JPH09277449A - Thermosetting resin decorative material and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a thermosetting resin decorative material having a sharp printing layer excellent in design effect and a surface protective layer excellent in physical properties such as scratch resistance of the like and chemical properties such as water resistance or the like by constituting a thermal adhesive resin layer so as to have the close adhesiveness to a thermosetting resin applied to or infiltrated into impregnated paper. SOLUTION: In a thermosetting resin decorative material 1 wherein a thermosetting resin impregnated paper layer 2, a thermal adhesive resin layer 5, a printing layer 4 and a transparent heat-resistant film layer 3 are successively laminated from below, the thermal adhesive resin layer has the close adhesiveness to a thermosetting resin applied to or infiltrated into the impregnated paper layer 2. The printing layer 4 is composed of a pattern printing layer 4a having arbitary patterns such as grain patterns or stone grain patterns formed thereto by printing or a solid printing layer 4b having printing applied to the entire surface thereof and ink forming the printing layer 4 is prepared by kneading a coloring agent being pigment or dye, a plasticizer, a stabilizer, other additives, a solvent or a diluent with vehicle. The thermal adhesive resin layer 5 is composed of a polyester urethane resin with a glass transition temp. of 45-50 deg.C.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a thermosetting resin decorative material which is used as a surface material for various kinds of furniture, interior materials for construction, etc., which has high designability and excellent surface physical properties. .

[0002]

2. Description of the Related Art Conventionally, as a thermosetting resin decorative material that is attached to the surface of a base material such as a building material or furniture for the purpose of decoration or surface protection, a printing pattern is provided on a printing sheet such as titanium paper. After making a decorative paper, melamine resin, diallyl phthalate resin, polyester resin, impregnated with a thermosetting resin such as a phenol resin, to make an impregnated paper to apply, laminated core paper, impregnated paper, overlay paper in this order, A thermosetting resin material type is known, which is produced by heating, pressurizing, and curing.

However, in the thermosetting resin material type as described above, the physical properties of the surface protective layer are scratch resistance,
It has excellent physical properties such as abrasion resistance and chemical properties such as water resistance, solvent resistance, and chemical resistance, but it cannot be post-processed. Since it uses a porous mixed paper with excellent resin impregnation properties, it has poor surface smoothness and lacks printability due to too good ink absorption, resulting in poor clear and precise printing and poor design. There was a problem.

In order to deal with such inconvenience, after a polyester film having a pattern printing layer and a polyester film having a heat-adhesive resin layer are laminated with an adhesive, a thermosetting resin is impregnated and applied. A method of laminating the impregnated paper and the heat-adhesive resin layer of the laminated polyester film so as to face each other, heating and pressurizing and curing is attempted, but in this case, it is clear and precise as a pattern printing layer. Although it can be printed and is excellent in design, it requires two polyester films, and the manufacturing process is complicated, resulting in poor productivity and high cost.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide a clear and precise printing layer having excellent designability and a surface protective layer. In terms of physical properties, it has excellent physical properties such as scratch resistance and abrasion resistance, and chemical properties such as water resistance, solvent resistance, and chemical resistance. Furthermore, it is a thermosetting material that can be postformed even in post-processing. To provide a resinous resin decorative material at low cost.

[0006]

Means for Solving the Problems The means for achieving the above-mentioned object of the present invention is to laminate a thermosetting resin-impregnated paper layer, a heat-adhesive resin layer, a printing layer, and a transparent heat-resistant film layer in this order from the bottom. In the thermosetting resin decorative material, the thermosetting resin layer has adhesiveness to the thermosetting resin applied or impregnated on the impregnated paper. With this structure, the transparent heat-resistant film is provided with the pattern print layer, and thus a clear and precise pattern excellent in design can be obtained. In addition, since the decorative sheet is formed by laminating the heat-adhesive resin layer on the pattern print layer surface of the transparent heat-resistant film, the manufacturing process can be simplified and the productivity is improved.

The heat-adhesive resin layer is a polyester type urethane resin having a glass transition temperature of 45 to 50 ° C. In this case, the thermosetting resin cosmetic material with stable quality can be mass-produced at a low price without the adhesiveness of the cosmetic material obtained being deteriorated due to the variation of the hot-press molding conditions at the time of molding the cosmetic material. .

