JPH0911409A - Thick melamine decorative laminate capable of bending - Google Patents

Abstract

PURPOSE: To provide a thick melamine decorative laminate having excellent bending processability by alternately superposing a plurality of base materials impregnated with a phenolic resin and ABS films having a specific water absorption on one another and further superposing a melamine resin-impregnated base material on one of or both of the surfaces of the laminated base material to be thermoformed together under pressure. CONSTITUTION: A plurality of base materials 2, 2... impregnated with a phenolic resin and ABS films 3, 3... whose coefficient of water absorption is 2.5-6% are superposed alternately on one another. The water absorption of the ABS films is limited because the phenolic resin is water-soluble and permeates into the ABS films to create an anchor effect. Further, decorative layers 1, 1 made of a melamine resin-impregnated base material are superposed on one of or both of the surfaces of the laminated base material and thermoformed together under pressure. In the case of the bending of the thick decorative laminate thus made, the laminate is heated at a temperature higher than the thermal deformation temperature of the ABS films. In this case, the base material layers impregnated with the phenolic resin are mutually deviated by the ABS film layers which work as slip layers, and the decorative laminate whose end is bent in the form of steps is obtained. The end is processed to a smooth face by cutting after the decorative laminate is thermoset.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a thick melamine resin decorative board excellent in bending work.

[0002]

2. Description of the Related Art A post-form decorative board is produced by placing a decorative paper impregnated with a melamine resin on the surface, laminating a plurality of core papers impregnated with a phenol resin, and heat-pressing. Has been done. However, when the thickness of the decorative plate is increased, the elongation of the outer layer is increased during bending, causing cracks and breaks, which makes post-form processing impossible.

In general, a post-form decorative plate to which a bending process is applied uses a modified melamine resin obtained by adding a plasticizer to a melamine resin in order to facilitate the bending process. However, in order to obtain the bending formability of 10 to 30 mmR (radius) that is practically required, it was possible to manufacture only a decorative plate having a thickness of about 1.6 mm at most.

Further, even if a modified phenol resin containing a plasticizer added to the core material layer is used, the strength of the whole thick decorative plate becomes large and post-form processing is difficult.

Next, there has been proposed a method of impregnating a woven fabric with a melamine resin as a base material in order to improve the crack resistance, which covers the brittleness of the melamine resin with the woven fabric. The effect of improving post-form processing cannot be expected when a thick decorative sheet is used.

For this reason, the conventional post-form decorative board is only a thin material of about 0.6 to 1.2 mm and is used as a surface decorative material that is adhered to the surface of a product base material such as a table, a counter, furniture, and a fabrication member. However, it was not possible to commercialize a post-form decorative board as a single product such as a fabrication member.

Further, JP-A-7-108654 discloses a thick postform decorative board obtained by alternately laminating a polyethylene film or the like and a plurality of phenol resin-impregnated core papers. The surface of is roughened by sanding,
Unless a treatment such as adding an adhesion promoter to the film is added to the phenolic resin, good adhesion with the phenolic resin cannot be obtained, so peeling occurs especially in the surface layer during bending, which makes it practical. Not at all.

[0008]

SUMMARY OF THE INVENTION The present invention has been made in view of such circumstances, and an object of the present invention is to make a bending work which is thick and excellent in bending workability and which can be commercialized into various parts as a single product. The present invention provides a possible thick decorative plate.

[0009]

According to the present invention, a plurality of base materials impregnated with a phenol resin and an ABS film having a water absorption of 2.5 to 6% are alternately arranged, and one or both surfaces are further arranged. The present invention relates to a thick melamine resin decorative board having a thickness of 3 to 15 mm which can be bent by stacking a melamine resin-impregnated base material on the above and heat-pressing.

The reason why the water absorption of the ABS film is limited in the present invention is that the phenol resin used for the phenol resin-impregnated base material layer is water-soluble and the phenol resin penetrates into the ABS film to produce an anchor effect. . Polyester film with small water absorption of 1% or less,
Satisfactory adhesiveness with phenolic resins cannot be obtained with polycarbonate films, polyethylene films and the like. A
The thickness of the BS film is preferably 60 to 150 μm. When the thickness of the film is 60 μm or less, it is not practical because the film tends to be broken during bending, and the thickness is 1
If the thickness is 50 μm or more, problems will occur in the water resistance and heat resistance of the product.

