JPS5913349B2 - decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to decorative laminates, particularly decorative laminates having an embossed surface.

Conventional decorative boards with embossed surfaces include those made by laminating decorative paper or decorative film, and those that are not.

The decorative paper or decorative board to which the decorative film is attached uses synthetic resin film as the decorative base material, most of which uses vinyl chloride film, and some use paper. There is something I did. When synthetic resin film is used, it is more expensive than paper products in terms of film cost, lamination work, and adhesive cost.

Also, pollution problems have been raised with PVC film.
Furthermore, thermoplastic films and the like have problems in surface hardness, stain resistance, and the like.

In addition, with conventional paper products, the paper layer is weak and the paper layer may peel off during boiling tests. Also, if you paste zero tape, stickers, etc. on the product and peel it off after use, it will peel off from the paper layer and the pattern on the surface will change. There are 5 problems such as damage.

In order to improve some of the above-mentioned drawbacks, a method of making an embossed decorative board using a base paper for decorative paper made of synthetic pulp made from synthetic resin and natural pulp has also been considered.

However, base paper for decorative paper containing synthetic pulp 10 is made in a state in which synthetic pulp and natural pulp are intertwined. Sufficient resin dissolution occurs due to the pressure, and the interpaper strength increases. Even in this case, strong 15
The limit to the improvement in strength is the strength of the resin used. On the other hand, regarding the convex portions, almost no resin dissolution occurs, and there are few targets where the synthetic pulp contributes to the interpaper strength. The present invention solves the various problems mentioned above, and will be described in detail below.

The present invention solves the drawbacks of conventional embossed decorative boards by creating embossed decorative boards using paper made by adding a cationic synthetic resin aqueous dispersion in the wet part of the papermaking process. did.

That is, the present invention relates to synthetic resin-containing paper (hereinafter simply referred to as synthetic resin-containing paper) that is made by adding a cationic synthetic resin aqueous dispersion onto a base material via an adhesive in the wet part of the papermaking process. ) is pasted on the synthetic resin-containing paper, and has a printing layer and a surface protection resin layer on the synthetic resin-containing paper, and is a decorative board having an embossed surface.

The decorative laminate of the present invention is produced by adding a cationic synthetic resin aqueous dispersion to a paper containing a synthetic resin, such as in a wet part of the paper manufacturing process, such as in a heater or in a mixing chamber. Print any other pattern, coat the surface with a synthetic resin such as Aminoor 15 Lucid resin, urethane resin, polyester resin, or acrylic resin as a protective layer, and then emboss it.The resulting decorative paper can be used as a base material such as plywood. Obtained by pasting on.

Another method for obtaining the decorative board of the present invention is to print and emboss synthetic resin-containing paper and coat the surface with the synthetic resin as a protective layer before or after laminating it to a base material such as plywood. There is a way to do it.

The base paper for decorative paper used in the present invention must be a synthetic resin-containing paper that is made by adding a cationic synthetic resin aqueous dispersion in the wet part of the papermaking process.

1. The reason for limiting the use to a cationic synthetic resin aqueous dispersion is that when an anionic synthetic resin aqueous dispersion is used, the addition rate of synthetic resin to cellulose pulp should be 15% to prevent machine troubles during the papermaking process. Furthermore, the fixation state of the resin is different from that when using a cationic synthetic resin aqueous dispersion, so it is not possible to substantially improve the peeling resistance of the embossed decorative board. It is. The synthetic resin-containing paper used in the present invention is a homopolymer of monomers having polymerizable unsaturated bonds, such as vinyl acetate, acrylic ester, styrene, and vinyl salt, or a copolymer of two or more thereof. It is made from a cationic synthetic resin aqueous dispersion with resin components such as agglomerates, etc., and cellulose pulp as the main raw materials.

Drying at a temperature higher than the softening point of the synthetic resin used in papermaking or carrying out a calendering process is effective in obtaining a strong synthetic resin-containing paper. Papers such as mochiron, clay, titanium white, calcium carbonate, antimony trioxide, pigments such as coloring pigments, water repellents such as paraffin emulsion, polyamide resin, polyimide resin, epichlorohydrin resin, urea-formalin resin, etc. It is also possible to mix paper with a strength enhancer.

The proportion of the synthetic resin component in the synthetic resin-containing paper is preferably 20 parts by weight or more per 100 parts by weight of cellulose pulp.

If the amount is less than 20 parts by weight, the surface flaking resistance of the resulting decorative board will not be satisfactory for practical use.

Although there is no upper limit for the ratio of synthetic resin components to cellulose pulp in synthetic resin-containing paper, if the ratio becomes too large, it becomes difficult to produce synthetic resin-containing paper, so 200 parts by weight per 100 parts by weight of cellulose pulp is The addition of synthetic resin is the old value in practical use. The synthetic resin-containing paper referred to in the present invention is not particularly limited in basis weight, and may be 509/M2 or 1009/M2.

This is because synthetic resin-containing paper has an excellent peel resistance value. In the present invention, printing layers with wood grain, stone grain, abstract patterns, and other arbitrary patterns can be applied using almost any ordinary printing method, but in general, gravure printing is appropriate from the viewpoint of productivity. The surface protective layer of the invention may be formed before or after embossing or laminating the decorative paperboard to the substrate.