The transparent heat-resistant film layer is a polyester film.
In this case, the decorative material has a surface excellent in transparency, heat resistance, scratch resistance, water resistance, solvent resistance, and stain resistance.

Further, the transparent heat-resistant film layer is provided with an uneven shape on its upper surface. By doing so, it is possible to impart a design property closer to that of the real product.

The thermosetting resin decorative material of the present invention uses, as a base material, an impregnated paper obtained by coating or impregnating an uncured thermosetting resin on a paper-based base material, and applying a pattern on one surface of the base material. As the heat-adhesive resin layer of the decorative sheet formed by applying the heat-adhesive resin having adhesiveness to the thermosetting resin on the surface of the pattern print layer of the transparent heat-resistant film provided with the print layer faces It is obtained by a method for producing a thermosetting resin decorative material, which is obtained by heating, pressurizing, and curing while overlapping.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, specific embodiments of the present invention will be described with reference to the drawings. 1 is a cross-sectional view showing an embodiment of a thermosetting resin decorative material according to the present invention, and FIG. 2 is a cross-sectional view illustrating a manufacturing process of the thermosetting resin decorative material of the present invention.
FIG. 3 is a cross-sectional view showing another embodiment of the thermosetting resin decorative material according to the present invention, in which 1 and 1'are thermosetting resin decorative materials,
2 is a thermosetting resin-impregnated paper, 3 is a transparent heat-resistant film, 4
Is a print layer, 4a is a pattern print layer, 4b is a solid print layer, 5 is a heat-adhesive resin layer, 6 is a decorative sheet, 7 is a recess, and 10 is a heating plate.

As shown in FIG. 1, the constitution of the thermosetting resin decorative material 1 of the present invention is, as shown in FIG.
The heat-adhesive resin layer 5, the solid print layer 4b, the print layer 4 including the pattern print layer 4a, and the transparent heat-resistant film 3 are laminated, and the thermosetting resin decorative material 1 has the following features.
Printing layer 4 on 3 sides of transparent heat-resistant film as a surface protection layer
And a decorative sheet 6 having a heat-adhesive resin layer 5 made of a polyester-based urethane resin having a glass transition temperature of 45 to 50 ° C. applied to or impregnated with an uncured thermosetting resin on a paper-based base material. Since it is placed on the impregnated paper 2 and heat-pressed, the manufacturing process can be simplified and the adhesive strength is stable.

The method of manufacturing the thermosetting resin decorative material 1 will be described below. First, in the present invention, FIG.
As shown in FIG. 5, the transparent heat-resistant film 3 has a print layer 4a and a heat-adhesive resin layer 5 each including a pattern print layer 4a and a solid print layer 4b.
The thermosetting resin-impregnated paper 2 in which the uncured thermosetting resin is applied or impregnated on the decorative sheet 6 provided with and the paper-based base material is prepared. Next, as shown in FIG. 2B, the heat-adhesive resin layer 5 of the decorative sheet 6 and the thermosetting resin-impregnated paper 2 are laminated so as to face each other, and the heat-adhesive resin layer 5 and the heat-curable resin-impregnated paper 2 are placed between the heated heating plates 10. Insert into and heat and pressurize. The thermosetting resin layer 5 of the decorative sheet 6 and the thermosetting resin of the thermosetting resin-impregnated paper 2 are heat-bonded to each other to obtain the thermosetting resin decorative material 1 of the present invention as shown in FIG. To be

The thermosetting resin-impregnated paper 2 used as the base material of the thermosetting resin decorative material 1 of the present invention has a weight of 50 to 1
It is obtained by coating or impregnating a thermosetting resin on titanium paper, kraft paper, etc. of 00 g / m ² . In this embodiment, titanium paper is impregnated with unsaturated polyester resin and diallyl phthalate resin. As the thermosetting resin, melamine resin, phenol resin, or the like can be used as well.

The transparent heat-resistant film 3, which is the outermost layer of the thermosetting resin decorative material 1, is made of polyethylene terephthalate resin. Since the transparent heat-resistant film 3 functions as a protective layer for the thermosetting resin decorative material 1, the material is selected considering heat resistance, scratch resistance, solvent resistance, stain resistance, etc. There is a need to. In addition, the transparency is set according to the type and color of the design in consideration of decorativeness. A translucent resin may be used depending on the design. Examples of resins satisfying such conditions include polyesters such as polyethylene terephthalate, polycarbonate, and nylon.

