JPH0948091A - Thermoplastic resin decorative sheet and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a thermoplastic resin decorative sheet whose surface physical properties are good, pattern is clear and whose color tone is uniform, and provide also a manufacturing method thereof. SOLUTION: This thermoplastic resin decorative sheet 1 is constituted by laminating PET film 1 with a pattern 12 printed on its lower surface, adhesive 13, interlaminar reinforcing paper 14, and kraft paper 15 with a thermoplastic resin impregnated. After the completion of laminating the PET film 11 and the interlaminar reinforcing paper 14, the kraft paper 15 with thermoplastic resin impregnated is overlapped for thermal molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative plate made of a thermosetting resin, and more particularly to a thermosetting resin decorative plate having a high design property and excellent surface properties.

[0002]

2. Description of the Related Art Thermosetting resin decorative boards used for various furniture surfaces and interior decoration building materials are desired to have excellent durability and decorativeness. Conventionally, thermosetting resin decorative boards have been mainly mixed with an opaque pigment such as titanium oxide in order to enhance the resin impregnation property and have the concealing property (conceal the base material color of the plywood or the like stuck to the lower surface). After making a decorative pattern by forming a printing pattern on the paper, so-called titanium paper, it is impregnated with a thermosetting resin such as melamine resin, diallyl phthalate resin, phenol resin, and laminated in the order of base material, impregnated paper, overlay paper. , And is integrally manufactured by thermocompression molding.

[0003]

The thermosetting resin decorative board prepared as described above has excellent surface physical properties such as heat resistance, chemical resistance, and stain resistance, but it has resin impregnation property. Since it uses a highly mixed porous paper, it has to print on a rough surface, and a sharp and beautiful pattern cannot be obtained. Further, in the case where the overlay paper impregnated with the thermosetting resin is used, it has a feeling of being blurred when viewed from the surface, and there is a problem in terms of decorativeness.

As one method for solving such a problem, the present applicant has previously disclosed in JP-A-60-122149 that the lower surface of a synthetic resin film is made of a synthetic resin having good adhesion to impregnated paper. We have proposed a technology in which a primer layer is formed, a pattern is printed on the lower surface of this primer layer, and it is superposed on impregnated paper and subjected to thermocompression molding. In this method, since the design is printed on the primer layer having a smooth surface, sharp printing can be performed and the sharpness of the design is improved. However, the influence of the rough surface of the impregnated paper at the time of thermocompression molding cannot be completely removed, resulting in an unclear image.

Therefore, in order to improve this point, a thermosetting resin makeup in which a thermoadhesive film is sandwiched between an impregnated paper impregnated with a thermosetting resin and a transparent heat-resistant film on which a pattern is printed. A plate was proposed in Japanese Patent Application No. 7-99097. In this configuration, since the surface roughness of the impregnated paper is absorbed by the heat-adhesive film, the pattern printed on the lower surface of the transparent heat-resistant film is not affected and the sharpness of the pattern is maintained.

However, since the transparent heat-resistant film and the heat-adhesive film have no concealing property, a new problem arises. That is, the impregnated paper as the base is seen through, and the color tone of the impregnated paper greatly affects the impression given by the pattern. Therefore, it is necessary to select the color of the ink used for printing the pattern in consideration of the color of the impregnated paper. Further, since the impregnated paper is a porous mixed paper such as kraft paper, it has unevenness in coloring and uneven coloring, and the thermosetting resin decorative board also has uneven coloring and spoils the aesthetics. Further, there is a slight difference in color between the impregnated papers, which makes it difficult to mass-produce thermosetting resin decorative boards having the same color tone. It is possible to improve the hiding property by printing the pattern on the entire surface of the transparent heat-resistant film, but even in that case, it is not possible to completely hide the impregnated paper, and it is difficult to avoid the above disadvantages. . In addition to this, there is also a problem that the cost is increased by using the two-layer film.

It is an object of the present invention to provide a thermosetting resin decorative board having good surface properties, a clear pattern and a uniform color tone. Moreover, it aims at providing the simple manufacturing method of such a thermosetting resin decorative board.

[0008]

In order to achieve the above object, a thermosetting resin decorative board of the present invention comprises an impregnated paper layer impregnated with a thermosetting resin, a paper layer, and an adhesive in order from the lower layer. The layer and the transparent heat-resistant film layer are laminated. In this laminated thermosetting resin decorative board, the impregnated paper is hidden by the paper layer, and the color tone of the paper layer appears. Further, since the roughness of the surface of the impregnated paper is absorbed by the paper layer, the upper surface of the paper layer and the lower surface of the transparent heat resistant film layer are kept smooth.

