JPH10138439A - Decorative plate having curable resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance a designing property by virtue of patterns printed on a decorative sheet by a method wherein a basic paper of the decorative sheet is impregnated with a curable resin so that it is made transparent or opaque, then it is possible to visually observe the surface of the basic paper through the transparent or opaque decorative sheet from a front side. SOLUTION: A decorative sheet 4 provided with a picture pattern layer 3 having desired picture patterns by printing on a surface of a basic paper 2 is laminated on a basic material 1 for a decorative laminated plate and the decorative sheet 4 is impregnated with a transparent or opaque curable resin to be cured together with the basic material 1 to be united, thereby forming a curable resin decorative plate. The basic paper 2 of the decorative sheet 4 is made transparent or opaque because of the impregnation of the basic paper 2 of the decorative sheet 4 with the curable resin. As examples of the basic material 1, a reneer, a plywood or glued laminated wood can be used. As the basic paper 2, a transparent paper of a resin impregnated paper of an overlay paper for a melamine resin decorative plate can be used. As the curable resin penetrated to the decorative sheet 4, a melamine resin or a diallyl phthalate resin can be used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a curable resin decorative board for use in interior materials such as walls and fittings of buildings such as houses, furniture, furniture, equipment housings, and the like.

[0002]

2. Description of the Related Art Conventionally, decorative boards used for furniture materials, interior materials and the like include wood-based base materials such as plywood, inorganic base materials such as calcium silicate boards, metal base materials, and synthetic resin base materials. Depending on the application, such as materials, various types of substrates are used, and the surface is directly printed on the surface, a direct-print decorative plate, a transfer decorative plate formed by transferring a pattern using transfer foil, paper or synthetic resin Laminate decorative sheet made by attaching decorative paper or decorative sheet printed on film etc., titanium paper etc. printed and then impregnated with a curable resin such as melamine resin or diallyl phthalate resin are stacked and hot-pressed. There is known a curable resin decorative board or the like formed by integrally molding or laminating a printed titanium paper and forming a curable resin layer such as an unsaturated polyester resin.

[0003] Although the production process of the above-mentioned direct print decorative board is simple, it is difficult to obtain a decorative board excellent in design since a substrate having a hard flat plate shape and often having irregularities on the surface is inferior in printability. It is. The transfer decorative board is improved in terms of the design of the printing, since the transfer foil base material to be printed is a flexible synthetic resin film or the like, but the transfer to the base material having irregularities on the surface is also difficult. Not always easy. In addition, all of these have insufficient surface properties such as abrasion resistance and solvent resistance since the surface is a picture layer such as ink.

[0004] Laminated decorative boards have poor strength in the case of paper-based decorative paper, and therefore have drawbacks in adhesive tape resistance, abrasion resistance and the like. Even in the case of a decorative sheet using a synthetic resin film, since the synthetic resin film suitable for printing is generally made of a flexible thermoplastic resin, its surface properties such as solvent resistance, stain resistance, heat resistance, and abrasion resistance. Is not always enough. Further, in the case of using a nonflammable base material such as an inorganic base material, there is also a problem that the nonflammability is impaired by sticking a combustible decorative paper or a decorative sheet.

On the other hand, the curable resin decorative plate, on which a pattern is printed, is printed on titanium paper having excellent printability, so that it is easy to provide a beautiful pattern with designability. Is impregnated with the substrate and cured and integrated, so that sufficient interlayer strength and adhesion to the substrate can be obtained. Moreover, because the surface is a curable resin, solvent resistance and stain resistance,
In terms of surface properties such as heat resistance and abrasion resistance, very excellent performance can be obtained.Curable resins are also generally excellent in heat resistance and flame retardancy, so the incombustibility of noncombustible base materials is remarkable It has many advantages, such as not being damaged.

[0006] In a conventional curable resin decorative board, titanium paper is generally used as a printing base paper as described above. This takes into account not only the impregnating property of the curable resin but also the concealing property so that the design property of the printed pattern is not reduced by the color tone, shading, etc. of the substrate surface. However,
For this reason, a decorative curable resin decorative plate utilizing the texture of the underlying substrate has not been obtained.

