JPH08187736A - Thermosetting resin decorative panel and manufacture thereof - Google Patents

Abstract

PURPOSE: To obtain a low-cost thermosetting decorative panel which has a light weight, no joint on the surface, texture like marble, excellent reproducibility of dimension and shape, toughness and easy component mounting. CONSTITUTION: A thermosetting resin decorative platen 3 is obtained by placing a woody core material 1 in a casting mold and a mold space between the material 1 and a mold surface, casting to fill thermosetting resin composition in the mold, curing it, and covering the material 1 with the cured material 21 of the composition.

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 panel used for partition panels, sinks, sinks, toilet members and other housing equipment, furniture members, tabletops and the like, and a method for producing the same. In particular, when the thermosetting resin decorative panel of the present invention is applied to an artificial marble product, it is possible to reduce the weight and improve the processability without impairing the texture.

[0002]

2. Description of the Related Art Conventionally, a thermosetting resin decorative panel is a flash in which a thermosetting resin decorative material is attached to at least one surface and a mouth end of a flash core material made of a reinforcing material such as a frame material, a crosspiece, and a paper core. Structure makeup panel.

A decorative panel having a composite structure in which a solid wood material such as plywood, particle board, and medium-quality fiberboard is used as a core material, and a thermosetting resin decorative material is attached to the surface and the mouth of the wood.

A decorative panel having a single-layer solid structure, which is obtained by casting or compression molding a thermosetting resin composition comprising a thermosetting resin and an inorganic filler using a molding die, that is, a so-called loose panel. There were artificial marble panels and so on.

[0005]

However, a decorative panel in which a flash core material is attached with a decorative material, or a decorative panel in which a wooden core material is attached with a decorative material has a simple manufacturing process and is lightweight. Although it has advantages such as good workability, it is difficult to express the texture as a solid material such as artificial marble at the boundary between the surface and the mouth, and it is difficult to express the texture as a solid material. However, it was not suitable for use because it was more likely to be submerged than the seam of the decorative material during long-term use.

[0006] Further, when finishing the mouthpiece into a shape having a change such as a curved surface, it takes a lot of man-hours for processing, and skill is required to reproduce an accurate shape.

The artificial marble panel, which is formed by molding a thermosetting resin composition comprising a thermosetting resin and an inorganic filler in a mold, is made of a single layer of solid wood, and thus has no seam and is unique to marble. It has a good texture, excellent appearance, and is not affected by water or the like.

[0008] Also, although it has many features such as the ability to accurately reproduce the same size and shape using a mold, it is possible to use a relatively expensive thermosetting resin. However, the raw material cost was high and the weight was high.

Further, since the material is hard and brittle, it is difficult to mount wood screws and the like, and it is not easy to mount parts.

The present invention is a thermosetting resin which is lightweight, has a seamless decorative panel surface, has a marble-like texture, is excellent in the reproducibility of dimensions and shape, and is tough and easy to mount parts. The purpose is to obtain a decorative panel at low cost.

[0011]

According to the present invention, after a wood core material is placed in a casting mold so that there is a space between the wood core material and the mold surface of the casting mold. A thermosetting resin, wherein the thermosetting resin composition is injected and filled into the casting mold so that the wood core material is covered with the thermosetting resin composition, and then cured. A decorative panel and a method for manufacturing the same, in particular for coating the wood core material,
If the thermosetting resin composition injected into the casting mold is 20
To 50 wt% of a thermosetting resin and 50 to 80 wt% of an inorganic filler, and the resin constituting the thermosetting resin composition is an unsaturated polyester resin, unsaturated melamine resin, methylmethacryl resin By using at least one type of resin selected from the above, the desired thermosetting resin decorative panel can be effectively obtained.

The casting mold used in the present invention is made of metal,
Alternatively, it is a closed mold made of reinforced plastic, and the mold surface is finished with gloss, semi-gloss, matte finish, etc., and a mold release agent treatment is carried out prior to casting if necessary.

As a method for treating the release agent, wax, silicone resin or the like is applied and wiped off, or a polyvinyl alcohol aqueous solution is applied and dried to form a film.

As the wood core material arranged in the casting mold, wood plate materials such as plywood, particle board, and medium-quality fiberboard are used, and a thermosetting resin is used between the casting mold and the die surface. Are positioned and arranged so that a defined space for filling is formed.

