JPH11210325A - Window sill and manufacture therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve performance by laminating facial tissue and kraft paper respectively impregnated with a prescribed resin by specifying a thickness, and lapping them on a base material for a window sill. SOLUTION: This window sill is constituted by lapping a melamine decorative sheet 1 having a thickness of 0.2 to 0.5 mm by integrally laminating facial tissue 11 impregnated with melamine resin and phenol resin impregnated kraft part 12 in order from the surface, on a base material 3 for a window sill through an adhesive 2. At manufacturing time, for example, the adhesive surface by applying a reactive hot melt adhesive to the reverse of the decorative sheet 1, is contacted with the base material 3 to press-fit/cover it by a lapping machine composed of a large number of continuous roller compressors. Therefore, the window sill can be easily worked, a camber can be restrained, an external appearance can be improved, and physical properties such as surface hardness, bending workability, weatherability, abrasion resistance, impact resistance, pollusion resistance and water resistance can be improved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a window sill covered with a decorative material having excellent surface properties and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a window stand (bay window) for placing a flower pot or the like under a window of a building has been made of a wooden frame, a metal frame, a natural stone,
It was composed of the base material of the building itself, such as a concrete frame. But in recent years. A window sill in which a base material surface is coated with a decorative material for the purpose of adding decorativeness is also being studied.

[0003] As window window decorative materials, thermoplastic resin sheets represented by vinyl chloride decorative sheets, thin leaf decorative sheets obtained by decorating thin leaf printing paper with aminoalkyd resin paint or polyurethane resin paint or the like, or Decorative paper (patterned paper) impregnated with a thermosetting resin such as melamine resin, diallyl phthalate resin or unsaturated polyester resin is used as a base sheet such as kraft paper impregnated with a similar thermosetting resin or phenol resin. It was a thermosetting resin decorative plate obtained by hot pressing with a multi-stage hot press or a continuous molding press.

[0004]

However, each of the above-mentioned decorative materials has unique characteristics depending on the material and the manufacturing method, but the appearance, surface hardness, bending workability, weather resistance, abrasion resistance, impact resistance ( Crack), stain resistance, chemical resistance,
In terms of water resistance, adhesive workability, and the like, they have not always been satisfactory as window window decorative materials.

That is, a thermoplastic resin decorative sheet typified by a vinyl chloride decorative sheet has good adaptability to design, is rich in flexibility, and is easy to wrap, but has low heat resistance, is easily damaged, and has a poor surface. Hardness, stain resistance,
There was a problem with chemical resistance.

[0006] Further, the thin leaf decorative sheet is low in cost and has good lapping property, but when it is adhered to a substrate, irregularities and the like are apt to appear, and the surface hardness, abrasion resistance, stain resistance, chemical resistance, Water resistance was low.

On the other hand, a thermosetting resin decorative board has a surface hardness,
It has excellent physical properties such as heat resistance and stain resistance, and has good appearance. However, compared to the decorative sheet, the bending resistance is poor, and when the bending workability such as V-cut bending or lapping or the thickness is reduced, the crack resistance is reduced. Sex was poor.

It is an object of the present invention to provide excellent appearance, surface hardness, bending workability, weather resistance, abrasion resistance, impact resistance, stain resistance, water resistance, and other physical properties required for a window siding decorative material. Another object of the present invention is to provide a window sill in which the decorative material is coated on a window sill base material and a method for producing the same.

[0009]

A first aspect of the present invention is that a melamine resin impregnated decorative paper and a phenolic resin impregnated kraft paper are laminated and integrated in this order from the surface in a thickness of 0.2 to 0.5.
A window stand characterized in that a melamine decorative board having a thickness of 1 mm is wrapped on a window base material.

A second aspect of the present invention is to form a continuous hot-melt melamine decorative plate having a thickness of 0.2 to 0.5 mm by applying a reactive hot-melt type adhesive to the back surface of the melamine decorative plate. A window wrapping method characterized in that the wrapping machine comprises a large number of continuous roll pressing machines and is coated by pressure bonding.

The method for producing a melamine decorative board having a thickness of 0.2 to 0.5 mm according to the present invention is as follows: a prepreg obtained by impregnating a decorative paper serving as a surface layer with a melamine-based resin and drying it; And a prepreg dried by impregnation with a phenolic resin and hot-pressed using a multi-stage hot press machine or a continuous molding press machine.

Among them, as the melamine decorative plate applied to the method for manufacturing a window sill according to claim 2, a kraft paper impregnated with a specific fast-curing phenol resin on the back layer is used, and a continuous hot-press molding press is used. A melamine decorative board having a thickness of 0.2 to 0.5 and capable of being continuously formed by a machine (eg, a double belt press forming machine) is optimal.