The print layer 4 is composed of a pattern print layer 4a on which an arbitrary pattern such as a wood grain pattern, an abstract pattern or a stone pattern is formed by printing, and a solid print layer 4b printed on the entire surface, and forms the print layer 4. The ink is prepared by kneading a vehicle with a coloring agent such as a pigment or a dye, a plasticizer, a stabilizer, other additives, a solvent or a diluent. As a suitable material for the vehicle, a known unsaturated polyester resin, a two-component curable acrylic urethane, and a curable resin such as a polyester urethane resin can be used.

The thermosetting resin decorative material 1 having the above-mentioned structure is formed on the transparent heat-resistant film 3 on the upper surface of the thermosetting resin-impregnated paper 2 in which an uncured thermosetting resin is applied or impregnated on a paper base material. The print layer 4 including the print layer 4a and the solid print layer 4b and the heat-adhesive resin layer 5 of the decorative sheet 6 provided with the heat-adhesive resin layer 5 are placed so as to face the thermosetting resin-impregnated paper 2.
It is manufactured by heating and pressurizing with a belt press molding device. The press plate may be either a mirror surface plate or an embossed plate provided with an uneven shape. The temperature, pressure, time, etc. applied in this thermocompression molding are 100 to 180 ° C., preferably 1
The temperature is 30 to 160 ° C., the pressure is 1 to 50 kg / cm ² , preferably ² to 30 kg / cm ² , and the time is 30 seconds to 10 minutes, preferably 1 to 5 minutes. Although a continuous thermosetting resin decorative material can be obtained by belt press molding, single-wafer press molding may be performed.

The thermal adhesive resin layer 5 has a glass transition temperature of 45.
It is made of polyester-based urethane resin in the range of up to 50 ° C. and is used for adhering the transparent heat-resistant film 3 as the surface protection layer and the thermosetting resin-impregnated paper 2 as the base material under the hot press molding conditions. Is preferably a resin that can be bonded in a so-called short cycle of about 150 ° C./1 minute or less. When the glass transition temperature is 50 ° C. or higher, the adhesive strength is significantly reduced with time and sufficient adhesion cannot be obtained. On the other hand, when the glass transition temperature is 45 ° C. or lower, adhesion after hot pressing is performed. The heat resistance of the layer is extremely lowered, and the non-adhesiveness after coating and drying is insufficient, so that the decorative sheet is easily blocked.

Examples of the polyester-based urethane resin constituting the heat-adhesive resin layer 5 in the present invention include glycols such as ethylene glycol, propylene glycol, neopentyl glycol and 1,6 hexane glycol, and adipic acid, isophthalic acid, It comprises a linear block copolymer obtained by the reaction of a polyester polyol obtained by a polycondensation reaction with a dibasic acid such as terephthalic acid and an isocyanate such as tolylene diisocyanate, hexamethylene diisocyanate and 4,4′-diphenylmethane diisocyanate.

FIG. 3 is a sectional view showing another embodiment of the thermosetting resin decorative material 1 of the present invention. The thermosetting resin decorative material 1'of the present invention is a transparent heat resistant film 3 as shown in FIG.
The recess 7 may be provided on the upper surface of the. For example, by printing the pattern print layer 4a in a wood pattern, the transparent heat-resistant film 3
When the concave portion 7 provided on the upper surface of the is formed into a wood grain conduit pattern, it is possible to impart a design property of the wood grain having a three-dimensional conduit pattern.

The decorative board in which the thermosetting resin decorative materials 1 and 1'of the present invention are laminated on plywood, MDF or the like by using an emulsion type adhesive or the like has heat resistance, scratch resistance, solvent resistance and stain resistance. Since it has excellent surface physical properties such as, it can be used for surface makeup of various interior materials such as furniture, cabinets and doors.