[0007]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems in a conventional curable resin decorative board, and has been developed by utilizing a texture of a base material of a base material and printing a pattern on the base material. It is an object of the present invention to provide a curable resin decorative board having excellent design properties in which is added.

[0008]

Means for Solving the Problems The curable resin decorative board of the present invention has a decorative paper laminated on a base material, and the decorative paper is impregnated with a transparent or translucent curable resin, and is cured integrally. In the cured curable resin decorative board, the base paper of the decorative paper is made transparent or translucent by impregnation with the curable resin.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a curable resin decorative board according to the present invention will be described in detail with reference to the drawings. 1 to 4 are side sectional views each showing an embodiment of the curable resin decorative board of the present invention.

[0010] The curable resin decorative board of the present invention is, for example, shown in FIG.
As shown in FIG. 1, a decorative paper 4 having a pattern layer 3 of a desired pattern provided by printing or the like on a surface of a paper base 2 is laminated on a surface of a decorative substrate 1. A transparent or translucent curable resin 4 is impregnated in the resin 4 and cured and integrated with the substrate 1. The purpose is that the base paper 2 of the decorative paper 4 is made transparent or translucent by impregnation with a curable resin.

As the substrate 1, any plate-like material conventionally used as a substrate of a decorative board can be used. Specifically, for example, wood veneer, plywood, veneer laminate, laminated wood, medium density fiberboard, particle board,
Wood-based base materials such as hardboard, glass, ceramics, gypsum board, calcium silicate board, slag cement board, slag gypsum board, wood-based cement board, slate board, inorganic base material such as lightweight aerated concrete board, iron, aluminum, A metal-based substrate such as stainless steel, a synthetic resin-based substrate such as a polyolefin resin, an acrylic resin, a polyester resin, a polystyrene resin, a polycarbonate resin, a polyvinyl chloride resin, and an ABS resin can be used. The thickness is not particularly limited, and depends on the type and use of the base material,
The range of about 1 to 30 mm is most common.

The paper substrate 2 used for the decorative paper 4 to be laminated on the surface may be any paper that can be made transparent or translucent by impregnation with a transparent or translucent curable resin described later. Preferable specific examples include, for example, transparent paper conventionally used as a base paper for resin impregnation of overlay paper for melamine resin decorative boards. This is a relatively bleached paper made from highly bleached long-fiber pulp, which has a large amount of internal space and is easily impregnated with resin.Also, since there are few colored impurities, the internal space is filled with impregnated resin. By suppressing irregular reflection of light on the fiber surface, the fiber is likely to be transparent.

Various thicknesses having a basis weight of about 30 to 200 g / m ² are commercially available, and any one of them is optional depending on the required degree of transparency.
As the thickness increases, the transparency decreases and the texture of the underlying substrate tends to be lost. Therefore, generally, the thickness is preferably smaller, and about 30 to 60 g / m ² is more preferable. In addition, other than the above-mentioned transparent paper, any material that can be made transparent or translucent by impregnation with a curable resin may be used. Even thin paper, Japanese paper, woven fabric or nonwoven fabric, etc., is thin and sufficiently bleached. Any resin can be used as long as it is easily impregnated with the resin.

The pattern layer 3 provided on the surface of the paper substrate 2 can be provided by any means such as a printing method such as a gravure printing method or an offset printing method, a coating method, and a transfer method, as in the conventional case. However, it is necessary that at least the surface of the underlying base material 1 be transparent when the decorative board is manufactured. For this purpose, for example, a transparent or translucent printing ink or a coating agent or the like obtained by dispersing a colorant such as a transparent or translucent dye or pigment in a transparent or translucent binder resin is used. Although a method can be used, even an opaque ink or the like can be made substantially transparent or translucent by providing a pattern in a discontinuous pattern such as a halftone dot. According to the general printing method, especially when consciously performing concealed solid printing or excluding the case of providing a high-density pattern close to black, etc., usually one of the above conditions is satisfied, so the problem is Absent.