As a method of arranging the wood core material so that the space between the wood core material and the mold surface has a predetermined size interval, the same texture as that of the thermosetting resin composition to be cast is used. The leg-shaped molded article is placed on a wooden core material, and the wooden core material is placed at a predetermined position in the mold so that the wooden core material is located at the center of the mold space. There is a method to support the core material with a pin.

In the method of installing the leg-shaped article on the wooden core material, the thermosetting resin composition is cast to be integrated with the leg-shaped molded article. Even if it is located on the surface, there is almost no discomfort. In the method of providing a pin on the casting mold, after the mold is removed, the opening formed by the pin is filled and cured with a resin composition having substantially the same texture as the thermosetting resin composition used for casting.

The thermosetting resin composition used in the present invention preferably contains 20 to 50% by weight of the thermosetting resin.
Liquid form comprising 50-80% by weight of inorganic filler,
It is a slurry-like material, and when cured, a marble-like texture is obtained.

When the thermosetting resin is 50% by weight or more, it is not economically advantageous and the strength and appearance are not sufficient. On the other hand, when it is 20% by weight or less, the fluidity is lowered, and defoaming or injection molding becomes difficult.

As the thermosetting resin component constituting the thermosetting resin composition of the present invention, unsaturated polyester resin, unsaturated melamine resin and methylmethacrylate resin are suitable, and moldability, physical properties of molded articles, etc. According to the requirement, these resins may be used alone or as a mixture of two or more kinds.

The unsaturated polyester resin used in the present invention is obtained by heating esterification of unsaturated polybasic acid, saturated polybasic acid and glycol, or epoxy resin and methyl (meth) acrylic acid. It is a liquid resin obtained by dissolving another vinyl ester resin in a vinyl monomer that acts as a crosslinking agent.

The unsaturated melamine resin in the present invention is a prepolymer having an average molecular weight of 200 to 8000, which is synthesized from melamine, paraformaldehyde and 2-hydroxyethyl (meth) acrylate by a condensation reaction. The methyl methacrylate resin means a syrup-like resin solution in which a methyl methacrylate prepolymer is dissolved in a methyl methacrylate monomer.

Organic peroxide curing agents such as methyl ethyl ketone peroxide and benzoyl peroxide are used as curing agents for curing these resins, and cobalt naphthenate, dimethylaniline and the like are used as curing accelerators. .

The inorganic filler compounded in the thermosetting resin composition of the present invention is aluminum hydroxide, calcium carbonate, silica, or stone powder obtained by crushing natural stone, preferably having a particle size of 3 to 100 μm. Is suitable.

If necessary, inorganic pigments, organic pigments, crushed particles of a cured product of a colored resin, etc. are used as the coloring agent, and the inorganic coloring agent is generally excellent in the fastness.

Each of the materials constituting the thermosetting resin composition is weighed based on the compounding ratio, and then stirred and mixed by a mixer to obtain a liquid or slurry-like substantially uniform composition. To adjust. By performing this stirring and mixing under reduced pressure, it is possible to reduce the inclusion of bubbles.
It is necessary that the thermosetting resin composition has such a fluidity that it can be easily injected and filled into the mold, that it can be defoamed, and that the filler does not separate and settle.
Further, the amount ratio of the curing agent, the curing accelerator, etc. is adjusted so as to cure at room temperature or a relatively low temperature with a required pot life.

After the stirring, the thermosetting resin composition is pressure-fed from a mixer using pressurized air or the like, and is injected and filled in a mold. The viscosity of the thermosetting resin composition is preferably 25 ° C.
In the range of 200 to 6000 Pa · S, it is possible to obtain appropriate fluidity and good filling property in the molding die. The type of the thermosetting resin, the type of the filler, and the compounding ratio Is appropriately selected within the range of 20 to 50% by weight of the thermosetting resin and 50 to 80% by weight of the filler.

After the casting, the molding die is left to stand at room temperature or in a heating state at a relatively low temperature to cure the thermosetting resin composition. The cured thermosetting resin composition is released from the mold, further cured by heating and subjected to aftercure to obtain a thermosetting resin decorative panel as a product. With this after-cure, the required physical properties as a product can be obtained.