The decorative paper of a melamine resin-impregnated decorative paper serving as a surface layer of a melamine decorative board is a paper made by incorporating a pigment (such as titanium white) into cellulose (pulp) or a pattern printed on paper. Printing paper (patterned paper) having a basis weight of 50 to 150 g / m ² is optimal.

The phenolic resin-impregnated kraft paper for the back layer of the melamine decorative board is a usual impregnated kraft paper for decorative boards, which is unbleached or bleached kraft paper and has a basis weight of 60 to 300 g / m2. ² , density 0.50-0.7
0 g / cm ³ is preferable, and the basis weight of kraft paper is selected according to the thickness of the decorative board and the number of layers to be overlapped.

As the melamine resin impregnated in the decorative paper, the molar ratio of formaldehyde to melamine is 1.
2-2.5 melamine formaldehyde precondensate is applied. As the impregnation amount, for 100 g of decorative paper,
100 to 200 g in terms of solid content is suitable.

As the phenolic resin impregnated in the kraft paper, a phenol formaldehyde precondensate having a formaldehyde to phenol monomer molar ratio of 1.0 to 1.5 is used. However, in order to perform molding in a short time with a continuous hot-press molding press, the reaction is performed using calcium hydroxide as a reaction catalyst for the purpose of rapidly curing the resin.
Further, a resin to which a plasticizer is added is most suitable so that lapping can be easily performed. Examples of the plasticizer to be applied include glycols such as polyethylene glycol and polypropylene glycol, paratoluenesulfonamide, caprolactam and the like. The impregnation amount is Kraft paper 1
80 to 180 g in terms of solid resin is suitable for 00 g.

Next, as a window base material, a material for architectural or structural materials such as medium density fiberboard (MDF), plywood, laminated wood, particle board, metal plate, ceramic products, furniture, fittings, etc. What is processed into a desired shape is provided for use.

Adhesives required for wrapping a melamine decorative board on a window-sill substrate include emulsions of thermoplastic resins such as vinyl acetate and acrylic, and organic solvent-based, chloroprene and styrene-butadiene-based adhesives. There are synthetic rubber latex and organic solvent type, condensation type resin such as urea resin and phenol resin, addition polymerization type resin such as urethane type and epoxy type, and hot melt type such as SIS, SEBS, EVA, etc. Depending on the required performance, any commercially available adhesive can be used.

However, in the method for manufacturing a window sill according to the present invention, the adhesive applied to the back surface of the melamine decorative board may be a reactive hot-melt type adhesive, for example, a carboxyl group in a polymer and a polyvalent metal ion. Ion-crosslinking type hot melt adhesives, blocked isocyanate type hot melt adhesives in which isocyanate groups introduced into molecular terminals or side chains are blocked with a blocking agent such as caprolactam and phenol, and isocyanate groups which react with water (moisture) to crosslink. There is a moisture-curable hot-melt adhesive in which an alkoxy group is introduced into a polymer. In particular, a urethane-based hot-melt adhesive is used as one having excellent overall characteristics including economy.

The urethane reactive hot melt adhesive is:
A urethane prepolymer having a molecular weight of thousands containing isocyanate groups is used as a base resin as a main component, and in some cases, a tackifier, a reactivity modifier, an antioxidant, a hydrolysis inhibitor, an antifoaming agent, an inorganic additive ( Filler) and the like. The isocyanate group contained in the prepolymer molecule is caused by moisture, bound water, OH group, C on the surface of the adherend.
Reacts with active hydrogen groups such as OOH groups and NH groups and moisture in the atmosphere, and produces bonds with high cohesive energy such as urea bonds and urethane bonds. It is said that. Such a urethane-based reactive hot melt adhesive reacts with an isocyanate group contained in urethane prepolymer molecules as a main component, an active hydrogen compound of a window base material, and moisture (moisture) contained in an atmosphere or the like. By curing
Excellent heat resistance compared to conventional hot melt adhesives.

In order to apply the reactive hot melt adhesive to the back of the melamine decorative board, for example, the above-mentioned moisture-reactive urethane hot melt adhesive is dissolved in a tank of an applicator dedicated to wrapping, and the temperature is controlled. Is applied to the back surface of the decorative plate from the nozzle, the adhesive-coated surface before solidification is brought into contact with the window base material, and pressure-coated by a lapping machine. The amount of the adhesive applied is 30 to 2
It is determined as appropriate at 00 g / m ² depending on the surface condition of the decorative plate and the substrate (adherend).

A wrapping machine is a machine for continuously bonding a sheet-like decorative material to a plate-like base material, and is composed of a number of continuous roll pressing devices. It is a mechanical device that can simultaneously press and bond materials.

Next, the present invention will be described with reference to embodiments and drawings.

