JPH0760911A - Thermosetting resin decorative panel and production thereof - Google Patents

Abstract

PURPOSE:To eliminate the generation of strain or irregularity in patterns and to prevent the generation of cracking. CONSTITUTION:A decorative sheet 5 obtained by applying patterns 2 to a thermoplastic resin sheet 1 and laminating and bonding a nonwoven fabric 3 to the patterned sheet 1 is laminated to a fibrous base material coated or impregnated with an uncured thermosetting resin soln. so that the surface of the nonwoven fabric 3 comes into contact with the layer of the resin soln. and the formed laminate is pressed or pressed under heating to cure the thermosetting resin soln. to be integrally bonded.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thermosetting resin decorative board that is preferably used as a surface material for furniture, kitchen appliances, interior materials for construction, cabinets for low-power appliances, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, when a decorative sheet is further laminated and adhered to the surface of a thermosetting resin decorative plate, it is difficult to bond the decorative sheet to the resin layer that has been once hardened. It was laminated and bonded. For example, a decorative sheet made of a thermoplastic resin is laminated and bonded simultaneously with molding via an adhesive layer, an easy-adhesion primer layer, etc., if necessary (for example, JP-A-60-122149, JP-A-3-218832). JP-A No. 4-37508, etc.) and a decorative sheet using heat-resistant and dimensional-stable paper that is laminated and adhered simultaneously with molding (for example, Japanese Patent Publication No. 26-4540). , JP-A-53-
No. 9872, JP-A No. 62-152733, etc.) are known.

[0003]

In the former case described in the prior art, since the thermoplastic resin is softened by heating, the decorative sheet is deformed by heat and stress during molding of the thermosetting resin decorative plate. The pattern often collapses or becomes uneven. This phenomenon varies depending on variations in molding conditions and sheet lots, so that the quality is not stable.

In the latter case, distortion or flow of the picture pattern does not occur, but on the other hand, it is not possible to print as sharply and delicately as in the former case due to the unevenness and absorption of the fibers of the paper, and uneven texture of the paper. Therefore, the pattern is likely to be uneven. This tendency is particularly pronounced when the pattern is entirely solid. In addition, there is also a problem in that the resulting decorative plate has neither flexibility nor flexibility, and is likely to crack or break when a force such as a bending force or an impact force is applied.

Therefore, it is conceivable to use a decorative sheet made of a thermosetting resin, but the cured thermosetting resin sheet has no chemical reactivity, and therefore has insufficient adhesiveness with other layers of the decorative board. In addition, the whole decorative plate is harder than the above, and there is no one that reinforces or releases stress, so that cracks or splits easily occur due to bending and the like, so there is no possibility of practical application.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a thermosetting resin having no distortion or unevenness in a pattern and no cracks or cracks. It is intended to provide a resin decorative board and a manufacturing method thereof.

[0007]

In order to achieve the above object, the thermosetting resin decorative board of the present invention is a thermosetting resin for a fibrous base material obtained by coating or impregnating a thermosetting resin and curing the resin. A non-woven fabric is provided on the surface in contact with, and a thermoplastic resin sheet having a pattern is further laminated thereon in this order.

In the method for producing a thermosetting resin decorative board of the present invention, a fibrous base material is coated or impregnated with an uncured thermosetting resin liquid, and a thermoplastic resin is applied onto the fibrous base material. A decorative sheet obtained by applying a pattern to a sheet and laminating and bonding non-woven fabrics is laminated so that the non-woven fabric surface and the resin layer are in contact with each other, and the thermoplastic resin liquid is cured by applying pressure or heat and the laminated body is bonded and integrated. The process consists of:

As the fibrous base material, paper, non-woven fabric, woven fabric,
Felt, mat, etc. are used. Among these, titanium paper, high-quality paper, kraft paper, Japanese paper, etc. can be used as paper, and as non-woven fabric, woven fabric, felt or mat, glass fiber, asbestos, potassium titanate fiber, alumina fiber, silica fiber, carbon fiber It is possible to use those made of inorganic fibers such as, and organic resins such as polyester and vinylon.

As the thermosetting resin, a melamine resin, a diallyl phthalate resin, a guanamine resin, an unsaturated polyester resin, an epoxy resin, a polyurethane resin, etc. are added with a polymerization initiator, a crosslinking agent, an extender pigment, etc., if necessary. Stuff used.

Impregnation of a state in which the resin is filled in the fibrous base material layer by penetrating into the fibrous base material layer, and does not penetrate into the fibrous base material layer at all or reaches the back surface even if it penetrates In the present invention, either coating or impregnation may be defined as the state where the coating is not applied. Then, as specific means for applying or impregnating, roll coating, flow coating,
Comma coat, dipping, brushing, pouring etc.