[0028]

Embodiments of the present invention will be described below with reference to the drawings. The parts and% in the examples represent parts by weight and% by weight, respectively. Example 1 A wooden core material 1 for producing an artificial marble panel which is a thermosetting resin decorative panel 3 has a thickness of 15 mm and a width of 0.8.
Two kinds of plywood having a length of 80 m and a length of 1.780 m were prepared, a sealer made of a polyurethane resin was applied to the entire surface of the two kinds of plywood, and left at 30 ° C. for 2 hours to dry. As a method of arranging the wood core material 1 at a desired position in the mold of the casting mold 4, a support rod 5 is temporarily fixed to the mouth part in the width direction, and the support rod 5 is used as a gasket constituting a mold. The wood core material 1 is arranged at a desired position in the mold by penetrating through the support hole 43 provided in 41.

As the supporting rod 5, a stainless rod having a diameter of 5 mm and a length of 80 mm is used. A hole having a diameter of 5.2 mm and a depth of 20 mm is formed at two wood mouth portions of the wood core material 1 in the width direction and the supporting hole 43 is formed. Then, the support rod 5 was inserted and fixed in the support hole 43.
The support rod 5 is to be removed immediately after the molded product is demolded.

The casting mold 4 for molding the thermosetting resin decorative panel 3 is composed of a gasket 41 made of urethane rubber and a contact plate 42 for sealing the gasket 41 from above and below. Flat heat plate 6
The mold space 47 is formed by inserting the mold space and pressing it.

The gasket 41 has a height of 25 mm and a thickness of 4
0mm rectangular frame shape, width 0.900m, length 1.800
m having an opening forming a mold space 47,
The plate 42 has a thickness of 3 mm, a width of 1.000 m, and a length of 1.90.
A 0 m stainless plate is used. In the gasket 41, a support hole 43 having a diameter of 5 mm and penetrating the gasket 41 for supporting the support rod 5 of the wooden core material 1 is provided at a position corresponding to the support rod 5 of the wooden core material 1, Furthermore, the support rod 5
In order to facilitate the attachment / detachment of the gasket 41, a slit 44 reaching the support hole 43 from the upper surface of the gasket 41 is provided.

Further, the gasket 41 is provided with an opening / closing inlet 45 and an outlet 46 for opening and closing in order to inject and discharge the thermosetting resin composition 2. Inlet 4
The thermosetting resin composition 2 is injected by installing the thermosetting resin composition 5 at a position close to the lower side of the mold and the discharge port 46 at a position near the upper side of the mold 45 substantially on the diagonal of the mold. This makes it easy to suppress and remove bubbles that are generated at the time.

In the manufacturing process of the thermosetting resin decorative panel 3, prior to the casting of the thermosetting resin composition 2, the urethane rubber gasket 41 and the stainless steel contact plate 42 are the mold surfaces. A silicone resin wax as a mold release agent was thinly and uniformly applied to the above.

Construction of casting mold 4 and wood core 1
As a method of arranging the
Bend the support bar 5 of the wood core 1 into the support hole 43
, The wood core 1 is positioned so as to be placed at a desired position in the mold in a well-balanced manner, and the stainless steel contact plates 42 are placed on the upper and lower sides of the gasket 41, and between the hot press hot plates 6. It was inserted into and was clamped with a pressure of 4.9 Pa to form a closed mold. By this pressing, the slit portion of the gasket and the support rod 5 and the support hole 43 are brought into close contact with each other, and the casting mold 4 is formed.

The thermosetting resin composition was prepared according to the materials and mixing ratio shown in Table 1 by using a closed type mixing stirrer. First, the materials of NO.1, NO.7, NO.3, and NO.5 were put into a mixing stirrer tank, and after stirring at normal pressure for 5 minutes, NO.2,
Add the material of NO.4, and under reduced pressure of 86.660Pa, 10
Mix and stir for a minute, then add the material of No. 6 and repeat 8
The mixture was stirred under a reduced pressure of 6.660 Pa for 5 minutes. The thermosetting resin composition 2 thus obtained was a slurry having a viscosity of 2.000 Pa · S at a temperature of 25 ° C.

Next, air is sent into the mixing agitator tank,
Further, the thermosetting resin composition 2 which has been prepared is pressurized at a pressure of 4.9 Pa with pressurized air and injected into the mold through the injection port 45 of the casting mold 4 to obtain the wood core material 1. It is filled in the mold space 47 formed between the mold surface and degassed from the discharge port 46,
The injection port 45 and the discharge port 46 are closed and left at 40 ° C. for 30 minutes for gelation, the pressure of the hot press machine is released, the support bar 5 of the wood core material 1 is pulled out, and as it is, for 90 minutes. It was left to cure and demolded.