As the resin forming the surface protective layer, aminoalkyd resin, urethane resin, polyester resin, acrylic resin, epoxy resin, etc. can be used. Regarding the coating method, gravure coating, roll coating, flow coating, knife coating, air knife coating, etc. can be used, although there are some overlaps before and after bonding the base materials.

In the present invention, the embossing can be formed by either a flat pressure method or a roll press method, but the roll press method is preferable from the viewpoint of productivity.

Among the double-roll press systems, there is one that embosses between an embossing roll and a rubber roll, which is usually used for thermoplastic films, and one that embosses between a male embossing roll and a female roll made of paper or steel, which is used for paper or aluminum foil, etc. There are two types of embossed paper, and embossed paper can be embossed with either of them. Furthermore, in the present invention, in order to form an emboss, heat is applied to raise the temperature to around the melting point of the mixed paper resin. At this time, the resin fixed (adhered) to the cellulose pulp melts and connects with each other to form a film containing the cellulose pulp. When molding is applied in this state, the resin deforms and an embossing can be obtained. As mentioned above, when synthetic pulp and natural pulp (cellulose pulp) are used, paper is made with pulp tangles, and even when heat treatment is applied, the natural pulp's wettability is not perfect. When embossing is applied to an object, heat and pressure will sufficiently melt the resin in the concave areas where pressure is applied, and it is expected that the strength between the sheets will improve, but almost no resin melt will occur in the convex areas, and the synthetic pulp will not melt into the paper. There are few points that contribute to the strength.

On the other hand, in the case of the synthetic resin-containing paper of the present invention, the resin is mixed in the form of an emulsion, so the pulp bonding points are strengthened by the resin from the beginning, and therefore a product with good interpaper strength can be obtained. .

Further, since resins that can be emulsified can be used as the synthetic resin-containing paper of the present invention, it is possible to improve the inter-paper strength by selecting various resins. In addition, examples of adhesives used when attaching the synthetic resin-containing paper of the present invention to a substrate include vinyl acetate resin, mono-modified vinyl acetate resin, acrylic ester resin, vinyl acetate/acrylic ester copolymer resin, Examples include ethylene vinyl acetate copolymer resin, urea resin, etc., or a mixture of two or more thereof. Substrates used in the present invention include plywood, wood veneer, synthetic resin board, stone board, particle board, paper, metal board, and the like.

As described above, the decorative board having an embossed surface according to the present invention not only has excellent paper layer peel strength but also excellent water resistance, has good surface properties, and is beautiful and deep.

Furthermore, in the adhesion process, there is no need to apply wet adhesive as with PVC film, and there is no need for a standing period after adhesion. It is possible to perform continuous lamination as shown in the figure, and the manufacturing cost is therefore low. or,
It is also possible to easily add and fix flame retardants during the papermaking process of producing synthetic resin-containing paper. According to this, it is possible to easily produce a decorative wall covering material, which is difficult to manufacture in today's world where there is a demand for making wall covering materials and other materials more difficult to make. In this way, the decorative laminate of the present invention has greatly improved the shapeability problem and paper layer peeling resistance that have been the bottleneck in the development of conventional paper-bonded embossed decorative laminates, and has a strong surface case and beautiful appearance. This is a decorative board with a deep embossed surface.

Next, examples will be shown.

Example 1 15% by weight of ethyl acrylate, 15% by weight of styrene, 3.3% by weight of Cationogen H (cationic surfactant manufactured by Daiichi Kogyo Seiyaku K.K.) Water-soluble azo compound V-15 (manufactured by Wako Pure Chemical Industries, Ltd.) A mixture of 0.1% by weight (manufactured by K.K.) and 66.6% by weight of water was reacted at 70 to 80°C for 3 hours to form a cationic synthetic resin aqueous dispersion with a solid content of 30.6% by weight. Obtained.

Meanwhile, separately adjusted Camedian Standard Freeness 3
The above synthetic resin aqueous dispersion was added to an aqueous dispersion of unbleached softwood kraft pulp with a filtration rate of 1.6 wt% and a filtration rate of 1.6 wt% so that the solids content ratio of the pulp was 50 wt%, and the mixture was processed into a cylinder Ankie type paper machine. A synthetic resin-containing paper with a basis weight of 509/M2 was obtained. A cross pattern was printed on the synthetic resin-containing paper obtained in this way using a gravure printing machine, and a urethane transparent paint UR2O3 (manufactured by Toyo Ink Mfg. K.K.) was applied to this using a gravure coater so that the solid content was 10y/M2. This was then embossed with a cross pattern using a roll embossing machine for thermoplastic films. Apply 2 shaku, 100
It was rolled and adhered onto a plywood board having a thickness of 411 which had been pre-dried at 0C for 30 seconds to obtain a decorative board having an embossing surface.

Claims (1)

[Claims] 1 A synthetic resin-containing paper made by adding a cationic synthetic resin aqueous dispersion in the wet part of the papermaking process is pasted onto the base material via an adhesive, and printing is performed on the synthetic resin-containing paper. and a surface protection resin layer, and the synthetic resin-containing paper has an embossed surface formed by heat embossing.