JPH11268220A - Decorative composite material and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a decorative composite material free from a molding defect such as 'undulation' 'distortion' or the like and having a decorative surface high in design effect even if a core material having unevenness on its surface is used. SOLUTION: A decorative composite material 1 is formed by integrating a core material having an uneven surface and a decorative material 2 with a water content of 0.4 wt.% or less or a decorative panel of which the surface is treated with a urethane primer through an adhesive layer comprising a polyurethane foam 4. This decorative composite material is produced by a method wherein the decorative material is placed on the surface of the lower mold cavity of a mold through a heat insulating buffering material and a polyurethane resin compsn. is ejected to the surface of the decorative material 1 and the core material 3 having an uneven surface is placed on the decorative material and the mold is clamped to foam and cure the polyurethane resin to compound the decorative material and the core material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative composite having a good finished appearance and a method for producing the same.

[0002]

2. Description of the Related Art A decorative composite material comprising a decorative material and a core material is widely used. A decorative top plate used for furniture, or a decorative material used for vertical surfaces such as furniture and indoor walls is manufactured by bonding a core material such as plywood and a particle board to various decorative materials using an adhesive. doing. As a specific example of the core material having irregularities on its surface, there is a hard panel (hereinafter abbreviated as EM panel) which is produced by reusing a waste magnetic tape developed by Fuji Kasei Kogyo Co., Ltd. and subjecting it to special processing.
The EM panel is a panel with a large number of irregularities of 2 mm or less on the surface. In addition to heat insulation, soundproofing, water permeability, air permeability, water resistance, light weight, etc., the basic material is polyester film coated with ferromagnetic powder. Magnetic tape with excellent electromagnetic wave shielding performance. The decorative composite using the EM panel as a core material can be expected to be used in a wide range of fields including the construction field and the electric field. Conventionally, a decorative composite material in which this kind of core material is composited with a decorative material has not been developed.

[0003]

SUMMARY OF THE INVENTION The present inventors have studied the bonding of a composite material by bonding such a core material having irregularities on its surface and a decorative material with various adhesives.
Irregularities on the surface of the core material of the EM panel having irregularities were exposed on the surface of the decorative material, the surface finish was poor, the surface was wavy, and the surface was distorted, and the appearance of the decorative material was impaired. In addition, it was found that the unevenness of application of the adhesive was exposed on the surface of the decorative material to lower the surface appearance. In particular, when a mirror-finished cosmetic material is used, these defects are conspicuous. Furthermore, when the decorative material is bonded onto the concave portion of the core material, the concave portion becomes a void, and the material of the melamine decorative board, the polyester decorative board, and the diallyl phthalate resin decorative board is hard,
When a material having poor impact resistance is used, when a figurine such as a vase falls on the top plate or collides, cracks and cracks are likely to be generated in the makeup portion that comes into contact with the gap portion. And so on. Therefore, the present invention is to provide a decorative composite material free from such defects and free from “undulation” and “distortion” and a method for producing the same.

[0004]

According to the present invention, a core material having irregularities on its surface and a decorative material having a moisture content of 0.4% by weight or less or a decorative plate whose surface is treated with a urethane primer are provided.
The present invention relates to a decorative composite material integrated via an adhesive layer made of polyurethane foam. The present invention also relates to the decorative composite, wherein the decorative material is a melamine decorative plate. The present invention also places a decorative material on the lower mold cavity surface of the mold via an insulating cushioning material, and after discharging the polyurethane resin composition on the decorative material, further places a core material having irregularities on the surface, The present invention relates to a method for producing a decorative composite material, comprising clamping a molding die, foaming and curing a polyurethane resin to composite a decorative material and a core material.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described with reference to the drawings.
FIG. 1 is a sectional view of the decorative composite material of the present invention. In the decorative composite 1, the decorative material 2 and the core material 3 are integrated via an adhesive layer made of urethane foam 4. 2 and 3 are cross-sectional explanatory views illustrating a method for producing a decorative composite material according to the present invention. As shown in FIG. 2, the heat-insulating cushioning material 5 is placed in a cavity of a lower mold 6b (preferably of a temperature controlled at 30 to 70 ° C.) of the molding die 6, and the decorative material 2 is placed thereon. The polyurethane resin composition 4a is discharged onto the
Then, as shown in FIG. 3, the upper mold 6a of the mold 6 is closed, and the polyurethane resin composition is foamed and cured to form the urethane foam 3, whereby the decorative composite is manufactured.