One example of a fibrous base material coated or impregnated with a thermosetting resin is SMC (sheet molding compound), which is manufactured by, for example, one side of a first separator film such as a polyethylene film.
Resin prepolymer, curing catalyst, accelerator, curing retarder,
A chopped strand obtained by cutting a glass roving made by bundling glass fibers after applying a resin compound prepared by kneading an air drying agent and a filler such as calcium carbonate, talc, clay, etc. by a knife coating method etc. After spraying, a separate resin compound similar to that applied to one surface of the first separator film is applied to one surface of the second separator film by the same application method, and then the first separator film and the second separator film are applied. The separator films are stacked so that the resin compound-coated surfaces of both separator films face each other via the spread chop strands, and pressure is applied by roll pressure to impregnate / remove the resin compound spread chop strands. A method of foaming, humidifying and curing is adopted. The resin for producing the SMC is not particularly limited, but usually unsaturated polyester or epoxy is often used.

Next, an outline of the SMC molding method for producing an FRP article using the above SMC will be described. An equipment capable of applying heat and pressure to a pair of opposing molds,
Usually, a large heat press with a mold installed is used.
Cut the SMC to the required size in the mold, peel off the front and back films, and place it. Also, after stacking several sheets if necessary, set the temperature to 1
It is heated and pressed under the conditions of 00 to 180 ° C. and a pressure of 30 to 200 kg / cm ² for 1 to 8 minutes to be cured by a reaction such as cross-linking polymerization and addition polymerization, and then molded.

As the thermoplastic resin sheet, methyl (meth) acrylate, ethyl (meth) acrylate, (meth)
Acrylic resins such as homopolymers or copolymers of (meth) acrylic acid esters such as butyl acrylate, ethylhexyl (meth) acrylate, etc. (Note that the notation of (meth) acrylic acid ester is "acrylic acid ester or methacrylic acid ester". Polyethylene terephthalate, polybutylene terephthalate, isophthalate / terephthalate copolymer, etc. polyester, polyvinyl chloride, vinyl chloride / acrylic copolymer, vinyl chloride / vinyl acetate copolymer, ethylene / vinyl alcohol copolymer Polymer, vinyl resin such as ethylene / vinyl acetate copolymer, polystyrene, acrylonitrile / styrene copolymer, styrene resin such as acrylonitrile / butadiene / styrene copolymer, polycarbonate, polystyrene naphthalate,
Resins such as polyimide and polyphenylene sulfide are selected.

When a desired pattern is applied to the thermoplastic resin sheet, the thermoplastic resin sheet may be printed on the side in contact with the thermosetting resin layer, or on the opposite side or both sides. Alternatively, the same or different thermoplastic resin sheets may be laminated and adhered to each other, and a pattern may be formed between both sheets (on the back of the upper sheet or on the lower sheet). In this case, the printing method may be gravure, offset, silk screen or the like, and the pattern ink used is a resin binder to which a colorant such as a pigment or dye is added. As the binder, cellulose acetate, cellulose acetate propionate, fibrin resin such as nitrified cotton,
Acrylic resins such as homo- or copolymers of (meth) acrylic acid esters such as methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, ethylhexyl (meth) acrylate, vinyl chloride vinyl acetate As a pigment, one or a mixture of two or more kinds such as a copolymer is used as a pigment, red iron oxide, cadmium red, yellow lead, ultramarine blue, titanium white,
Inorganic pigments such as carbon black, organic pigments such as quinacridone, polyazo, isoindolinone, and phthalocyanine blue are used. The pattern to be printed is a grain pattern,
Natural products such as stone patterns, cloth patterns, geometric patterns, letters,
It may be any of symbols and the like.

Nonwoven fabrics that form a decorative sheet by laminating and adhering to a thermoplastic resin sheet include acrylic, nylon,
Non-woven fabrics using organic fibers such as polyester, polyethylene, polypropylene, rayon, acetate, vinyl chloride, cellulose, pulp, vinylon, glass fibers, asbestos, potassium titanate fibers, alumina fibers, silica fibers, inorganic fibers such as carbon fibers, Japanese paper is used. It is suitable that the basis weight is 10 to 400 g / m ² .

As a concrete means for applying pressure or heat to cure the thermosetting resin layer and bond and integrate the laminate, a fibrous base material layer between two flat plates and an uncured thermosetting resin are used. A laminated body of resin and decorative sheet is sandwiched and both flat plates are pressed or heat-pressed, and biaxially stretched in a □ -shaped form as is conventionally done in the manufacture of unsaturated polyester decorative plates. A method in which a polyethylene terephthalate film is tensioned and attached, and the four corners are fixed to a mold, and the film surface is placed on the surface of the uncured resin and pressed, in the cavity between the male and female molds. A so-called stamping molding in which a laminated body is inserted and pressure or heat and pressure is applied by both molds is used. The heating is performed to start or accelerate the crosslinking of the thermosetting resin or the polymerization reaction itself, and may be omitted if heating is not required. In addition, the temperature for heating depends on the type of resin,
Although it is determined by the composition, it is usually about 40 to 150 ° C.

