JPH1095091A - Melamine decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To supply a melamine decorative sheet of superior surface design properties inexpensively and with good production efficiency by laminating successively a melamine resin immersed paper and a core layer on the back of a decorative sheet not immersed with resin and heating, pressurizing and integrating. SOLUTION: A melamine resin immersed paper 2 and a core layer 3 are overlapped successively on the back of a decorative sheet 1 not immersed with resin, and the upper and the lower are clamped by a mirror plate and heated, pressurized and integrated to manufacture a melamine decorative sheet. In that case, as a result of permeating melamine resin, which is impregnated into a melamine resin immersed paper 2, is immersed into the decorative sheet 1, superior surface physical properties characterized in the melamine decorative sheet such as surface hardness, resistance to heat, resistance to chemicals and the like not different from the case of impregnating the melamine resin into the decorative sheet 1 itself can be provided. Also when pearl pigment containing ink is used as pattern printing ink, a melamine decorative sheet of high grade design properties demonstrating sufficiently the characterized gloss effect can be manufactured without the troubles of screening and damaging the pearl gloss by an overlaid paper.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a melamine decorative board used for furniture and various building materials. More specifically, the present invention relates to a melamine decorative board which has high production efficiency, can be supplied at low cost, and has excellent surface design.

[0002]

2. Description of the Related Art Conventionally, melamine decorative boards have been used as decorative boards having excellent surface hardness, heat resistance, chemical resistance, surface gloss, etc. among various decorative boards. Widely used for etc. As such a melamine decorative board, a decorative paper obtained by performing a desired pattern printing on a paper surface is impregnated with a melamine resin, and the surface of the decorative paper is an overlay paper impregnated with a melamine resin on a paper that becomes transparent when the resin is impregnated. On the back side, a core layer in which a thermosetting resin such as a phenol resin is impregnated into a paper base material such as kraft paper is superposed, and the core layers are most commonly formed by heating and pressing.

One of the problems of the conventional melamine decorative board having the above structure is that the production process is complicated and the production efficiency is low.
It has been pointed out before. That is, it is necessary to produce a large number of varieties having various patterns as decorative boards according to the difference in use and the taste of customers. However, the uncured melamine resin has low stability and it is difficult to store the decorative paper impregnated with it for a long period of time, so it is necessary to perform the melamine resin impregnation process on the decorative paper little by little. There is a lot of waste of decorative paper to be consumed by the time it is consumed, and a large amount of waste due to excessive impregnation in anticipation of defective printing or impregnation of decorative paper, etc., resulting in poor production efficiency. On the other hand, if a large amount of impregnation is performed at once, the amount exceeding the demand during the storage period is wasted. In any case, there is a problem that the decorative paper impregnated with the resin is wasteful and it is difficult to improve the production efficiency.

As a method for solving such a problem, the step of impregnating the decorative paper with the resin is omitted, the overlay paper is laminated on the surface of the decorative paper not impregnated with the resin, and the core layer is laminated on the reverse surface, respectively. Melamine decorative board
It has already been proposed (see JP-A-48-5866, JP-A-52-100576, etc.). This is because the melamine resin impregnated in the overlay paper is fluidized by heat and a part of the melamine resin penetrates into the decorative paper and is thermally cured and integrated, resulting in a melamine decorative board comparable in performance to the conventional melamine decorative board. The present invention simplifies the manufacturing process by omitting the step of impregnating the decorative paper with the resin, eliminates the waste of the decorative paper, and enables a drastic improvement in production efficiency.

[0005] However, such a melamine decorative board still has an unsolved problem by the above-mentioned method.
That is, in the case of a melamine decorative board in which overlay paper is laminated on the surface of decorative paper, it can be said that the paper serving as the core material of the overlay paper becomes transparent by impregnation with resin, but this is not completely transparent. And some cloudiness remains,
This somewhat masks the pattern printing on the decorative paper surface, making the original vivid pattern on the decorative paper surface slightly turbid, and also causes color unevenness due to uneven thickness of the overlay paper and uneven resin impregnation. This may cause the design to deteriorate.
In particular, in the case of performing pattern printing with pearl pigment-containing ink for the purpose of improving the gloss of the surface pattern, as a result of a thicker resin layer overlapping the pearl pigment-containing ink, its unique gloss effect is reduced, The expected design effect cannot be obtained.