The unevenness of the surface of the decorative material in the present invention means smooth unevenness, rectangular unevenness, light and uneven surface and other non-smooth surfaces. In the prior art, it is considered that "wavy" or "distortion" that is exposed on the surface of the decorative material 2 when the decorative material 2 and the core material 2 having irregularities on the surface are bonded together with an adhesive is caused by the following action.

[0007] Since a thin decorative material having a thickness of 1.2 mm or less is generally used, when the decorative material is bonded to a core material having irregularities via an adhesive, the uneven surface of the core material is transferred to the surface of the decorative material. This is considered to be due to the influence of the stress generated due to the non-uniform application of the adhesive or the non-uniform configuration due to the depression of the core material surface. Therefore, when the decorative material and the core material are combined via an adhesive layer made of polyurethane foam so as to prevent the influence of the unevenness of the core material surface from affecting the decorative material, the above-described “undulation” and “distortion” are prevented. be able to.

In the present invention, the decorative material 2 and the core material 3 are integrated with each other via the polyurethane resin composition 4a to absorb irregularities of the core material, and as shown in FIG. 2 and FIG. The cushioning material 5 is placed in the cavity of the lower die 6b of the molding die 6, the decorative material 2 is placed thereon, and after discharging the polyurethane resin composition 3a, the core material 3 is placed thereon, and the upper die 6a
By closing and closing the polyurethane resin composition 4a to foam and harden it, it is possible to eliminate air pockets between the decorative material and the mold surface, and as a result, to manufacture a decorative composite material having no “undulation” and “distortion” it can. Further, the heat-insulating cushioning material 4 exerts a force caused by a thermal expansion contraction and a curing contraction caused by an exothermic temperature generated when the polyurethane resin composition is foamed and cured, and a difference in a thermal expansion coefficient between the polyurethane foam, the core material and the decorative material. Because it can be alleviated, it is possible to produce a decorative composite material without "wavy" and "distorted".

As a decorative material constituting the decorative composite material of the present invention, a melamine decorative board, a polyester decorative board, a diallyl phthalate resin decorative board and the like are used. Melamine veneer is a dry prepreg after melamine resin is soaked in the pattern paper, which is the design of the veneer, and then phenol resin is soaked in a kraft paper called the core layer that comes on the back of the pattern layer to make a dry prepreg. , And those obtained by pressing them are integrated by pressing. In the present invention, a melamine decorative board is particularly preferred.

If the decorative board has a high moisture content, a peeling phenomenon occurs between the decorative material and the urethane foam, and the decorative material surface swells, so that the decorative board has a moisture content of 0.4% by weight or less. Alternatively, it is necessary to apply a urethane-based primer. Although it depends on the thickness of the decorative board, if the thickness is 1.5 mm or less, which is the preferred thickness in the present invention, the moisture content of the decorative board can be reduced to 0.
It can be less than 4% by weight.

When the urethane primer is applied, the back surface of the melamine decorative board is brush-coated or spray-coated. The coating amount is preferably from 100 to 250 g / m ² . The urethane-based primer is a kind of polyurethane resin paint, and may be either a one-pack type or a two-pack type. The one-pack type includes a lacquer type and a moisture-curable type which do not particularly require heating, and a blocked isocyanate-curable type which requires a heating reaction. Further, the two-pack type includes a liquid containing a polyisocyanate such as diisocyanate such as tolylene diisocyanate and diphenylmethane diisocyanate, and a component containing a curing agent such as a polyol such as polyester polyol and polyether polyol. The one-pack lacquer type urethane primer is obtained by dissolving a thermoplastic polyurethane obtained by reacting a polyol and a polyisocyanate in an organic solvent.

