JPH08267471A - Decorative panel for processing curved surface and manufacture thereof - Google Patents

Abstract

PURPOSE: To obtain a decorative panel for processing a curved surface which can be bent by heating, has excellent color and pattern reproducibility, high surface hardness and excellent physical properties such as wear resistance by simple steps. CONSTITUTION: This decorative panel for processing a curved surface is obtained by the steps of coating the surface 2 of a casting mold 6 with a thermosetting resin, forming a resin film 3, then mounting a decorative sheet 4 in the mold, pouring a thermosetting resin composition in the cavity 5 of the mold 6, curing it, and integrally molding the composition with the film 3 and the sheet 4.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative panel for curved surface processing and a method for manufacturing the same. The decorative panel for curved surface processing obtained by the present invention is excellent in design, such as expressing the texture of artificial marble, and is suitable for applications requiring curved surface processing such as sinks, wash basins, housing equipment, furniture and other members. It is a thing.

[0002]

2. Description of the Related Art Conventionally, as a decorative panel for curved surface processing,
There were so-called melamine decorative boards for post-forms that can be bent by heating and vinyl chloride resin decorative panels that are thermoplastic resins. These decorative panels for processing curved surfaces are placed on a core material that has been processed in advance to form a curved surface part via an adhesive, and are heated and pressed to match the surface shape of the core material. It is a method of sticking.

Further, there is a method of obtaining a molded product such as an artificial marble product having a curved surface by performing compression molding or cast molding of a thermosetting resin composition using a molding die having a cavity having a curved surface shape. .

[0004]

However, the curved surface-finished decorative panel product to which the melamine decorative board for postform is adhered has features such as a hard surface, scratch resistance, and contamination resistance, but in terms of designability. , It is difficult to give a deep three-dimensional effect such as marble, and the color of the paper phenolic resin layer of the base material appears, causing a feeling of strangeness and a thickness of 2
There was a problem in appearance and workability, such as bending work being difficult for mm or more.

The vinyl chloride resin decorative panel is easy to bend, but its surface hardness, scratch resistance, solvent resistance, etc. are lower than those of the thermosetting resin, and since it contains chlorine in its components, it is incinerated. At times, hydrogen chloride gas is generated, which damages the furnace and is not preferable for the environment.

In a method for obtaining an artificial marble product by compression-molding or cast-molding a thermosetting resin composition using a molding die whose cavity has a curved surface shape, high dimensional accuracy and beautiful Although the finish can be obtained, an expensive mold is required, and a mold corresponding to each shape must be prepared every time the size and shape change, which is not suitable for high-mix low-volume production. .

According to the present invention, each layer of a thermosetting resin film layer on the surface, a resin impregnated decorative paper layer in the middle, and a resin composition layer composed of polymethylmethacrylate, a filler and a reinforcing material and having excellent heat bending property are provided. By being integrated and forming a decorative panel, it can be bent by heating, has excellent reproducibility of colors and patterns, has high surface hardness, and has excellent physical properties such as abrasion resistance. The purpose is to obtain a decorative panel for use in a simple process.

[0008]

According to the present invention, a thermosetting resin liquid is applied to the mold surface of a casting mold to form a resin film, and then a decorative paper is placed on the resin film. Curved surface processing characterized in that a resin composition containing an oligomer and monomer of methyl methacrylate, a filler and a reinforcing material is injected and cured to integrate the resin film, the decorative paper and the resin composition. Cosmetic panel and a method for manufacturing the same, and, in particular,
The thermosetting resin liquid applied to the mold surface of the casting mold is at least one selected from unsaturated polyester resin, vinyl ester resin, unsaturated melamine resin, and the above-mentioned resins modified with polyfunctional acrylate. As a result, favorable characteristics such as moldability, various physical properties including surface hardness, and excellent transparency effect can be obtained.

The casting mold used in the present invention is a metal mold or a plastic mold. In the present invention, a mold having a complicated three-dimensional shape is not necessary, and a simple mold for flat plate molding can be used.