In a melamine decorative board having a structure in which the step of impregnating the decorative paper with the resin is omitted as described above, the amount of resin sufficient to satisfy the physical properties required for the decorative board is determined. It is necessary to secure only the amount of resin impregnated on the overlay paper on the surface, not by resin impregnation, but of course, a sufficiently large amount of resin to ensure the permeability of the resin into decorative paper in the heating and pressing process However, since the resin impregnation rate of the paper serving as the core material of the overlay paper is naturally limited, it is inevitable to use a thick overlay paper. Then, as a result, the haze of the overlay paper increases, the sharpness of the pattern decreases, and the thickness unevenness and resin impregnation unevenness of the overlay paper itself cause color unevenness. Also, if there is unevenness in the state of penetration of the resin from the overlay paper to the decorative paper, as a result, thickness unevenness and residual resin amount unevenness will occur in the overlay paper layer after heat and pressure integration, which also causes color unevenness. Under such circumstances, there has been a problem that it is difficult to obtain a melamine decorative board having a sufficiently satisfactory design without vivid color tone and uneven color.

[0007]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems in the conventional melamine decorative board, and has a high production efficiency and can be supplied at a low cost. An object of the present invention is to provide a melamine decorative board having excellent properties.

[0008]

The melamine decorative board of the present invention is obtained by sequentially laminating a melamine resin-impregnated paper and a core layer on the back surface of a decorative paper not impregnated with a resin, and heating and pressurizing and integrating them. It is.

[0009] In particular, the present invention is one wherein a pearl pigment-containing ink is used as the picture printing ink for decorative paper.

[0010]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The decorative melamine board of the present invention is shown in FIG.
As illustrated in FIG. 1, a melamine resin-impregnated paper 2 and a core layer 3 are sequentially laminated on the back surface of a decorative paper 1 not impregnated with a resin,
It is formed by heating and pressurizing.

The decorative paper 1 is obtained by printing a desired pattern on a highly concealable paper such as titanium paper. Its thickness is 200 g / m ² , the maximum basis weight of a general melamine decorative board.
Thick materials that reach the front and rear are also used, but for the purpose of the present invention, from the viewpoint of resin permeability, a basis weight of 50 to 120 g /
Those of about m ² are suitable. In the case where the melamine resin-impregnated paper 2 or the like described later has a sufficient concealing property, or in a case where the pattern printing itself has a sufficient concealing property,
It is also possible to use thin paper or the like having no concealing property as the decorative paper 1.

The melamine resin-impregnated paper 2 may be any paper obtained by impregnating a suitable paper with a melamine resin, and may be an overlay paper used for a conventional melamine decorative board, Since transparency is not required because of being laminated on the back surface, a material obtained by impregnating a melamine resin with a concealable paper as a core material may be used. However, in the subsequent heating and pressurizing step, it is necessary that the resin content contains a sufficient amount of resin to permeate and integrate into the decorative paper 1, and as the resin, a resin having high fluidity under heating is used. It is preferred to use.

More specifically, a paper having a basis weight of 25 to 120 g / m ² and a melamine resin impregnated in a range of 200 to 400 parts by weight per 100 parts by weight of paper is most preferably used. can do.

As the material of the core layer 3, any material used as a core layer of a conventional melamine decorative board can be used. Specifically, the basis weight is 100 to 200 g / m ^2.
It is most common to use a non-bleached kraft paper impregnated with a thermosetting resin such as a phenolic resin. In the present invention, when the core layer 3 impregnated with a melamine resin having better permeability than the phenol resin is used, the melamine resin lost from the melamine resin impregnated paper 2 due to the penetration into the decorative paper 1 is used as the core. Since it is supplemented from the layer 3, as a result, the permeability of the melamine resin into the decorative paper 1 can be improved, which is effective for shortening the process time, improving the surface strength, preventing uneven penetration, and the like. Usually, on the back surface of the core layer 3,
A backer layer 4 made of resin-impregnated paper for preventing warpage is provided.

As the core layer 3, other than the above, various decorative board base materials such as a metal plate, a synthetic resin plate, a wood veneer, a plywood, a particle board, a medium density fiber board and the like can be used. It is. Further, between the core layer 3 and the melamine resin-impregnated paper 2, one or more resin-impregnated papers of the same type or different from the melamine resin-impregnated paper 2 may be laminated. For example, if a layer of opaque resin-impregnated paper is sandwiched between the core layer 3 and the melamine resin-impregnated paper 2, sufficient concealment can be achieved even when a conventional overlay paper without opacity is used as the melamine resin-impregnated paper 2. It is possible to have the property.

