JPS59209863A - Manufacture of decorative board - 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 [Technical Field] The present invention relates to a method for manufacturing decorative laminates used as interior building materials and the like.

[Background technology]

With the trend toward higher quality decorative materials, various methods of expressing the astronomical stone pattern, which is a representative example of abstract expression patterns, have been devised and are now being used in decorative laminates. One method is to add marble powder, dyes, or pigments to polyester resin or acrylic resin to express color tones, and resin molding is mainly done by cast molding or mold molding. However, if decorative boards are made using this manufacturing method, specific expensive molds are required, and a large number of molds are required depending on the application and purpose, resulting in a large cost burden. there were. The other is a manufacturing method based on SMC or BMC, but the resulting decorative board has a sense of depth in terms of design expression.
There was a problem in that it lacked a sense of solidity and lacked a sense of luxury.

On the other hand, in order to express abstract patterns such as astronomical stones, melamine resin multilayer board molding methods have been studied.

For example, a method that creates a sense of transparency and depth by stacking multiple sheets of overlay printing paper (including back printing) impregnated only with melamine resin and combining the resulting laminate with a phenolic resin-impregnated core. It is.

However, due to the hardness of melamine resin, there are many quality problems such as chips, cracks, and warping in the decorative board, and a lack of transparency due to the color problem of phenolic resin. [Objective of the Invention] This invention was made in view of the above circumstances. [Disclosure of the Invention] In order to achieve the above-mentioned object, the present invention provides a method for manufacturing decorative laminates that can mass-produce decorative laminates. The first prepreg is made by firstly soaking a long strip-like base material with a transparent thermosetting resin, and The required number of second prepregs each impregnated with a thermosetting resin having the following properties are laminated and hot-press molded in succession, and the obtained strip-shaped cured product is cut into a desired length. The gist is a method for manufacturing decorative laminates that is characterized by: The present invention will be explained in detail below.

Here, regarding the first prepreg (base material prepreg),
Paper base materials such as transparent paper, bleached kraft paper, and linter paper, and cloth base materials such as nonwoven fabrics made from glass fiber and polyester resin are used as long strip-shaped base materials. Most preferably, transparent paper or bleached kraft paper is used. Also, the areal density is 10
It is preferable that the amount is about 250 g/rd. As a resin for primary impregnation that has affinity for the base material,
At least one selected from amino resins such as urea resin, melamine resin, and guanamine resin, and water-soluble vinyl acetate resin is used. When the base material is paper, it is preferable to use melamine resin, urea resin, or water-soluble vinyl acetate resin, which has high permeability to cellulose and is compatible with paper. Among these, it is most preferable to use melamine resin. Delicious. Melamine resin is not only commonly used for decorative boards, but also for paints, adhesives, etc. As a transparent thermosetting resin,
At least one selected from polyester resin, melamine resin, acrylic resin, etc. is used. The polyester resin may be unsaturated, saturated or a mixture of both, but styrene or diallyl butarate monomers are suitable as the crosslinking agent. As a polymerization initiator for polyester resin, benzoyl peroxide (B P O), which has a fast decomposition rate, is preferably used because a continuous method is used. As the acrylic resin, those commonly used as acrylic resins such as polymethyl methacrylate and glycidyl mechacrylate can be used, but it is particularly preferable to use an emulsion type of the first prepreg. It is made by sufficiently permeating the base material with the resin for the primary impregnation (in some cases, it is only for coating) and drying it, and then impregnating it with the resin for the secondary impregnation. This is because the polyester resins listed for secondary impregnation have poor compatibility (permeability, chemical bonding, etc.) with the base material, so prepregs made by impregnating the base material with polyester alone are used. This is because the adhesion strength between the prepregs becomes low (and quality problems such as heat resistance and water resistance occur in the resulting decorative board. Instead, paper made from a mixture containing resin and fibers for primary impregnation, such as melamine resin sanded paper, may be used.Substrate containing resin for primary impregnation. It is preferable that the resin content (resin content) is in the range of 3 to 50%.If it is less than 3%, the effect of primary impregnation (lining effect) will be small, and in terms of the quality of the decorative board obtained, polyester etc. will be used alone. On the other hand, if it exceeds 50%, chips, cracks, warping, etc. will occur in the decorative board obtained especially when using melamine resin. It tends to occur frequently.

Regarding the second prepreg (printed transparent paper fabric prepreg),
The printed transparent long strip base material is base paper for overlays or other commonly used transparent paper printed with a stone grain pattern, etc., and has an areal density of 10 to 1.
Preferably, 50 glrd transparent paper is used. As the transparent thermosetting resin, the same resin as mentioned above for the first prepreg is used.

The second prepreg is made by impregnating a printed transparent base material with a transparent thermosetting resin, but this second prepreg is also made by impregnating a transparent thermosetting resin. It is preferable to first impregnate the base material with a resin that has an affinity for the base material in the same manner as described above. The content of the primary impregnating resin is preferably 3 to 50%. After successively laminating the required number of long strip-shaped first prepreg and long strip-shaped second prepreg, the upper and lower A long decorative board (laminated cured product) is produced by continuous hot-pressing using a pair of heated rolls or the like. Next, it is cut into desired dimensions to form a decorative board for the product.