The mold surface of the casting mold used in the present invention must have releasability when the applied thermosetting resin coating film is cured, and the mold releasability of the mold itself is sufficient. If not, a mold release agent is applied to the mold surface, or an internal mold release agent is added to the coating resin. As these release agents, silicone resin type, wax type, fatty acid metal soap type, fluororesin type and the like are used.

The coating resin applied to the mold surface is a liquid, non-reactive solvent such as unsaturated polyester resin, vinyl ester resin, unsaturated melamine resin, or the above-mentioned resin modified with polyfunctional acrylate. Thermosetting resins containing no are suitable. Examples of polyfunctional acrylates include trimethylolpropane trimethacrylate and dipentaerythritol hexamethacrylate. These resins can be used alone or in combination, and can be diluted with a reactive monomer as necessary, such as adjusting the viscosity. Further, a thixotropic agent such as silica powder or a thickening agent may be added to maintain the film thickness. Further, in the single-color decorative board, it is possible to add a coloring agent such as a pigment. Forming a coating film on the mold surface
Brush coating, double head curtain flow coater, spray coating with a spray gun, etc.

After the coating film is formed on the mold surface and before the resin of the coating film undergoes gelation reaction, a decorative sheet is placed on the mold surface, and a part of the coating resin is applied to the decorative sheet. Transfer impregnation, or placed on the coating film, inject the resin composition,
A decorative sheet is impregnated with a resin liquid of the resin composition. It is preferable to apply the coating so that the thickness of the coating on the mold surface is maintained at 0.1 to 1 mm. If it is 0.1 mm or less, abrasion resistance and stain resistance are reduced, and if it is 1 mm or more, bending workability and crack resistance are reduced. Sex and so on.

Next, the mold materials are assembled to form a casting mold, and a resin composition containing an oligomer and a monomer of methyl methacrylate, a filler and a reinforcing material is injected and filled into the mold, and the back surface of the decorative sheet is used. The resin is permeated and defoamed, and cured at room temperature or by heating.

The resin component of the resin composition used for casting is mainly composed of so-called acryl syrup in which a methyl methacrylate oligomer is dissolved in a monomer. The cured product of methyl methacrylate resin is plasticized to some extent by heating and enables bending workability.

As the filler, powders of aluminum hydroxide, calcium carbonate, silica, glass, etc., crushed stones, and granular materials of resin cured products are used. As the reinforcing material, glass fibers, synthetic fibers or other fibers cut into short fibers are used.

A resin liquid and a filler which are components of the resin composition,
The type and mixing ratio of the reinforcing material are appropriately determined according to the required performance, appearance, manufacturing conditions and the like of the molded product, and a curing agent, an internal release agent, a coloring agent, etc. are added as necessary.

It is desirable that the decorative paper, which is placed after the coating film is formed on the mold surface, has sufficient strength for handling and is unlikely to cause wrinkles. It is desirable that it has the air permeability necessary for easy replacement, and it is transparent or has a concealing property by mixing titanium oxide, and it is plain or printed with stones, wood grain, other patterns and patterns As the paper quality, pulp, linter, rayon pulp, and paper made of synthetic fiber such as vinylon can be used. A paper having a basis weight of 30 to 200 g / m ² is preferable from the viewpoint of handleability and resin impregnation property.

When the decorative paper is made transparent by resin impregnation, the printed surface can be placed on the outside or inside of the molded product, but in general, the pattern can be placed by placing it on the outside. Becomes clear, and if it is placed so that it is on the inside, the abrasion resistance to the design is improved.

When the decorative paper is placed in a state where the coating film on the mold surface is uncured, the surface of the decorative paper is placed in a paper layer by using a roller or the like so that the coating film resin may well penetrate into the decorative paper. The air contained in is replaced and air is removed.

Next, if necessary, a molding die is set, the resin composition is injected and filled in the die, and when the decorative paper has an unimpregnated portion, the resin composition is applied from the back surface of the decorative paper. Impregnate part of the resin. Injection of the resin composition can be carried out in either an uncured state of the resin film applied to the mold surface or after gelation, but after gelation,
The casting method forms a more stable surface resin layer.

