Coated. Pattern layer 2
Was made with the same ink as in Example 1, but 5 parts of silica having an average particle size of 2.5 μ was added to the release layer 3 to remove the luster at the printed part of the conduit pattern and A transfer paper was obtained in which the luster of the non-printed part of the appearance was slightly lost.

Next, black titanium paper having a basis weight of 80 g / m ² was impregnated with diallyl phthalate resin and then dried to prepare a semi-cured tree-impregnated paper.
Next, using the same molding method as in Example 1, between the upper and lower heating plates,
After stacking the upper cushion, the mirror plate, the pattern printing surface of the transfer paper manufactured above in the downward direction, the black impregnated paper, the plywood with a thickness of 3 mm, and the lower cushion in this order, the maximum temperature is 130.
After heat and pressure molding at ℃, pressure of 15 kg / cm ² for 7 minutes, the transfer paper was peeled off, and there was a duct pattern on the surface that had lost its luster, and the entire surface had a slight loss of gloss. Got

<Effects of the Invention> As described above, the present invention makes it possible to easily manufacture a decorative board having a pattern with a difference in gloss simply by inserting a transfer paper when the thermosetting resin decorative board is heated and pressed. This transfer paper
It can also serve to prevent scratches and stains on the decorative plate in the manufacturing process.

In addition, since the transfer paper which gives the pattern having the gloss difference can be manufactured by the usual printing method, the expensive mirror surface plate having the pattern formed by the conventional etching method or the like is not required for the number of steps, so that the transfer paper can be manufactured at low cost. In addition, when changing the pattern, the work of changing the mirror plate can be omitted, the work time can be shortened, and various patterns can be easily handled.

This transfer paper can be used not only once but also many times, and at the time of transfer, a part of the release layer is transferred to the surface of the decorative plate, so that the abrasion resistance of the surface of the decorative plate, The stain resistance is improved.

Furthermore, when manufacturing transfer paper by gravure printing,
The pattern layer and the release layer can be printed and manufactured online, and patterns with slightly different gloss can be reproduced.

Further, since it is possible to add a gloss adjusting agent also to the release layer, it is possible to delicately remove the gloss of the high gloss portion.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a transfer paper, FIG. 2 is a cross-sectional view of a state in which a melamine resin decorative plate is laminated at the time of heat and pressure molding, and FIG. 3 is a cross-sectional view of a melamine resin decorative plate and peeled transfer paper. Is. 1 ... Base sheet 2 ... Pattern layer 3 ... Release layer 4 ... Transfer paper 5 ... Overlay paper 6 ... Melamine impregnated paper 7 ... Phenol core paper 8 ... Backer paper 9 ... Release sheet 10 ... Mirror surface plate 11 ... Cushion sheet 12 ... Hot platen 13 ... Melamine resin decorative board

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B29K 105: 06

Claims (2)

[Claims] 1. A vehicle having good adhesion to the base sheet on one side of the base sheet, a pattern layer formed by printing an ink containing an extender pigment having a particle size of 1 to 20 μm and drying the base sheet, and the base sheet and Insert the transfer paper with the release layer on the pattern layer between the heating plate or mirror surface plate and the semi-cured thermosetting resin-impregnated paper with the pattern layer side as the thermosetting resin-impregnated paper side, and then heat it. A method for producing a thermosetting resin decorative board, which comprises press-molding to cure an impregnated resin. 2. The method for producing a thermosetting resin decorative board according to claim 1, wherein the release layer has a thickness of 0.2 μm or more and less than the thickness of the concave portion of the pattern layer.