The thickness of the decorative material in the present invention is not particularly limited, but is preferably 1.5 mm or less from the viewpoint of cost.
As the core material having irregularities on the surface used in the present invention, the already described EM panel can be used, but it is not particularly limited, and all similar materials can be used. For example,
A plywood or a particle board can be used as the core material, but even a plywood or a particle board having a depression that is itself defective is not affected by the depression of the core material according to the present invention. A decorative composite having an excellent surface appearance is obtained. In addition, a porous material such as lightweight concrete can also be used as the core material.

The polyurethane resin used in the present invention includes polyol components such as polyester polyol, polyester polyol, polycarbonate polyol and acrylic resin polyol, tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MD
I), a polyisocyanate component such as polymeric MDI (polymethylene polyphenylene polyisocyanate),
A foamable polyurethane resin composition comprising an amine / tin-based catalyst or the like, a foaming agent such as highly active silicon, and a foaming agent such as water or Freon-11, and further containing a pigment or a flame retardant as an additive if necessary. can get.

The expansion ratio and thickness of urethane foam are as follows:
It varies depending on the thickness of the decorative material and the degree of unevenness of the core material surface.
A thickness of the polyurethane foam layer of 0.5 to 3 mm is suitable.

The heat-insulating cushioning material used in the present invention may be any of foams such as polyolefins (polyethylene, polypropylene, etc.), polyesters (PET, polyethylene-2,6-naphthalate, etc.), polyvinyl chloride, etc., and non-foamed foams. However, those made of a foam are preferred from the viewpoint that the heat insulating property and the buffer property are easily obtained. In addition, the thickness of the thermal insulation cushioning material is 0.5 to 1.5 mm from the viewpoint of thermal insulation and cushioning properties.
Is preferred.

[0016]

The present invention will be described below in more detail with reference to examples.

Preparation of molding material (1) Decorative material (A) Melamine decorative board (Hitterlite H-834-S, trade name of Hitachi Chemical Co., Ltd.) Surface: mirror finish Thickness: 0.8 mm Size: 2100 mm × 800 mm Moisture Content: 0.55% by weight (2) Cosmetic material (B) Cosmetic material (A) is kept at 50 ° C for 1 hour as a drying treatment,
Water content is 0.35% by weight.

(3) Cosmetic material (C) A urethane-based primer is brush-coated on the back surface of the cosmetic material (A).
Processed. The urethane primer used was Konishi Bon
Co., Ltd., Bond Primer 80
200g / m^TwoAnd (4) Core material with unevenness EM panel (trade name of Fuji Chemical Industry Co., Ltd.) Thickness: 10 mm Density: 0.4 g / cm^Three Size: 2100mm x 800mm

(5) Polyurethane resin composition Liquid A (polyol component): HM-1110 (manufactured by Polyurethane Chemical Co., Ltd., 95% by weight of polyether polyol, 1.3% by weight of water, 3.7% by weight of catalyst, etc.) B Liquid (isocyanate component): Polymec MDI (M-
20S, manufactured by Polyurethane Chemical Co., Ltd.) Foaming characteristics 1) Condition mixing ratio Liquid A: Liquid B: 100: 135 (weight ratio) Liquid temperature: 25 ° C Indoor temperature: 25 ° C 2) Reactivity Cream time: 18 seconds Gel time: 58 Second Rise time: 105 seconds 3) Free density: 80 kg / m ³

(6) Thermal insulation cushioning material Polyethylene foam sheet LSL-8 black (trade name of INOAC CORPORATION) Expansion ratio: 20 times Thickness: 0.8 mm Size: 2100 mm × 800 mm

Example 1 A prepared insulating material was placed in a cavity of a lower mold 6b of a molding die 6 adjusted to a temperature of 50 ° C., a decorative material (B) was placed, and a polyurethane resin composition was injected into the cavity from above with a high-pressure injection machine. (P-80, manufactured by Polyurethane Engineering Co., Ltd.), 2.5 kg of a mixture A solution: B solution: 100: 135 (weight ratio) was introduced. Immediately after the charging, the EM panel prepared as a core material having irregularities is placed, and the mold 6
The upper mold 6a was closed so as to have a molding thickness of 12.5 mm, and the polyurethane resin was foamed and cured. Five minutes after the introduction of the polyurethane resin composition, the mold 6 was opened and the molded product was taken out.
A decorative composite in which the decorative material (B) and the EM panel were composited via the polyurethane foam was obtained. This molded article had a mirror appearance having a high design on the surface side, was free from defects such as "undulation" and "distortion", and had an appearance excellent in design. 80 ° C at 20 ° C for 1 hour
The heat cycle test was repeated 10 times per hour, and the appearance was observed. No change in appearance was observed.