The phenol resin-impregnated base material is required to have adhesiveness with a thermoplastic film, and is a material obtained by impregnating and drying a phenol resin on a base material such as kraft paper or other commonly used paper. To improve bending workability, plasticizers such as polyvinyl butyral, "glucosider" (trade name), aliphatic epoxy compounds, paratoluene sulfonic acid amide, etc. are added, and the molar ratio of formalin to phenol is reduced. By doing so, plasticity is imparted.
A water-soluble phenolic resin is particularly preferably used because it has a particularly excellent impregnation property into the substrate. The base material may be any as long as it is well impregnated with the phenol resin varnish, but a paper base material such as kraft paper is usually used, and its basis weight is about 100 to 200 g / m ² . The outermost layer is a decorative layer in which a melamine resin is impregnated into a base material into which a pigment is incorporated, and it is preferable to add a plasticizer in order to impart bendability.

In the present invention, by alternately laminating a plurality of phenol resin-impregnated papers (usually 4 to 6 sheets) and an ABS film, it is possible to obtain a thick decorative board having an arbitrary thickness and good bending workability. it can. When the phenol resin-impregnated base material and the ABS film are used as one constituent unit, the laminated thickness thereof is preferably in the range of 0.6 to 1.6 mm, which is the same as the thickness of a general postform decorative board. The heat and pressure molding can be carried out by a normal hot cold press.

When the thick decorative sheet thus obtained having good bending workability is to be bent, it is used A
Bending is performed by heating to a temperature not lower than the heat distortion temperature of the BS film. That is, as shown in FIG. 1, at least one of the surfaces is used as the decorative layer (1) and the ABS film (3) is arranged between the phenol resin-impregnated base material layers (2) to form the ABS film layer. As a slipping layer, the phenol resin-impregnated base material layers are displaced from each other, and a decorative board having a stepwise bent end is obtained. This end can be processed into a smooth surface by cutting after hardening.

[0014]

【Example】

Example 1 A 120 g / m ² basis weight decorative paper was impregnated with a melamine resin for postform and dried, and a decorative layer having a resin content of 50% was placed on a mirror surface plate, and the thickness after heating and pressing was 1 0.0 m
Five pieces of kraft paper having a basis weight of 195 g / m ² adjusted to have m were laminated with an impregnated paper having a resin content of 35% obtained by impregnating and drying a water-soluble phenol resin for postform. Next, an ABS film having a water absorption rate of 4% and a thickness of 110 μm is overlaid, the construction of the phenol-impregnated paper layer and the ABS film layer is repeated 10 times, and the thickness after heating and pressing is 1.
Five sheets of phenol-impregnated paper having a thickness of 0 mm were stacked, a decorative layer obtained by impregnating and drying the same melamine resin as described above was stacked, and a mirror surface plate was arranged. By heating and pressing these, thickness 1
A 2.0 mm thick decorative plate was obtained. The heating and pressurizing conditions are 160
° C., is 100kg / cm ^2, 30 minutes.

<< Comparative Example 1 >>
60 sheets of phenol-impregnated paper were stacked without using the S film, and a thick decorative sheet having a thickness of 12.0 mm was obtained in the same manner as in Example 1.

<< Comparative Example 2 >>
A thick decorative board having a thickness of 13.5 mm was obtained in the same manner as in Example 1 except that a polycarbonate film (thickness: 0.25 mm) having a water absorption rate of 0.5% was used instead of the S sheet.

<< Comparative Example 3 >>
A thick decorative board having a thickness of 13.5 mm was obtained in the same manner as in Example 1 except that a polyester film (thickness: 0.25 mm) having a water absorption rate of 1.0% was used instead of the S sheet.

In each of the above examples, gravure printing paper was used as the decorative paper for the surface layer. Each of the obtained decorative plates was evaluated for bending workability, appearance after heating and pressing, and water resistance, and the results shown in Table 1 were obtained.

[0023]

[Table 1]

The bending condition was that the temperature of the decorative plate was heated to 130 to 150 ° C. by a hot press and the bending process was performed by a bending roll.

[0025]

The bendable thick decorative plate of the present invention is
The ABS film arranged between the core layers made of thermosetting resin-impregnated base materials such as multiple sheets of phenol resin-impregnated paper softens during bending and acts as a sliding layer, and the thermosetting resin-impregnated base material core layers mutually It has a very good bending workability because it causes a deviation.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a thick decorative board according to the present invention.

[Explanation of symbols]

 1 Decorative layer 2 Phenolic resin impregnated base material layer 3 ABS film

Claims (2)

[Claims] 1. A plurality of base materials impregnated with a phenol resin and an ABS film having a water absorption of 2.5 to 6% are alternately arranged, and a melamine resin-impregnated base material is overlaid on one or both surfaces. , A thick melamine resin decorative board having a thickness of 3 to 15 mm which can be bent by heating and pressing. 2. The ABS film has a thickness of 60 to 150 μm.
The decorative plate according to claim 1, which is m.