It is desirable that the resin composition is immediately defoamed after casting, and the defoaming method includes natural defoaming by standing, forced defoaming by vibration or pressure reduction, and the air contained in the material. By removing. The cast product after defoaming is heated and cured, and then demolded to obtain a curved decorative panel for integrally molding the surface resin film layer, the resin-impregnated decorative paper layer, and the resin composition. The curved decorative panel thus obtained has excellent physical properties such as surface hardness, has a beautiful finished appearance, and can be bent by heating and pressing.

【Example】

All parts and percentages shown below are expressed by weight. First Embodiment Hereinafter, an embodiment of the present invention will be described with reference to the drawings. thickness
A plate glass of 10 mm was used as the mold material 1 of the casting mold.
Using one side of the plate glass as the mold surface 2, the plate glass was wiped with a cotton cloth impregnated with an 8% toluene solution of a wax-based release agent to form a thin film of the release agent. Next, a method of applying a thermosetting resin liquid to the mold surface 2 to form the resin film 3 is obtained by condensing 1 mol of fumaric acid, 0.4 mol of phthalic anhydride, 0.6 mol of isophthalic acid, and 2 mol of propylene glycol. 100 parts of an unsaturated polyester resin consisting of a 55% styrene monomer solution of polyester, and 1 part of bis (4-t-butylcyclohexyl) peroxydicarbonate as a curing agent, t-
Hexyl peraxyl 2-ethylhexanate 1 part of the resin solution is applied uniformly by a double head curtain flow coater to the release agent application surface of the above-mentioned plate glass so that the application amount of the resin solution is 500 μm. did.

As a decorative paper 4, a decorative paper which is made transparent by resin impregnation is placed on the coated surface of the resin liquid, and the operation of lightly pressing the paper surface with a hand roller from above is repeated,
A part of the applied resin liquid was permeated and impregnated into the decorative paper, and the air in the paper layer was replaced to defoam.

The above-mentioned decorative paper is made of a pulp of α-cellulose as a raw material, has a basis weight of 40 g / m ² , an air permeability of 10 sec,
It is gravure-printed with a marble pattern on paper that does not contain fillers or pigments and becomes transparent when impregnated with resin.

By these operations, two sheet glass molds each having a resin film formed on the sheet glass surface and a decorative sheet placed thereon are prepared, and the treated surfaces are arranged so as to face each other and face each other. A gasket made of a soft vinyl chloride resin having a thickness of 2 mm is sandwiched between the end faces 3 between the plate glasses and fixed by a clamp to form a casting mold 6 having a flat plate-shaped cavity 5 with an opening on the upper side. The casting mold 6 was installed so that.

40 parts of a so-called acrylic syrup consisting of 25% of methyl methacrylate oligomer and 75% of monomer, a silane coupling agent as a filler, as a resin composition 7 containing an oligomer and monomer of methyl methacrylate, a filler and a reinforcing material. Treated with, particle size 12
60 parts of aluminum hydroxide powder of μm, as a reinforcing material,
3 parts of 1.5 mm long glass fiber chop strands, 1 part of titanium oxide as a coloring agent, and bis (4-
t-butylcyclohexyl) peroxydicarbonate
0.4 parts and 0.4 parts of t-hexyl peraxyl 2-ethylhexanate were mixed by stirring under a reduced pressure of Hg 100 mm using a closed mixer to obtain a uniform slurry.

Next, the slurry-like material was injected and filled through the opening of the mold and left in a room at a temperature of 100 ° C. for 1 hour to cure, then the casting mold 6 was disassembled and the molded product was taken out.
The peripheral edge portion was cut to manufacture an artificial marble plate material for postform which is a decorative panel 8 for curved surface processing.

The artificial marble plate material for postform thus obtained has a layer of the decorative paper 4 and the resin film 3 on the surface integrated on the cast resin composition 7, and has a depth like natural marble. The texture and the fine stone pattern were expressed, and it had an aesthetic appearance and was capable of being bent by heating and pressing.