1 is a sectional view showing the structure of a window sill according to the present invention. From the surface, a melamine resin impregnated decorative paper 11 and a phenolic resin impregnated kraft paper 12 are laminated and integrated in this order in a thickness of 0.2.
This is a window base obtained by lapping a melamine decorative board 1 of about 0.5 mm on a window base material 3 via an adhesive 2.

Example 1 A wood grain pattern printed decorative paper having a basis weight of 80 g / m ² was used in a molar ratio of 1.4.
In a resin content of 65% by weight of melamine formaldehyde precondensate the (melamine resin) to about 120 g / m ² (solid resin in terms of value) impregnated and dried prepreg were a melamine resin impregnated decorative paper for surface layer.

A basis weight of 200 g / m ² and a density of 0.55 g / c
To a bleached kraft paper of m ³ , paratoluenesulfonamide was added in a molar ratio of 1.2 using calcium hydroxide as a catalyst so as to be 10% of the phenol monomer, and methanol was added to reduce the resin content to 50% by weight. The prepared phenolic resin was impregnated with about 250 g / m ² (solid resin equivalent), and the dried prepreg was made into a phenolic resin-impregnated kraft paper for the back layer.

Next, the above layers were superposed in the order of a front layer and a rear layer, and the pressure was adjusted to 15 kg /
It was molded under a heat and pressure condition of 30 cm ² for 30 seconds and wound up on a 3-inch paper tube to obtain a decorative board for Example 1 having a thickness of 0.45 mm.

Comparative Example 1 The procedure of Example 1 was repeated, except that a melamine resin for the surface layer was used instead of the phenolic resin of the phenolic resin-impregnated kraft paper for the backside layer.
Of Comparative Example 1 was used. However, because the decorative board is hard,
Due to the large rebound, it could not be wound on a 3-inch paper tube, but was wound on a 6-inch paper tube.

COMPARATIVE EXAMPLE 2 Comparative Example 2 having a thickness of 0.45 mm was prepared in the same manner as in Example 1 except that a diallyl phthalate resin was used instead of the melamine resin for the surface layer and the phenolic resin for the back layer.
Veneer.

FIG. 1 shows a surface where a reactive hot-melt adhesive composed of a moisture-reactive urethane hot-melt adhesive was applied to the back surface of each decorative plate of Example 1, Comparative Examples 1 and 2 at about 100 g / m ² . As shown, thickness 18mm or end 40m
m with a water-resistant MDF having a thickness of 36 mm, a width of 190 mm and a length of 2000 mm, in contact with the surface of a window-sill base material processed into a corner radius of curvature of 6 mm, and a profile wrapping machine comprising a number of continuous roll pressing machines. The performance test was measured as follows as a window sill having the surface of the base material covered with a decorative plate by compression bonding. The results are shown in Table 1.

The decorative plate for Comparative Example 1 had cracks in the bent portion during lapping.

1. Warp test The test specimen was left for 7 days at 40 ° C. and 90% humidity for 7 days, and then left for 7 days at 40 ° C. and 30% humidity for 1 cycle. Unit: mm).

2. Crack resistance test A notch having a width of 3 mm and a length of 30 mm was cut into a test piece, left at 50 ° C. for one day, and left at −20 ° C. for one day as one cycle. The presence or absence of the occurrence of cracks was measured (〇: no occurrence,
X: cracks occurred).

3. Outdoor exposure test The test specimen was allowed to stand outdoors for 30 days in the autumn, and changes in appearance such as peeling, floating, and discoloration were observed (〇: no abnormality).

4. Surface hardness According to the pencil scratch value test method of JIS K5400 “General Paint Test Method”, the pencil hardness when no scratch, gloss change or dent was generated on the surface of the test specimen was measured.

Table 1

[0036]

As is clear from Table 1, the window sill of the present invention is easy to wrap, has little warpage, has excellent crack resistance, has no abnormalities in outdoor exposure tests, and has a high surface hardness. The window sack which wrapped the decorative board of the comparative example,
It failed any of the warp, crack resistance, and outdoor exposure tests, and the surface hardness was not sufficiently satisfactory.

[Brief description of the drawings]

FIG. 1 is a sectional view of the configuration of a window sill according to the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Melamine decorative board 11 Melamine resin impregnated decorative paper 12 Phenolic resin impregnated kraft paper 2 Adhesive 3 Window base material

Claims (2)

[Claims] 1. A melamine decorative board having a thickness of 0.2 to 0.5 mm, which is laminated and integrated from the surface in the order of a melamine resin impregnated decorative paper and a phenolic resin impregnated kraft paper, is wrapped on a window base material. Window stands to be characterized. [Detailed description of the invention] 2. A continuously molded thickness of 0.2 to 0.5 mm
Window base characterized in that the adhesive surface coated with a reactive hot-melt adhesive on the back side of the melamine decorative board is brought into contact with the base material for the window base and pressure-coated by a wrapping machine comprising a number of continuous roll presses. Recipe.