The type of the pattern of the pattern layer 3 is not particularly limited, and any desired pattern can be used depending on the purpose of use and the taste of the user. When the material is a wood grain pattern or a conduit pattern, and when the base material 1 is an inorganic base material, a stone pattern, a sand pattern, a stucco pattern,
It is preferable to make the pattern according to the texture of the surface of the base material 1 such as a mortar coating pattern, a bare concrete pattern, or the like.

As a method of laminating the decorative paper 4 on the base material 1, for example, as in the case of the conventional titanium paper, the decorative paper 4 may be bonded via an appropriate adhesive. The type of the adhesive is not particularly limited, and any conventionally known adhesive can be applied. However, from the viewpoint of physical properties, it is preferable to use a curable adhesive. However, in the conventional curable resin decorative board, an opaque adhesive containing a pigment, a filler or the like was used for the purpose of supplementing the concealing property of the titanium paper. It is necessary to use a transparent or translucent adhesive that can see through the base material 1.

Further, as has been widely practiced with melamine resin decorative boards and the like, a decorative paper 4 is impregnated with a curable resin in advance before lamination, or via a separately prepared curable resin impregnated paper. It is also possible to laminate the decorative paper 4 on the base material 1 without using an adhesive by a method of overlapping the base material 1 with the decorative paper 4.

In addition, when the curable resin is impregnated after the decorative paper 4 is adhered to the base material 1 such as a decorative polyester resin board, the curable resin to be impregnated into the decorative paper 4 later is used. It can be used as a substitute for the adhesive. That is,
After a curable resin is applied to the front surface of the base material 1 or the back surface of the decorative paper 4, the base material 1 and the decorative paper 4 can be laminated and fixed via the curable resin. By doing so, the curable resin impregnated later and the curable resin applied instead of the adhesive are well adapted to each other and cured and integrated, which is advantageous in terms of transparency and strength.

Prior to laminating the decorative paper 4 on the surface of the substrate 1, the surface of the substrate 1 is subjected to, for example, a polishing treatment, a sealer treatment, a bleaching treatment, a coloring treatment, a filling treatment, a degreasing treatment, and a rust prevention treatment. It is optional to perform well-known substrate adjustment processes such as ultraviolet treatment, radiation treatment, corona treatment, ozone treatment, flame treatment, primer treatment, anchor treatment and the like as necessary.

The curable resin impregnated in the decorative paper 4 includes
For example, thermosetting resins such as melamine-based resins, diallyl phthalate resins, unsaturated polyester resins, urethane-based resins, epoxy-based resins, and room-temperature-curable resins, acrylic resins, polyester-based resins, epoxy-based resins, and thiol-
An ionizing radiation curable resin such as an olefin resin can be used. After the curable resin is applied to and impregnated in the decorative paper 4, it is crosslinked or polymerized and cured by performing a treatment such as heat treatment, standing at room temperature, irradiation of ultraviolet rays or electron beams, and integrated with the base material 1 and the decorative paper 4. A decorative board is obtained.

In order to protect the design layer 3 of the decorative paper 4 from contamination, abrasion, etc., it is not preferable that the design layer 3 is exposed on the surface. For example, as shown in FIG. It is preferable that a transparent or translucent curable resin layer 5 is further provided on 4. The curable resin layer 5 may be the same kind of resin as the curable resin impregnated in the decorative paper 4 or a different kind thereof, and may be separately provided after the decorative paper 4 is impregnated and cured with the curable resin. is there. However, if the curable resin impregnated in the decorative paper 4 is a resin different from the curable resin, or if the curable resin impregnated in the decorative paper 4 is laminated after being cured, the adhesiveness between the resins is not sufficient, or the manufacturing process becomes difficult. It is preferable to use the same kind of resin and to cure simultaneously using the same type of resin.