Comparative Example 1 40 parts of an unsaturated polyester resin liquid having the same composition as the resin liquid applied to the mold surface in Example 1 was used as the resin composition to be injected into the casting mold, and a silane cup was used as the filler. 60 parts of aluminum hydroxide powder having a particle size of 12 μm treated with a ring agent, 3 parts of a glass fiber chop strand of 1.5 mm in length as a reinforcing material, and titanium oxide of 1 as a coloring agent.
Parts as in Example 1 using a closed mixer
The mixture was stirred and mixed under a reduced pressure of 0 mm to obtain a uniform slurry. A decorative panel was produced in the same manner as in Example 1 except that this slurry was used as a resin composition which was poured into a mold and cured.

The decorative panels obtained in Example 1 and Comparative Example 1 were subjected to the bending test shown below, and as a result, Example 1
The decorative panel obtained in Example 1 could be bent without causing irregularities such as cracks on the surface, but the decorative panel obtained in Comparative Example 1 cracked.

Test Method From a decorative panel, a 25 mm × 150 mm test piece was cut out, heated in an oven at a temperature of 140 ° C. for 15 minutes, and immediately pressed and bent on a steel jig having a semicircular surface with a radius of curvature of 15 mm. After that, it was cooled and examined for bending workability and occurrence of cracks.

[0032]

In the present invention, the cast resin composition is coated with the decorative paper layer, and the decorative paper is covered with the thermosetting resin film and integrally molded. By applying a desired color or pattern to the decorative paper, a desired appearance can be easily obtained and a mixture of methyl methacrylate oligomer and monomer is used as the resin component of the cast resin composition, Softens when heated, allowing bending. Therefore, it is not necessary to prepare a casting mold suitable for each change in the shape of the decorative panel, and by heating and bending the flat plate-shaped decorative panel, the three-dimensional design of various different shapes can be obtained. It is easy to obtain a decorative panel having

In the present invention, unlike the method of expressing a pattern by the non-uniform dispersion of the colorant, no skilled skill is required,
Excellent reproducibility. Moreover, since the decorative paper is coated with a thermosetting resin coating film, it has excellent wear resistance and scratch resistance, and patterns and patterns are not easily worn or damaged.
Not easily affected by water or chemicals. In particular, by using a thermosetting resin having high hardness and excellent chemical resistance as the coating resin on the surface, the physical properties of the molded product can be improved.

[0034]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a state in which a resin film is formed on a mold surface of a casting mold and a decorative paper is placed in the present invention.

FIG. 2 is a plan view showing an example of a state where a casting mold is assembled in the present invention.

FIG. 3 is a perspective view showing an example of a state where a resin composition is cast in a casting mold in the present invention.

FIG. 4 is a sectional view showing an example of a decorative panel for curved surface processing according to the present invention.

[Explanation of symbols]

 1 Mold Material 2 Mold Surface 3 Resin Film 4 Decorative Paper 5 Cavity 6 Cast Mold 7 Resin Composition 8 Decorative Panel for Curved Surface Processing

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B29L 9:00

Claims (3)

[Claims] 1. A thermosetting resin liquid is applied to the mold surface of a casting mold to form a resin film, and then decorative paper is placed on the resin film and filled with oligomers and monomers of methyl methacrylate. A decorative panel for curved surface processing, characterized in that a resin composition containing an agent and a reinforcing material is injected and cured to integrate the resin film, the decorative paper and the resin composition. 2. The thermosetting resin liquid applied to the mold surface of the casting mold is unsaturated polyester resin, vinyl ester resin,
The decorative panel for curved surface processing according to claim 1, which is at least one selected from the above-mentioned resins modified with an unsaturated melamine resin or a polyfunctional acrylate. 3. A thermosetting resin liquid is applied to the mold surface of a casting mold to form a resin film, and then decorative paper is placed on the resin film and filled with oligomers and monomers of methyl methacrylate. A method for manufacturing a decorative panel for curved surface processing, comprising injecting a resin composition containing an agent and a reinforcing material and curing the resin composition to integrate the resin film, the decorative paper and the resin composition.