A thermosetting resin decorative board may be formed by appropriately combining the following configurations with the thermosetting resin decorative board having this configuration.

A pattern printing layer is provided on the lower surface of the transparent heat-resistant film layer, the upper surface of the paper layer, or both of them. Since the lower surface of the transparent heat-resistant film layer and the upper surface of the paper layer are smooth, the pattern becomes clear.

The paper layer is made of thin paper or inter-paper reinforcing paper having smoothness. These papers have high strength against tensile forces from both sides, and are high-strength thermosetting resin decorative boards. Moreover, when the pattern is printed on the upper surface of the paper layer, the pattern becomes clear.

The transparent heat resistant film layer is composed of a polyester film. When the outermost transparent heat-resistant film layer is a polyester film, the decorative plate has a surface excellent in transparency, heat resistance, scratch resistance, water resistance, solvent resistance, and stain resistance.

Irregularities are formed on the upper surface of the transparent heat-resistant film layer. In this configuration, the refraction of light on the upper surface of the transparent heat-resistant film is not uniform, and the appearance of the picture differs depending on the arrangement of the unevenness and the viewing angle.

Further, in the method for producing a thermosetting resin decorative board having the above-mentioned constitution, a transparent heat-resistant film layer and a paper layer are adhered with an adhesive to form a laminated sheet, and the laminated sheet and the impregnated paper are formed. And are laminated so that the paper layer is in contact with the impregnated paper, and thermocompression molding is performed. The transparent heat-resistant film layer and the paper layer are bonded by the adhesive layer to form a strong laminated sheet. At the time of hot pressing, the thermosetting resin contained in the impregnated paper infiltrates the paper layer, and the impregnated paper and the laminated sheet are attached. By printing a pattern on the lower surface of the transparent heat-resistant film layer or the upper surface of the paper layer, a thermosetting resin decorative board having a clear pattern can be obtained. At this time, since the transparent heat-resistant film layer and the paper layer are firmly adhered by the adhesive layer to form a laminated sheet, the lower surface of the transparent heat-resistant film layer and the upper surface of the paper layer are not affected by thermocompression molding. Since the surface roughness of the impregnated paper is absorbed by the lower surface of the paper layer, the sharpness of the pattern is not impaired by the roughness of the impregnated paper.

[0015]

BEST MODE FOR CARRYING OUT THE INVENTION A cross section of a thermosetting resin decorative board 1 according to a first embodiment of the present invention is schematically shown in FIG. The impregnated paper layer 15, the paper layer 14, the adhesive layer 13, and the transparent heat-resistant film layer 11 are laminated in this order from the lower layer side. Since the transparent heat-resistant film layer 11 is the outermost layer of the thermosetting resin decorative board 1 and functions as a protective layer of the decorative board 1, in addition to heat resistance, scratch resistance, water resistance, It is necessary to select the material in consideration of solvent resistance and stain resistance.
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.

As resins satisfying such conditions, there are polyester such as polyethylene terephthalate (PET), polycarbonate, and nylon. In this embodiment, the transparent heat resistant film layer 11 is formed of a PET film having a thickness of 25 μm. This PET
A pattern 12 is printed on the lower surface of the film 11.

As the paper layer 14, a 30 g / m ² inter-paper reinforcing paper having a smooth surface is used. Here, the paper-reinforced paper is selected from synthetic rubber latex such as acrylic synthetic resin, vinyl synthetic thermoplastic resin, styrene-butadiene copolymer, acrylonitrile-butadiene copolymer, methylmethacrylate-butadiene copolymer and the like. A mixed solution using one or two or more kinds of resins described above, or a mixed solution obtained by mixing a thermosetting resin such as melamine or diallyl phthalate with this mixed solution is made or impregnated at the time of papermaking.

The paper layer 14 preferably has smoothness so as not to impair the sharpness of the design 12, but the design 1
When 2 is intentionally made unclear, the surface may be rough. Further, since the heat-resistant film layer 11 is transparent and the paper layer 14 is seen through, the color thereof greatly affects the color tone of the decorative board 1. Therefore, the color of the paper layer 14 is selected in consideration of the pattern and color of the design 12. Picture 12
The bottom surface of the PET film 11 on which is printed and the inter-paper reinforcing paper 14
Are bonded by a two-component curing type urethane resin adhesive, and the adhesive layer 13 is formed by this adhesive.

As the impregnated paper 15, titanium paper or kraft paper impregnated with a thermosetting resin such as diallyl phthalate resin, unsaturated polyester resin, melamine resin or phenol resin can be used. Here, kraft paper impregnated with unsaturated polyester resin is used. The diallyl phthalate resin and the unsaturated polyester resin have the following characteristics and are particularly preferable.