Example 2 In place of the cosmetic material (B) used in Example 1, a cosmetic material (C) was used.
Was used to form a decorative composite in the same manner as in Example 1.
As in Example 1, the obtained cosmetic composite was a molded article having an excellent appearance with no specks such as "wavy" and "distortion" on the surface side, having a mirror appearance having high designability. . Further, the results of the cooling / heating cycle test were the same, and no change in appearance was observed.

Comparative Example 1 A decorative material (A) was used instead of the decorative material (B) used in Example 1.
Was used to form a decorative composite in the same manner as in Example 1.
In addition to the occurrence of "undulation" and "distortion", a phenomenon in which a peeling phenomenon occurred between the decorative material (A) and the urethane foam layer, and the decorative material surface swelled was observed. The swelling was further increased by the thermal cycle test, and the decorative material (A) was peeled off at the fifth cycle.

Comparative Example 2 An adhesive was applied to the decorative material (B) using an epoxy-based adhesive (bond E250 (hardener polyamideamine) manufactured by Konishi Co., Ltd.) instead of the polyurethane resin composition used in Example 1. A decorative composite material was formed in the same manner as in Example 1. "Waviness" and "distortion" occurred on the mirror surface of the decorative material, and the design was spoiled to obtain a satisfactory product. As a result of the cooling / heating test in the same manner as in No. 1, "wavy" and "distorted" in the appearance of the decorative surface were further increased.

[0025]

The cosmetic composite according to claims 1 and 2,
It has no molding defects such as "undulation" and "distortion" and has a decorative surface with a high designability even when a core material having irregularities on its surface is used. According to the method of the third aspect, it is possible to obtain a decorative composite material having no decorative defects such as "undulation" and "distortion" and having a decorative surface with a high design even if a core material having irregularities on the surface is used.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of an example of the decorative composite material of the present invention.

FIG. 2 is an explanatory cross-sectional view of the manufacturing method of the present invention.

FIG. 3 is an explanatory sectional view of the manufacturing method of the present invention.

[Explanation of symbols]

 1: Cosmetic composite material 2: Cosmetic material 3: Core material having irregularities on the surface 4: Polyurethane foam 4a: Polyurethane resin composition 5: Thermal insulation cushioning material 6: Mold 6a: Upper mold 6b: Lower mold

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI B32B 31/20 B32B 31/20 (72) Inventor Kazuo Suzuki 4-3-1 Higashicho, Hitachi City, Ibaraki Prefecture Hitachi Chemical Co., Ltd. Inside the Yamazaki Plant (72) Inventor Kazuki Tsujino 5--12-15 Namekawa Honmachi, Hitachi City, Ibaraki Prefecture Inside the Namerikawa Plant, Hitachi Chemical Co., Ltd. No. 15 Nippon Kasei Kozai Co., Ltd. Namekawa Plant (72) Inventor Hideo Aoki 279 Kayaji Horiuchi, Kamo-shi, Shimo-shi, Miwa-machi, Iwaki, Fukushima Pref.

Claims (3)

[Claims] 1. A core material having irregularities on its surface and a decorative material having a moisture content of 0.4% by weight or less or a decorative plate whose surface is treated with a urethane primer are bonded via an adhesive layer made of polyurethane foam. A decorative composite material that is integrated. 2. The decorative material is a melamine decorative board.
A cosmetic composite as described. 3. A molding material is placed on the lower mold cavity surface of the mold via a heat insulating cushioning material, and after the polyurethane resin composition is discharged on the decoration material, a core material having irregularities on the surface is further placed. A method for producing a decorative composite material, comprising: closing a mold to foam-harden a polyurethane resin to form a composite of a decorative material and a core material.