JPS58224750A - Manufacture of melamine-resin decorative material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a melamine resin decorative material.

Traditionally, melamine resin decorative boards have been made using a surface layer sheet made by impregnating decorative paper with melamine resin and a carbonate formaldehyde resin (
A core layer sheet made of kraft paper or the like impregnated with carbonic acid resin (hereinafter referred to as carbonic acid resin) was laminated and hot-press molded. However, it took a long time to harden the carbonic acid resin, resulting in a long molding cycle and poor productivity. Naturally, therefore, continuous molding was completely impossible.

The present invention relates to a method for producing a melamine resin decorative material that solves the known problems. Modified carbonic acid formaldehyde resin with improved curing speed (hereinafter referred to as modified carbonic acid resin)
The present invention relates to a method for producing a melamine resin decorative material, which comprises laminating a sheet for a core layer prepared by impregnating the melamine resin with a core layer sheet and then hot-pressing the same.

The modified carbonic acid resin is prepared by co-condensing various phenols with a fast reaction curing rate, such as m-cresol, p-cresol, 3.5-xylenol, 3.4-xylenol, resorcinol, and 2.5-xylenol. Alternatively, a mixture of carbonic acid resin and a reactant of these various phenols and formaldehyde can be used.

To co-condense carbolic acid and various phenols, formaldehyde is added to a mixture of carbolic acid and various phenols, the reaction is continued while heating under a weak alkali, and the mixture is cooled at the appropriate end point of the reaction. Alternatively, phenols that react particularly quickly can be synthesized by gradually adding the phenol during the reaction between carbolic acid and formaldehyde, and then cooling at an appropriate end point of the reaction. In some cases, a modified carbonic acid resin obtained by mixing individually synthesized carbonic acid resin with various phenol-formaldehyde resins synthesized from various phenols can also be used. The co-condensation ratio or mixing ratio of the modified carbonic acid resin is determined depending on the physical properties of the intended molded product, molding conditions, and the type of various phenols used.

Furthermore, the reaction molar ratio of the carbonic acid resin, modified carbonic acid, \resin:resin with formaldehyde, pH (for example, caustic soda,
carbonic acid), amount of IJum, etc.), type and addition of reaction catalyst
Since the reaction curing rate is faster than K, p may be added as necessary.
Do you want to adjust H (e.g. adjust the amount of caustic soda)?
Aniline m(p)-phenylenediamine, m(p)
-Mold curability can be improved by adding a reaction catalyst such as -aminophenol, o(pi)luidine, ethylenediamine, diethylenetriamine, diaminodiphenylmethane, or a composite reaction catalyst in which paraformaldehyde is added to these.

The melamine resin and the modified carbonic acid resin may be made from natural fibers such as α-cellulose fiber, craft fiber, linter fiber, synthetic fibers such as vinylon, nylon, acrylic, inorganic fibers such as glass fiber, asbestos fiber, or mixtures thereof. A molded material such as impregnated paper is produced by applying or impregnating the resin onto a porous base material such as paper, cloth, or nonwoven fabric.

As mentioned above, the purpose of the present invention is to achieve cycle shrinkage and continuous molding of melamine resin decorative materials. Next, an example of a continuous molding method will be described. For example, FIG. This is a schematic diagram of the molding device employed, in which a surface layer sheet (4) and a core layer sheet (B) are placed between two endless belts (5) (5) that run continuously in parallel in the same direction. is inserted continuously, and is capable of being heated and pressurized continuously using a heating means such as a heating plate (b) attached to the nucleic acid device and a pressurizing means that pressurizes with compressed air. 0 Heating oil or steam is circulated through the heating plate (b), and the temperature can be set to any desired temperature as long as it is below 250°C, and the pressure can be adjusted between 1 and 25"9/1 with a pressure regulator. Since the pressure can be adjusted to a predetermined value, continuous molding is possible under constant heat and pressure conditions.

Also, by setting the running speed and heating temperature of Endrespel (505), it is possible to correspond to the molding conditions of the simelamine resin and the core layer. In order to provide uneven embossing on the surface of the melamine resin decorative material, use an etched steel endless belt or a stainless steel endless belt on the endless heald, and use a material that can withstand the molding conditions between the endless belt and the sheet for the Shishimen layer. By inserting a forming sheet such as embossed paper, embossed resin sheet, woven fabric, or embossed metal sheet, these uneven embossed surfaces can be transferred and molded.

In addition to the above-mentioned molding methods, continuous molding methods can be used such as a drum molding method in which a metal endless belt is pressed against a rotating molding drum, and a continuous roll method in which continuous molding is performed by heating and pressurizing between continuous rolls.

According to the method for producing a melamine resin decorative material according to the present invention, the molding time, which conventionally required a long molding process using a high-pressure press, can be significantly shortened and molding efficiency can be significantly improved. In addition, energy saving is achieved because the heating time is shortened, and at the same time, with continuous molding, molding materials such as impregnated paper are automatically and continuously inserted into the molding machine, which is not necessary in conventional Nobachi Gress. The process of preparing for lamination (setting) of impregnated paper, etc., which was previously required, was no longer necessary, and labor savings were also achieved.

Examples and Comparative Examples α-cellulose paper with a basis weight of 50”/m was impregnated with a melamine resin containing a curing agent and a reaction molar ratio of 1.5 at a resin rate of 180% to form a sheet for the surface layer. /n?
Craft paper is impregnated with 60% resin ratio of modified carbonic acid resin, which is a co-condensation of carbonic acid and various phenols, to create core layer sheets A-C, and modified carbonic acid resin is mixed with various phenolic formaldehyde resins. A sheet DSE for the core layer was prepared by impregnating the same kraft paper with a resin ratio of 60%, and one sheet for the surface layer was laminated on three sheets for each core layer to obtain the melamine resin decorative material of the example ( stomach)
～(E) was molded. In addition, as a comparative example, a sheet for the core layer was prepared by impregnating the same kraft paper as in the example with a resin ratio of 60%, and one sheet for the surface layer was laminated on three of these sheets. A melamine resin decorative material was molded. The molding conditions and test results are as shown in Table 1.

(8) Note 01: Molding time when a molded product without blistering, peeling, etc. was obtained after being left in boiling water for 30 minutes.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram of one example of a continuous molding machine according to the present invention, and FIG. 2 is a schematic diagram of the other side of the continuous molding machine. 1.9... Tension roll 2... Drive roll 3... Pressure chamber 4...
Compressor 5.10... Endless bay (4 6... Seal material 7... Molding drum 8.8
'...Crimping roll 11...Heating plate 12.12
′・・・Hydraulic cylinder 13.13′・・・Molded decorative material patent applicant Aikanigyo Co., Ltd.

Claims (1)

[Claims] (11 Impregnated with modified carbonic acid formaldehyde resin made by reacting formaldehyde with various phenols having a reaction rate faster than carbonic acid, or modified carbonic acid formaldehyde resin mixed with carbonic acid formaldehyde resin and various phenolic formaldehyde resins) A method for manufacturing a melamine resin decorative material characterized by using a core layer sheet 0(2) A method for manufacturing a melamine resin decorative material according to claim 1, which involves continuous molding.