The above-mentioned materials are successively superimposed, and the upper and lower portions are sandwiched by end plates to be heated and pressed together to obtain the melamine decorative board of the present invention. At that time, the melamine resin impregnated in the melamine resin-impregnated paper 2 penetrates into the decorative paper 1, and as a result, the surface hardness, heat resistance, chemical resistance, etc., are the same as when the decorative paper 1 itself is impregnated with the melamine resin. Excellent surface properties unique to melamine decorative boards can be obtained.

Furthermore, since there is no obstacle such as overlay paper on the pattern printing surface of the decorative paper 1, the vividness of the pattern printing is not impaired by the fogging of the overlay paper, and the thickness unevenness of the overlay paper. And non-uniform coloration due to non-uniform resin impregnation, non-uniform permeation into decorative paper, etc., can be obtained, so that a melamine decorative board excellent in design can be obtained.

In particular, in the case of using a pearl pigment-containing ink as a picture printing ink, if the composition of the present invention is adopted, the pearl gloss is not obstructed by the overlay paper and the specific gloss effect is not impaired. This is very suitable because a melamine decorative board having a high degree of design that sufficiently exerts the above characteristics can be obtained.

[0019]

Example: A decorative paper made by printing a pattern on a titanium paper having a basis weight of 80 g / m ^{2 with} a pearl pigment-containing ink, and a basis weight of 25 g
/ M ² paper impregnated with a melamine resin at a weight ratio of 300% is commercially available overlay paper for decorative melamine boards (manufactured by Ota Sangyo Co., Ltd., trade name Suntop Overlay), and has a basis weight of 14
A core layer made by impregnating 110 g of melamine resin into kraft paper of 5 g / m ² and a backer layer made of melamine resin-impregnated paper for preventing warpage are sequentially superimposed, sandwiched between end plates, and subjected to a pressure of 160 kg / cm ^2. 7 at the temperature of 140 ° C
The resin was permeated, cured and integrated by heating and pressing for 1 minute to produce a melamine decorative board of the present invention.

In the obtained melamine decorative board, the melamine resin contained in the overlay paper on the back side of the decorative paper on the surface is sufficiently penetrated and hardened to the surface of the decorative paper, and is different from the conventional melamine decorative board. It was confirmed that they had equivalent surface physical properties such as surface hardness, scratch resistance and solvent resistance. Further, since the surface of the pattern printing layer made of the pearl pigment-containing ink was not covered with the overlay paper, the glitteriness inherent to the pearl pigment-containing ink was maintained as it was, and the design was extremely excellent.

[0021]

The melamine decorative board of the present invention is obtained by sequentially laminating a melamine resin-impregnated paper and a core layer of a paper base material impregnated with a thermosetting resin on the back of a decorative paper not impregnated with a resin.
By adopting a configuration in which heating and pressure are integrated, the step of impregnating the decorative paper with the melamine resin can be omitted, and the manufacturing process is simplified, and the step of impregnating the decorative paper with the melamine resin is performed. The occurrence of waste and the occurrence of waste due to the aging of the impregnated decorative paper are prevented, so that production efficiency can be improved and production and supply can be performed at low cost.

Furthermore, there is no overlay paper covering the pattern print on the surface of the decorative paper, and the design of clear pattern print is not impaired by the fogging of the overlay paper. Further, color unevenness due to thickness unevenness of the overlay paper, unevenness of impregnation of the resin, unevenness of the permeation of the resin into the decorative paper, and the like does not occur, so that a melamine decorative board excellent in design can be easily obtained.

In particular, in the case of a melamine decorative board using a pearl pigment-containing ink as the pattern printing ink for decorative paper, there is no overlay paper covering the pattern printing with the pearl pigment-containing ink, and the An excellent effect that an extremely high-design melamine decorative plate with a sufficient gloss effect can be easily obtained because the surface gloss characteristic of the pigment-containing ink is not impaired by the overlay paper. It is.

[Brief description of the drawings]

FIG. 1 is a side sectional view showing an embodiment of a melamine decorative board of the present invention.

[Explanation of symbols]

 1 decorative paper 2 melamine resin impregnated paper 3 core layer 4 backer layer

──────────────────────────────────────────────────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 melamine decorative board obtained by sequentially laminating a melamine resin-impregnated paper and a core layer on the back surface of a decorative paper not impregnated with a resin, and heating and press-integrating them. 2. The melamine decorative board according to claim 1, wherein a pearl pigment-containing ink is used as the picture printing ink for the decorative paper.