The melamine resin and the phenol resin need to be cooled once when the thermocompression molding is performed, but the diallyl phthalate resin and the unsaturated polyester resin can be treated while being hot. Therefore, continuous processing such as belt press molding is possible, the processing efficiency is high, and the thermosetting resin decorative plate can be formed continuously. Further, since it has a high bendability even after curing, the thermosetting resin decorative plate can be easily bent and can be easily formed into a curved shape. Therefore, the secondary processing including the process of bending the end portion of the decorative plate is facilitated, and it can be used for a wide range of purposes.

A method of manufacturing the thermosetting resin decorative board 1 will be described with reference to FIG. First, as shown in (a), the pattern 12 is formed on one side of the PET film 11 by printing. Next, a urethane resin adhesive is applied to the surface of the PET film 11 on which the pattern 12 is formed, and after drying, it is superposed on the inter-paper reinforcing paper 14 and pressed to form the PET film 11
And the inter-paper reinforcing paper 14 are bonded. By this dry laminating process, the laminated sheet 17 is formed as shown in (b).

The laminated sheet 17 and the kraft paper 15 impregnated with the unsaturated polyester resin are attached by thermocompression molding. The thermocompression molding may be performed by either single-wafer molding by heating and pressing with a single-wafer pressing machine or continuous molding by heating and pressing with a belt-pressing machine.

At the time of single-wafer forming, as shown in (c), the laminated sheet 17 and the kraft paper 15 are preliminarily cut into appropriate sizes, and sandwiched between the upper and lower press plates 62a and 62b, and 7 to 15 kg / cm. Pressurize to ² and heat plate 61
Heat to 135-160 ° C with a, 61b. By pressurization, a part of the unsaturated polyester resin contained in the kraft paper 15 leaches out and infiltrates the inter-paper reinforcing paper 14,
Cured by heating. In this way, the laminated sheet 17 and the kraft paper 15 are attached, and the thermosetting resin decorative board 1 is obtained. The processing time of this hot press molding is about 5 to 10 minutes. The press plate 62a has a smooth lower surface for mirror surface processing, and the upper surface of the PET film 11, that is, the outermost surface of the decorative plate 11 is smooth.

When performing continuous molding, as shown in (d), the uncut laminated sheet 17 and the kraft paper 15 are superposed and passed between the heating and pressing rollers 71a and 71b.
Although these rollers are shown small in the drawing, they actually have a large diameter, and a wide range of the laminated sheet 17 and the kraft paper 15 is pressed against the surfaces of the rollers 71a and 71b. As a result, a long continuous thermosetting resin decorative board 1 is obtained. Since the roller 71a is for mirror finishing and has a smooth surface, the upper surface of the PET film 11 is also smooth.

The thermosetting resin decorative plate 1 thus constructed has excellent properties such as heat resistance, water resistance, and stain resistance, has no fear of delamination, and has high strength against external force. Is shown. Moreover, since the surface roughness of the impregnated paper 15 is absorbed by the paper layer 14, the pattern 1
The clearness at the time of printing of 2 is maintained even after the thermocompression molding, and it has excellent decorativeness.

A cross section of the thermosetting resin decorative board 2 of the second embodiment is schematically shown in FIG. Transparent heat-resistant film layer 2
1, the material of the adhesive layer 23, the paper layer 24, and the impregnated paper layer 25 are the same as those in the first embodiment, but the PET film 2
The difference is that the lower surface of 1 is printed with two layers. The pattern 22 is a pattern, and is another printed layer 22a.
After printing the pattern 22 and drying it, the PET film 2
1 is a solid print over the entire bottom surface. The entire surface printing layer 22a serves as a background of the design 22, and, for example, has a grain pattern, an abstract pattern, or the like. Further, even if the patterns 22 have the same pattern and the same color, it is possible to obtain a decorative board having a different impression depending on the color of the entire surface printing layer 22a. The thermosetting resin decorative board 2 is manufactured according to the method described in the first embodiment.

FIG. 3 shows a cross section of the thermosetting resin decorative plate 3 of the third embodiment. This decorative plate 3 is made of P having a thickness of 50 μm.
ET film 31, urethane adhesive layer 33, 30 g /
It is formed by laminating m ² thin paper 34 and titanium paper 35 impregnated with diallyl phthalate resin as a thermosetting resin. The lower surface of the PET film 31 is not printed, and the pattern 32 is printed on the upper surface of the thin paper 34. Here, in order to increase the sharpness of the pattern 32,
The thin paper 34 has a high smoothness.

FIG. 4 shows a cross section of the thermosetting resin decorative plate 4 of the fourth embodiment. This decorative plate 4 is made of PE with a thickness of 50 μm.
T film 41, urethane adhesive layer 43, 30 g / m
^{It is} composed of the inter-paper reinforcing paper 44 of No. 2 and the kraft paper 45 impregnated with the unsaturated polyester resin. PET film 4
The pattern 42 is printed on the lower surface of No. 1 and the entire printing layer 42a is formed on the upper surface of the inter-paper reinforcing paper 44.

In this structure, the entire printing layer 42a is the pattern 42
Therefore, the same thing as the above-mentioned second embodiment can be obtained. In addition, here, the pattern 42 and the entire printing layer 42
a is the lower surface of the PET film 41 and the inter-paper reinforcing paper 44, respectively.
Although formed on the upper surface, instead of printing the pattern 42 on the PET film 41, the entire surface printing layer 42 is formed on the inter-paper reinforcing paper 44.
After forming a, the pattern 42 may be formed by printing directly on it.

A cross section of the thermosetting resin decorative plate 5 of the fifth embodiment is schematically shown in FIG. A 25 μm-thick PET film 51, a urethane-based adhesive layer 53, an inter-paper reinforcing paper 54 of 65 g / m ² , and a craft paper 55 impregnated with a diallyl phthalate resin are laminated. The design 52 is printed. Also PE
Unevenness is formed on the upper surface of the T film 51.

FIG. 7 shows a thermocompression molding method for manufacturing the decorative plate 5. Similar to the method described in the first embodiment, the PET film 51 is formed by the dry laminating process.
And the inter-paper reinforcing paper 54 are adhered to each other to prepare a laminated sheet 57. The laminated sheet 57 and the impregnated paper 55 are thermocompression-molded by using a press plate 62c having a projection formed on the lower surface.
The depression 56 is formed on the upper surface of the PET film 51 by the protrusion of the press plate 62c. In the case of continuous molding, instead of the mirror-finishing roller 71a shown in FIG.
A roller having protrusions on its surface may be used. Alternatively,
The concave portion 56 may be formed by sandwiching and pressing a film having a convex portion made of an ionizing radiation curable resin on the lower surface between the roller 71a and the laminated sheet 57.

Since the thermosetting resin decorative plate 5 has unevenness on the surface, the refraction of light is not uniform, and the appearance of the pattern 52 varies depending on the viewing angle. By forming these irregularities in accordance with the design 52, the texture of the design can be enhanced. For example, when the design 52 is wood grain,
By forming the portion corresponding to the wood grain conduit as the concave portion, a three-dimensional effect is generated and a feeling close to that of real wood can be given. Similarly, leather wrinkles, grains, stones, etc. can also be expressed, resulting in a texture-rich pattern.

As described above, in the thermosetting resin decorative board according to the present invention, the impregnated paper is concealed, so that the aesthetic feeling is not impaired due to the uneven color and uneven unevenness that are typical of impregnated paper. Moreover, the roughness of the surface of the impregnated paper does not reduce the sharpness of the picture pattern, resulting in a decorative board with high decorativeness. Further, since the synthetic resin film is not used other than the outermost layer, the cost can be kept low. In the manufacturing method, a laminated sheet is produced by an ordinary dry laminating method, and since the laminated sheet and the impregnated paper are simply thermocompression-molded, it is not necessary to apply an adhesive to the laminated sheet or the impregnated paper. The process does not become complicated.

[0034]

In the thermosetting resin decorative board of the present invention, since the impregnated paper is hidden by the paper layer, the color tone is not affected even if the impregnated paper has uneven color or uneven stain. Since a paper layer having a uniform color and surface property can be adopted, a thermosetting resin decorative plate having a uniform color tone can be obtained.

When a picture is printed as in the structure of claim 2, a clear picture pattern is obtained because the lower surface of the transparent heat-resistant film layer and the upper surface of the paper layer are smooth. Since the roughness of the surface of the impregnated paper is absorbed by the paper layer, the roughness of the impregnated paper does not impair the sharpness of the pattern.

In the third aspect, the strength of the paper layer is high and the strength of the thermosetting resin decorative board is also high. Further, the pattern becomes clear when the pattern is printed on the paper layer, and the aesthetics of the thermosetting resin decorative board is improved.

In the structure of claim 4, the surface of the decorative plate is protected by a polyester film having excellent transparency, heat resistance, scratch resistance, water resistance, solvent resistance, and stain resistance. It is a decorative board with excellent versatility.

In the case of the thermosetting resin decorative plate according to the fifth aspect, the texture of the pattern can be enhanced by forming the unevenness on the upper surface of the transparent heat-resistant film in accordance with 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. It can enhance the inorganic impression.

According to the method for producing a thermosetting resin decorative board of claim 6, a decorative board having high strength can be obtained. In addition, since the transparent heat-resistant film layer and the paper layer are firmly adhered to each other by an adhesive layer to form a laminated sheet prior to the thermocompression molding, the lower surface of the transparent heat-resistant film layer and the upper surface of the paper layer are treated with an impregnated paper of Not affected. That is, the surface roughness of the impregnated paper is absorbed by the lower surface of the paper layer. Therefore, when a pattern is formed on the lower surface of the transparent heat-resistant film layer or the upper surface of the paper layer, the sharpness of the pattern is not impaired by the roughness of the surface of the impregnated paper, and the obtained decorative plate has an excellent aesthetic appearance. It becomes a thing. Moreover, in this method, after the laminated sheet is produced, the laminated sheet and the impregnated paper can be attached by simply thermoforming without applying an adhesive or the like, so that the manufacturing process is simplified. Further, the thermocompression molding can be performed by either single-wafer molding or continuous molding, and a particularly high processing speed can be obtained when performing continuous molding.

[Brief description of drawings]

FIG. 1 is a sectional view of a thermosetting resin decorative plate according to a first embodiment.

FIG. 2 is a cross-sectional view of a thermosetting resin decorative plate according to a second embodiment.

FIG. 3 is a sectional view of a thermosetting resin decorative plate according to a third embodiment.

FIG. 4 is a sectional view of a thermosetting resin decorative plate according to a fourth embodiment.

FIG. 5 is a cross-sectional view of a thermosetting resin decorative plate according to a fifth embodiment.

FIG. 6 is a diagram showing a method for manufacturing a thermosetting resin decorative board of the present invention.

FIG. 7 is a diagram showing another method for manufacturing the thermosetting resin decorative board of the present invention.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Thermosetting resin decorative board 11 PET film (transparent heat-resistant film layer) 12 Design (pattern printing layer) 13 Urethane resin adhesive (adhesive layer) 14 Reinforcement paper (paper layer) 15 Kraft paper (impregnated paper) Layer) 17 Laminated sheet 2 Thermosetting resin decorative plate 21 PET film (transparent heat-resistant film layer) 22 Design (design printing layer) 22a Full-surface printing layer (design printing layer) 23 Urethane resin adhesive (adhesive layer) 24 Inter-paper reinforcing paper (paper layer) 25 Kraft paper (impregnated paper layer) 3 Thermosetting resin decorative board 31 PET film (transparent heat-resistant film layer) 32 Pattern (pattern printing layer) 33 Urethane resin adhesive (adhesive layer) ) 34 thin paper (paper layer) 35 titanium paper (impregnated paper layer) 4 thermosetting resin decorative board 41 PET film (transparent heat-resistant film layer) 42 picture (picture printing layer) 42a Full surface printing layer (pattern printing layer) 43 Urethane resin adhesive (adhesive layer) 44 Paper reinforced paper (paper layer) 45 Kraft paper (impregnated paper layer) 5 Thermosetting resin decorative plate 51 PET film (transparency) Heat-resistant film layer) 52 Design (pattern printing layer) 53 Urethane resin adhesive (adhesive layer) 54 Paper reinforced paper (paper layer) 55 Kraft paper (impregnated paper layer) 56 Recess 57 Laminated sheet

Claims (6)

[Claims] 1. A thermosetting resin makeup characterized in that an impregnated paper layer impregnated with a thermosetting resin, a paper layer, an adhesive layer, and a transparent heat-resistant film layer are laminated in this order from the lower layer. Board. 2. The thermosetting resin decorative board according to claim 1, wherein a pattern printing layer is provided on the lower surface of the transparent heat-resistant film layer, the upper surface of the paper layer, or both of them. 3. The thermosetting resin decorative board according to claim 1, wherein the paper layer is thin paper or inter-paper reinforced paper having smoothness. 4. The thermosetting resin decorative board according to claim 1, wherein the transparent heat-resistant film layer is a polyester film layer. 5. The thermosetting resin decorative board according to claim 1, wherein the transparent heat-resistant film layer has irregularities on its upper surface. 6. A transparent heat-resistant film layer and a paper layer are adhered together with an adhesive to form a laminated sheet, and then the impregnated paper impregnated with a thermosetting resin and the laminated sheet are replaced by the paper layer. A method for producing a thermosetting resin decorative board, which is characterized in that the thermosetting resin decorative board is superposed so as to be in contact with the impregnated paper and is thermocompression molded.