Specifically, for example, when the decorative paper 4 is impregnated with a curable resin and then laminated on the substrate 1, a curable resin-impregnated paper (overlay paper) prepared separately is further laminated on the surface thereof and cured. An integrating method or the like can be used. When the curable resin is impregnated on the base material 1 after the decorative paper 4 is attached, the curable resin is applied in excess of the impregnated amount on the decorative paper 4 and the decorative paper 4 is not impregnated. A method of leaving the curable resin in a layer on the surface can be used. The former is a melamine resin decorative board or the like, and the latter is a polyester resin decorative board or the like.

The thickness of the curable resin layer 5 is not particularly limited. Although a thicker layer is more advantageous in terms of abrasion resistance and solvent resistance, if it is too thick, the material cost of the resin increases and the price increases. It is disadvantageous in view of the above, and sometimes the internal residual strain after curing becomes large and the impact resistance is reduced. For example, in the case of a polyester resin decorative board, it is generally selected in the range of about 20 μm to 2 mm. In particular, the range of about 200 to 700 μm is considered to be most suitable.

As shown in FIG. 3, for example, as shown in FIG. 3, the surface of the curable resin decorative plate of the present invention can be embossed 6 to give a three-dimensional design. Although FIG. 3 shows an example in which the curable resin layer 5 is provided on the decorative paper 4, the emboss 6 can be applied even when the curable resin layer 5 is not provided.

As a method of forming the embossment 6, as is well known in the art, it is often difficult to apply the embossment before or after the curable resin layer 5 is cured. It is preferable to use a method in which the embossing 6 is applied and then completely cured, or a method in which an embossed plate or a shaping film or the like is stacked in an uncured or semi-cured state and peeled and removed after complete curing. The latter method is a technique commonly used as a film method on a conventional polyester resin decorative board or the like.

Examples of the method for producing the embossing plate include: an engraving method for imparting a concavo-convex pattern to a metal plate material by hand engraving or mechanical engraving; a resist pattern made of a photosensitive resin or the like on the surface of the metal plate material to cause corrosion. Conductive on the surface of a corrugated manuscript such as natural wood or natural stone, or a master mold molded from it with room temperature curing silicone rubber, etc. by vapor deposition or silver mirror method, etc. An electroforming method of forming a conductive thin film and plating a metal layer on the surface thereof is used.

As a method of manufacturing the imprinting film, for example, a concavo-convex pattern is extracted from a concavo-convex original such as a natural wood by a photoengraving method, and a thick plate printing is performed on a suitable support film by a screen printing method or the like. A printing method, a molding method in which a molding resin layer is molded on a support film using a mother die directly from an irregular original or from a concave original is used. In the film method, since the depth of the irregularities of the molding film regulates the thickness of the curable resin layer, if it is too deep, the curable resin layer becomes too thick and may not be physically preferable. In particular, when a molding method using a natural irregularity original is adopted, it is preferable to appropriately adjust by a polishing method or the like so that the irregularities of the imprinting film do not become excessively deep.

As the pattern of the embossing 6, any desired pattern can be provided according to the purpose of use and the taste of the user, similarly to the above-mentioned pattern. When the base material 1 is an inorganic base material, such as stone-grained, sand-grained, stucco-like, mortar-coated, exposed concrete, etc. It is preferable to use a pattern that matches the texture of the surface of the substrate 1. In general, the pattern of the emboss 6 and the pattern of the pattern layer 3 do not always need to be synchronized, but, for example, in the case of a woodgrain or the like, it is more preferable in design to provide both in synchronization. Become.

In addition to the above, as shown in FIG. 4, the filling of the colorant 7 into the groove of the emboss 6 by a wiping method or the like,
The formation of the top coat layer 8 on the surface and the like can be appropriately performed as needed. As the top coat layer 8, any conventionally known top coat agent such as a urethane type, an acrylic type, a polyester type, an epoxy type, a silicone type and a fluororesin type can be used. Further, a gloss adjusting agent such as silica or calcium carbonate is added to the top coat agent to adjust the gloss state of the surface, or a gloss change pattern is formed by a method of forming the top coat agent added with the gloss adjuster into a pattern. It is also optional to add the design property of the above.

[0030]

【Example】

<Example 1> ^On a transparent paper having a basis weight of 40 g / m ^2, a woodgrain pattern was printed by a gravure printing method using a nitrified cotton-based ink to produce a decorative paper. The decorative paper is attached to the surface of a medium-density fiberboard having a thickness of 3 mm via an unsaturated polyester resin, and the surface is further coated with an unsaturated polyester resin. Rolling the unsaturated polyester resin by coating the mold film, peeling and removing the shaping film after heat curing, applying wiping coloring to the embossed concave portions, and applying a urethane-based top coat to the entire surface, the curable resin cosmetic of the present invention I got a board.

The above-mentioned curable resin decorative board is reminiscent of a natural wood, in combination with the wood texture of the medium-density fiberboard of the base material, the wood grain pattern by printing, and the conduit pattern by embossing and wiping. It had excellent design properties, and its surface had excellent surface properties (conforms to the special plywood FM standard of Japanese Agriculture and Forestry Standard) unique to polyester resin decorative board.

Example 2 A decorative paper was prepared by exposing a concrete-like pattern to the surface of transparent paper having a basis weight of 40 g / m ² by gravure printing using a nitrified cotton-based ink. After subjecting the surface of a slag cement board 8 mm thick to a sealer treatment for stopping alkali with a urethane-based sealant, the decorative paper is attached via an unsaturated polyester resin, and the surface of the unsaturated polyester is further After applying the resin, covering the molded film molded from the exposed concrete, rolling the unsaturated polyester resin, peeling off the molded film after heat curing, applying a urethane top coat on the entire surface, The curable resin decorative board of the present invention was obtained.

The above-mentioned curable resin decorative board has an appearance similar to that of real bare concrete due to the combination of the inorganic texture of the base slag cement board and the printed pattern or embossed concrete. In addition, in terms of surface properties as well as incombustibility, the composition sufficiently conformed to the quasi-noncombustibility standard specified in the Ministry of Construction Notification No. 1231 based on the Building Standards Law.

[0034]

The decorative resin curable sheet of the present invention has decorative paper laminated on a base material, and the decorative paper is impregnated with a transparent or translucent curable resin and cured and integrated. In the curable resin decorative plate, the base paper of the decorative paper is made transparent or translucent by impregnation of the curable resin, so that the surface of the base material is made transparent or translucent. Since it is possible to see through the paper from the front side, the unique texture of the surface of the base material is taken into account by the printed pattern applied to the decorative paper, the surface embossing, wiping, etc. applied as appropriate. As a result, it is possible to realize excellent design properties comparable to, for example, natural wood and stone materials.

In addition, since the surface is a curable resin, very excellent properties can be obtained in terms of surface physical properties such as solvent resistance, stain resistance, heat resistance, and abrasion resistance. Even when a nonflammable base material such as an inorganic base material is used as the material, the curable resin generally has excellent heat resistance and flame retardancy, so that the nonflammability of the nonflammable base material is not significantly impaired. . As described above, the curable resin decorative board of the present invention has practically satisfactory performance in both design and physical properties, which cannot be achieved with conventional curable resin decorative boards and laminate decorative boards. It is of high value.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing an embodiment of a curable resin decorative board according to the present invention.

FIG. 2 is a side sectional view showing an embodiment of a curable resin decorative board according to the present invention.

FIG. 3 is a side sectional view showing an embodiment of the curable resin decorative board of the present invention.

FIG. 4 is a side sectional view showing an embodiment of the curable resin decorative board of the present invention.

[Explanation of symbols]

 1 base material 2 paper base material 3 pattern layer 4 decorative paper 5 curable resin layer 6 emboss 7 colorant 8 top coat layer

Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04F 13/18 E04F 13/18 C

Claims (1)

[Claims] A decorative paper laminated on a base material, wherein the decorative paper is impregnated with a transparent or translucent curable resin and is cured and integrated; Wherein the base paper is transparent or translucent by impregnation with the curable resin.