Example 1 A solid printing layer and a wood grain pattern printing layer were printed on a polyester film having a thickness of 50 μm with an ink composed of a two-component curing type polyester polyol resin by a gravure printing machine, and a glass transition temperature of 48 was further printed on the upper surface thereof. Coating amount of thermo-adhesive resin layer made of polyester type urethane resin at ℃ (dry)
A coating was applied to give a decorative sheet having a weight of 5 g / m ² . Next, an unbleached kraft paper with a weight of 80 g / m ² was impregnated with an unsaturated polyester resin so that the resin ratio was 120%, to prepare a resin-impregnated paper. Next, the printed polyester film is laminated so that the heat-adhesive resin layer side is in contact with the resin-impregnated paper, set in a hot press, and the temperature is 150 ° C.
Heat and pressurize at a pressure of 12 kg / cm ^{2 for} 1 minute to mold,
A thermosetting resin decorative material having excellent surface properties and excellent design was obtained.

[0023]

As described above, the thermosetting resin decorative material of the present invention is formed of a synthetic resin that exhibits good adhesion to the thermosetting resin in the impregnated paper as the base material. Since a transparent heat-resistant film provided with an adhesive resin layer is laminated on the base material and thermocompression-molded,
The quality of the cosmetic material obtained is uneven due to variations in the amount of thermosetting resin impregnated in the thermosetting resin-impregnated paper and non-uniformity of the paper quality of the paper-based base material used in the thermosetting resin-impregnated paper. In addition, since a pattern printing layer is provided on the transparent heat-resistant film surface, it is possible to obtain a thermosetting resin decorative material that has a clear and precise printed pattern and is excellent in design and uniform in quality. Can be done.

Since the heat-adhesive resin layer is formed of a polyester urethane resin having a glass transition temperature in the range of 45 to 50 ° C., the decorative material obtained by the variation of the thermocompression molding conditions at the time of molding the decorative material. The thermosetting resin decorative material with stable quality can be efficiently produced by the continuous belt press system without the adhesiveness being deteriorated, and the thermosetting resin decorative material can be mass-produced at low cost.

Further, since the surface of the thermosetting resin decorative material is formed of a polyester film having excellent transparency, heat resistance, scratch resistance, water resistance, solvent resistance and stain resistance, the conventional heat A curable resin decorative material with bending workability that does not easily crack or chip corners as in the past, has significantly improved handleability, and is a durable and versatile decorative material. You can

Further, the texture of the pattern can be enhanced by forming the unevenness on the upper surface of the transparent heat-resistant film according to the pattern. For example, if the design is wood grain, the portion corresponding to the conduit is made a recess to give a warm impression as if it were a real tree, and if it is stone or sand, fine unevenness is formed. The inorganic impression can be enhanced, and a highly designed thermosetting resin decorative material can be obtained.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a thermosetting resin decorative material of the present invention.

FIG. 2 is a cross-sectional view illustrating a manufacturing process of the thermosetting resin decorative material of the present invention.

FIG. 3 is a sectional view showing another embodiment of the thermosetting resin decorative material of the present invention.

[Explanation of symbols]

 1, 1'thermosetting resin decorative material 2 thermosetting resin-impregnated paper 3 transparent heat-resistant film 4 printing layer 4a pattern printing layer 4b solid printing layer 5 heat-adhesive resin layer 6 decorative sheet 7 recess 10 hot plate

Claims (5)

[Claims] 1. A thermosetting resin decorative material in which a thermosetting resin-impregnated paper layer, a thermoadhesive resin layer, a printing layer, and a transparent heat-resistant film layer are laminated in this order from the lower layer, wherein the thermoadhesive resin layer is the A thermosetting resin decorative material having adhesiveness to a thermosetting resin coated or impregnated on impregnated paper. 2. The glass transition temperature of the thermoadhesive resin layer is 4.
The thermosetting resin decorative material according to claim 1, which is a polyester-based urethane resin at 5 to 50 ° C. 3. The thermosetting resin decorative material according to claim 1, wherein the transparent heat-resistant film layer is a polyester film. 4. The thermosetting resin decorative material according to claim 1, wherein the transparent heat-resistant film layer is provided with unevenness on its upper surface. 5. A transparent heat-resistant film having a paper-based base material coated with or impregnated with an uncured thermosetting resin as a base material, and having a pattern printing layer on one surface of the base material. The heat-adhesive resin layer of a decorative sheet obtained by applying a heat-adhesive resin having adhesiveness to the thermosetting resin on the surface of the pattern printing layer is laminated so that the heat-adhesive resin layers face each other, and heat and pressure are applied for curing. A method for producing a thermosetting resin decorative material, comprising: