JPH10109383A - Manufacture of decorative board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simplify a manufacturing process and enable a continuous production by applying a blend containing an inorganic filler from one of the faces of a long fiber base material and thermally drying the coat to manufacture a sheet material for a core layer, and further, thermally pressing the molding blank for the core layer. SOLUTION: A long base material 2 fed out from a feed device 1 is transferred by a conveyor roller 3 and at the same time, a thermosetting resin varnish 4 with which an inorganic filler is blended is applied to the upper face of the long base material 2 to a specified film thickness using a coater 5. After that, the coated base material 2 is allowed to pass through a drying device 6 to evaporate moisture or a solvent, and thus the prepreg 8 of a sheet material for a core layer is obtained. After heating, this prepreg 8 is cut to the specified length using a cutter 7 or may be used for continuous molding without cutting. The sheet material 8 for the core layer obtained as described is heated and pressed into formings in combination with a sheet material for surface decoration and a sheet for reinforcement in accordance with the thickness and formula of a decorative board.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board mainly used as an interior material for various uses.

[0002]

2. Description of the Related Art The demand for non-combustible and semi-non-combustible decorative panels in the market for decorative panels used as interior materials is increasing.
The decorative plate used for it contains a non-combustible base material such as a calcium silicate plate with a decorative layer on its surface, or a glass nonwoven fabric or glass woven fabric as a base material and contains an inorganic filler such as aluminum hydroxide and a resin. In most cases, the products impregnated with the compound are laminated and heated and pressed. A non-combustible substrate such as a silica plate provided with a decorative layer on its surface is lightweight and inexpensive but brittle, and contains an inorganic filler such as aluminum hydroxide and a resin based on a glass nonwoven fabric or a glass woven fabric. Heat-press molding of the laminate impregnated with the compound has a limitation in the impregnation rate of the compound to the glass non-woven fabric or glass woven fabric substrate, and the ratio of the glass substrate in the decorative plate increases. Although it has high strength, it is expensive.

[0003]

SUMMARY OF THE INVENTION The present invention relates to a process for applying a compound containing an inorganic filler such as aluminum hydroxide and a resin to a glass nonwoven fabric or a glass woven fabric as a base material. It is intended to provide an inexpensive decorative board by realizing a thick coating, which was difficult in the method.

[0004]

Means for Solving the Problems According to the present invention, a composition containing an inorganic filler is applied from one side of a long fiber base material and dried by heating to prepare a sheet material for a core material layer. The present invention relates to a method for manufacturing a decorative board, which comprises a step of heating and pressing the core material forming material. The manufacturing process is simple and continuous production is possible. Or more can be obtained.

[0005] In the present invention, an example (schematic sectional view) of a step of applying a compound to a long substrate is shown in FIG. The long base material (2) unwound from the unwinding device (1) is transferred by a transport roller (3), and a thermosetting resin varnish (4) containing an inorganic filler on the upper surface thereof is coated with a coater ( The coating is performed to a predetermined thickness according to 5). As the long base material, a glass fiber woven fabric, a glass fiber nonwoven fabric,
Although not particularly limited, such as synthetic fiber woven or nonwoven fabric, kraft paper, and linter paper, glass fiber woven or nonwoven fabric made of inorganic fibers is preferable from the viewpoint of flame resistance. On the other hand, when workability and cost reduction are particularly required, a cellulosic paper base such as kraft paper or linter paper is preferably used.

As the coater (5), there are a comma roll coater, a knife coater, a die coater, a reverse coater and the like. However, since the coating thickness is as thick as 0.3 to 2.0 mm, it is necessary to increase the viscosity of the compound. There is. For this reason, a method suitable for coating a high-viscosity compound, such as a comma roll coater or a knife coater, is preferred.

After applying a thermosetting resin composition in which an inorganic filler is blended into a long base material, it passes through a drying device (6) to evaporate water and solvent, thereby forming a core material sheet material (prefreg). ) (8) is obtained. The heating and drying conditions vary depending on the amount of resin in the composition, the components and amounts of volatile components, and the thickness of the coating.
Approximately 5 to 15 minutes at １６０160 ° C. After drying, the pre-flag (8) is cut into a predetermined length by a cutter (7). Alternatively, it is also possible to perform continuous molding without cutting.

The core material sheet material thus obtained is combined with a surface decorative sheet material, or a surface decorative sheet material and a reinforcing layer sheet material, depending on the thickness and formulation of the decorative board. It is heated and pressed. The surface decorative sheet material is decorative paper or the like impregnated with melamine resin,
The sheet material for the reinforcing layer is a pre-flag or the like obtained by impregnating a woven glass fiber fabric with a phenol resin or the like. The molding condition at this time depends on the fluidity of the thermosetting resin composition of the obtained core material layer sheet material, but the temperature is 120 to 150 ° C and the pressure is 60 ° C.
It is suitable that the pressure is 110 kg / cm ² and the time is 60 to 120 minutes.

[0009]

The present invention will be specifically described below with reference to examples and comparative examples. << Example 1 >> A glass nonwoven fabric having a basis weight of 75 g / m ² was unwound, and subsequently, a thermosetting resin composition A having the following composition was formed to a thickness of 1.3 mm (after drying) with a comma roll coater. Coated as follows. (Blend of Compound A) 20 parts by weight of phenolic resin 80 parts by weight of inorganic filler (aluminum hydroxide) Thereafter, it was dried at 150 ° C. for 10 minutes with a drying apparatus to prepare a core material layer sheet material. On the other hand, a basis weight of 80 g / m ² of building materials cosmetic base paper melamine resin containing a curing agent to prepare a coating impregnated with dipping decorative layer sheet material B, also curing agent in cosmetic base paper having a basis weight of 80 g / m ² Was applied and impregnated with a melamine resin containing dipping by a dipping method to prepare a sheet material C for a decorative layer. Four sheets of the prepared core material sheet are laminated,
The sheet material B for a decorative layer is layered on the front side and the sheet material C for a decorative layer on the rear side, and the maximum temperature is 140 ° C. and the pressure is 70 kg / c.
It was heated and pressed at m ² for 90 minutes to obtain a decorative plate having a thickness of 3.3 mm.

Comparative Example 1 The thermosetting resin composition A of Example 1 was diluted 1.5 times with water by adding water, and the basis weight was 75 g / m ^2.
The glass nonwoven fabric was applied and impregnated by a dipping method using a glass nonwoven fabric as a base material to obtain a core material layer sheet material. Six sheets of the prepared core material sheet material are laminated, and the decorative material sheet material B is formed on the surface.
Was laminated with a sheet material C for decorative layer on the back surface, and heated and pressed under the same conditions as in Example 1 to obtain a decorative plate having a thickness of 3.2 mm.

As described above, regarding the manufacturing cost of the decorative board obtained in the examples and the comparative examples, the manufacturing method of the examples is simple in the process and the number of expensive glass fiber nonwoven fabrics used is small. The cost was reduced by about 30% as compared with the obtained decorative board.

[0012]

According to the method for producing a decorative board of the present invention, coating with high viscosity is possible, so that it is not necessary to dilute the composition with a solvent, water or the like, and it is possible to apply the composition thickly. Therefore, it is excellent in terms of cost reduction, for example, the ratio of the glass base material in the decorative board can be reduced, and the manufacturing process is simple, so that it is suitable as an industrial decorative board manufacturing method.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view showing a process of manufacturing a core material sheet in a manufacturing process of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Unwinder 2 Long base material 3 Conveyance roller 4 Varnish (with inorganic filler) 5 Coater 6 Drying device 7 Cutter 8 Prepreg

──────────────────────────────────────────────────続 き Continued on front page (51) Int.Cl. ⁶ Identification code FI B32B 27/42 B32B 27/42 31/20 31/20

Claims (2)

[Claims] 1. A sheet material for a core material layer is prepared by applying a thermosetting resin containing an inorganic filler from one side of a long fiber base material and drying by heating. A method for producing a decorative board, comprising superposing a sheet material for surface decoration on a sheet material and subjecting the sheet material to heat and pressure molding. 2. The method according to claim 1, wherein the surface decorative sheet material is a decorative paper impregnated with a melamine resin.