After demolding, aluminum hydroxide alone is doubled in the hole formed by withdrawing the support rod 5 at the mouth of the molded product, with the same composition as the thermosetting resin composition 2 used for casting. Fill the increased amount of compound, place it on a horizontal table,
Artificial marble which is a thermosetting resin decorative panel 3 in which the entire surface of the wood core material 1 is covered with the cured product 21 of the thermosetting resin composition 2 after curing for 2 hours in a heating chamber at a temperature of 100 ° C. Got the panel. Table 2 shows the physical properties of this artificial marble panel.

Comparative Example 1 A single-layer thermosetting resin decorative panel made of only the thermosetting resin composition under the same composition and the same production conditions as in Example 1 except that the wood core material was not used. Manufactured an artificial marble panel. Table 2 shows the physical properties of this artificial marble panel.
Shown in

[0039]

【Test method】

(1) Wood screw holding force According to the wood screw holding force test specified in JIS A5908. (2) Impact strength A test piece with a size of 300 mm x 300 mm is cut out, placed on a horizontal concrete base, and a copper ball weighing 1000 g is dropped vertically onto the test piece to find the maximum height that does not cause abnormalities such as dents and cracks. It was

[0040]

[Table 1]

[0041]

[Table 2]

[0042]

In the thermosetting resin decorative panel of the present invention, the core material made of a wooden board is completely covered and integrated with a layer of the thermosetting resin composition having a predetermined thickness. Compared to a molded product that is simply embedded, it is possible to prevent warpage from occurring because it is possible to have a material structure that is not affected by moisture such as moisture absorption and is approximately symmetrical with respect to the center line of the material. Improves stability.

Since the core material is a wood board material, it is lightweight,
The weight is reduced compared to a decorative panel having a single layer of a thermosetting resin composition. Moreover, since the wood core material is generally lower in price than the thermosetting resin composition, the material cost is reduced and the economical efficiency is increased.

Further, since the thermosetting resin composition is hard and brittle, it is not always easy to attach parts by wood screws or the like, but since the wood core material is combined, it can be easily attached and required. You can obtain mounting strength such as a simple screw holding force.

In the present invention, since the decorative panel surface has no seams or the like and is entirely covered with the core material, it is possible to express a marble-like texture and is also advantageous in cast molding. A thermosetting resin decorative panel with excellent reproducibility of a certain size and shape can be obtained.

[0046]

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of the structure of a thermosetting resin decorative panel of the present invention.

FIG. 2 is a cross-sectional view showing an example of a state in which a wooden core material is arranged in a mold in the present invention.

FIG. 3 is a sectional view showing an example of a state in which a thermosetting resin is cast in a mold in the present invention.

FIG. 4

FIG. 4 and FIG. 5 are explanatory views showing an example of a method for fixing a wood core material in a mold in the present invention.

[Explanation of symbols]

 1 Wood Core Material 2 Thermosetting Resin Composition 21 Cured Product 3 Thermosetting Resin Decorative Panel 4 Cast Mold 41 Gasket 42 This Plate 43 Support Hole 44 Slit 45 Injection Port 46 Discharge Port 47 Mold Space 5 Support Rod 6 Heat Board

Claims (4)

[Claims] 1. A wooden core material is arranged in a casting mold so that a space is provided between the wooden core material and a mold surface of the casting mold, and then, in the casting mold. 1. A thermosetting resin decorative panel, characterized in that the thermosetting resin composition is injected and filled so that the wooden core material is coated with the thermosetting resin composition, and then cured. 2. A thermosetting resin composition for injecting, filling and curing in a casting mold for coating the wood core material,
20-50% by weight of thermosetting resin and 50-80
The thermosetting resin decorative panel according to claim 1, wherein the thermosetting resin decorative panel is constituted by a weight% of an inorganic filler. 3. The resin constituting the thermosetting resin composition, which is filled and cured in a casting mold to coat the wood core material, is an unsaturated polyester resin, vinyl ester resin, The thermosetting resin decorative panel according to claim 1 or 2, which is at least one kind of resin selected from saturated melamine resin and methylmethacryl resin. 4. A wooden core material is arranged in the casting mold so that there is a space between the wooden core material and the mold surface of the casting mold, and the wooden core material is then placed in the casting mold. Liquid or slurry type thermosetting resin composition is pressurized and injected, and the wood core material,
Manufacture of a thermosetting resin decorative panel, characterized in that the wood core material is coated with the thermosetting resin composition and cured by filling the space between the mold surface of the casting mold. Method.