The shape of the thermosetting resin decorative plate can be a flat plate, a curved plate or the like. Further, if necessary, various base materials may be lined and laminated on the back surface (opposite surface of the decorative sheet) of the decorative plate of the present invention. As the backing base material, a plate or sheet made of synthetic resin, metal, wood or the like is appropriately used.

[0019]

When the thermosetting resin decorative sheet is formed only with the thermoplastic resin sheet on which the pattern is printed, the adhesiveness with the thermosetting resin is insufficient, and the thermoplastic resin sheet is generated by the heat and pressure in the mold. However, in the thermosetting resin decorative board of the present invention, the non-woven fabric laminated on the thermoplastic resin sheet prevents the resin from adhering due to the impregnation effect (anchoring effect) and dimensional stability. Demonstrate performance.

[0020]

Embodiments of the present invention will be described below with reference to the drawings.

(Example 1) A biaxially stretched polyethylene terephthalate film (manufactured by Diafoil Hoechst: S type) having a thickness of 25 μm was prepared, and as shown in FIG. 1, the back surface side of this thermoplastic resin sheet 1 was cured by isocyanate. Polyurethane ink (The Inktech product: NL-AL
FA) printed a marble-like stone pattern by the gravure printing method. Then, as shown in FIG. 2, the polyethylene terephthalate film with the pattern 2 and the non-woven fabric 3 (manufactured by DuPont Japan: Sontara 8000, basis weight 41 g /
m ² ) and a two-component curing type urethane adhesive (using a polyol (Dainichi Seika: E-295) as a main agent and an isocyanate (Dainichi Seika: C-75N) as a crosslinking agent) Then, the laminate was dry-laminated, and the both were adhered via the adhesive layer 4 to prepare a decorative sheet 5.

Next, two sheets of SMC having a thickness of 2 mm were laminated by peeling off the separator films on the front and back sides thereof, and the decorative sheet 5 was laminated so that the non-woven fabric 3 side of the sheet was in contact with the SMC 6. Cut it to a large size and set it in the mold 7 as shown in FIG.
The composition was heated and pressed at 50 ° C. and a pressure of 50 to 100 kg / cm ^{2 for} 3 minutes for molding to obtain a bathroom wall panel on which a stone pattern was clearly applied.

(Example 2) A decorative sheet having a wood grain pattern printed thereon was prepared in the same manner as in Example 1, and three SMCs were stacked on top of each other with their separator films peeled off.
After the decorative sheets were overlaid so that the grain pattern was on the surface, they were molded using a mold to obtain a FRP decorative plate for a table top having a flat surface and a portion corresponding to the mouth of the periphery. This veneer also had a clear woodgrain pattern.

[0024]

Since the thermosetting resin decorative board of the present invention is constructed as described above, it is possible to prevent the laminated decorative sheet from breaking.
There is no distortion and deformation, and therefore the quality is stable and excellent without the flow and unevenness of the design.

Further, according to the method for producing a thermosetting resin decorative board of the present invention, the decorative sheets can be laminated and adhered simultaneously with the molding of the decorative board, and the decorative sheet is deformed by heat and stress during molding. Since it does not occur, the decorative board can be manufactured without causing the collapse of the design.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of a thermoplastic resin sheet having a pattern.

FIG. 2 is a schematic cross-sectional view of a decorative sheet obtained by applying a pattern to a thermoplastic resin sheet and laminating and bonding a nonwoven fabric.

FIG. 3 is a schematic cross-sectional view showing a state in which a laminated body is bonded and integrated in a mold.

[Explanation of symbols]

 1 Thermoplastic resin sheet 2 Picture 3 Nonwoven fabric 4 Adhesive layer 5 Decorative sheet 6 SMC 7 Mold

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Claims (2)

[Claims] 1. A thermoplastic resin sheet having a non-woven fabric on a surface of a fibrous base material formed by coating or impregnating with a thermosetting resin and contacting the thermosetting resin, and further having a pattern thereon. However, the thermoplastic resin decorative board is characterized by being laminated and integrated in this order. 2. A makeup obtained by coating or impregnating an uncured thermosetting resin liquid on a fibrous base material, applying a pattern on a thermoplastic resin sheet and laminating and bonding a nonwoven fabric on the fibrous base material. A thermosetting resin decorative board, characterized in that the sheets are laminated so that the non-woven fabric surface and the resin layer are in contact with each other, and the thermoplastic resin liquid is cured by applying pressure or heat and pressure and the laminate is adhered and integrated. Manufacturing method.