More specifically, for example, the decorative board is manufactured in the following manner. FIG. 1 is a schematic diagram showing a specific example of the manufacturing method according to the present invention. As shown in the figure,
Arrow A from roll 1 of a transparent base material impregnated with a resin for primary impregnation and printed in the form of a long strip and roll 2 of a base material in the form of a long strip also impregnated with a resin for primary impregnation. The substrates l' and 2' are continuously fed in the direction of .

Next, the base material 1' and the base material 2'...
Next, the base material 1' is made into a second prepreg 5 and the base material 2' is made into a first prepreg 6 by immersing it in a dip pan 4 containing a resin 3 for impregnation to perform resin impregnation. If necessary, use a temperature-adjustable dip pan to control the temperature during resin impregnation.

The first and second prepregs 6.5 are squeezed by a pair of upper and lower squeezing rolls 7, 7 to adjust the resin content of both prepregs 6.5. After that, the first and second prepregs 6..., 5 are sent to a pair of upper and lower assembly rolls 8, 8, and both prepregs 6..., 5 are successively laminated by the assembly roll 8.8 and integrated into an assembly. Then, a laminate 9 is produced. An air-blocking film 10 made of polyethylene (PE) or polypropylene (PP) is rolled into a pair of upper and lower rolls 8',
After laminating the upper and lower surfaces of the laminate 9 using
A plurality of upper and lower pairs of hot press rolls 11.11 whose temperature can be adjusted within a range of about 150° C. are used to continuously perform hot press forming (hardening). After hot-pressing, the air-blocking film IO was removed, and the resulting long decorative board 1
2 is wound onto a winding drum 13 or the like. In the figure, 14 is a film feeding drum, and 15 is a film peeling drum. Next, the long decorative board is cut into a desired length using a cutter or the like to obtain a finished decorative board. The thickness of the long decorative board is thick,
If winding is not possible, or even if winding is possible, the film may be cut to a desired length without being wound on a winding drum.

The number of sheets of the first prepreg and the second prepreg used or the order of lamination must be determined as appropriate depending on the purpose of use of the decorative board or the desired thickness of the decorative board.
It is preferable to stack a plurality of prepregs, one second prepreg on the surface thereof, and one first prepreg having a transparent base material on the surface.

This is because there is an effect that the resulting decorative board is less likely to warp or the pattern will be worn away.

Making decorative laminates in this way reduces manufacturing costs because expensive molds are not required, and mass production is possible because long strips of prepreg are used and continuous lamination and hot-pressing are performed. It's easy to do. Furthermore, transparency is achieved due to the use of the first and second prepregs as described above.

It is possible to obtain a decorative board with excellent depth and solidity, and excellent performance such as boiling resistance and heat resistance.

Next, examples and comparative examples will be explained.

[Example 1] Overlay paper for decorative boards printed with a marble pattern (linter, 30 g/rrf) and bleached kraft base paper (12 g/rrf)
5 g/m) was first impregnated with an aqueous solution of methylol melamine resin obtained by condensation at a ratio of F/M = 2.3 as a pretreatment, resulting in a resin content of 12% and a volatile content of 3.
．． It was set to 0%. This overlay paper and bleached kraft base paper are rolled up into a roll, and then a long decorative board is made as shown in Figure 1, and the long decorative board is cut to a regular length to become a product. I made a decorative board. However, if polyester resin is used as the resin for secondary impregnation,
The resin content of the side base material was 50%.

Then, seven sheets of bleached kraft base paper were stacked, an overlay paper was layered on the surface thereof to form a laminate, and the laminate was heated and pressurized under curing conditions of 60 to 70°C to be cured. The composition of the polyester resin is as follows.

Unsaturated polyester resin 100 parts by weight (average molecular weight 1400-2゛0) Styrene monomer 70 parts by weight Benzoyl peroxide 20 parts by weight (50% paste) [Example 2] Decorative board printed with a marble pattern as in Example 1 Overlay paper (printing linter paper) and bleached kraft base paper (bleached kraft paper) were first impregnated with methyl roll melamine resin and wound up into a roll. Thereafter, a long decorative board was made in the same manner as shown in Fig. 1, and the long decorative board was cut to a regular length to produce a finished product. However, a polyester resin was used as the resin for secondary impregnation, six sheets of bleached kraft base paper were stacked, one sheet of overlay paper was stacked on the surface of the overlay paper, and one sheet of bleached kraft base paper was further stacked on the surface to form a laminate. The composition of the polyester resin is as follows.Unsaturated polyester resin
100 parts by weight (average molecular weight 1400-2300) Diaryl phthalate monomer 60 parts by weight Benzoyl peroxide 20 parts by weight (50% paste) [Comparative example] Overlay paper for decorative boards printed with a marble pattern (printed linter paper) and bleached kraft base paper was wound into a roll without pretreatment for resin impregnation, and then the same operations as in Example 1 were performed to produce a decorative board.

The decorative boards obtained in Examples 1 and 2 were superior in transparency, depth, and oppressive feel compared to those obtained in Comparative Examples.

The decorative boards obtained in Example 1.2 and Comparative Example had boiling resistance (JIS method), heat resistance 9 surface hardness (JAS method),
Impact resistance and stain resistance (JIS method) were examined. However, heat resistance is determined by using a steel plate with a diameter of 10 cm and a thickness of 1 cI11 that is equipped with an electric heater and whose temperature can be controlled, and whether or not there are any abnormalities on the surface of the decorative board when this steel plate is placed on the decorative board and heated. The evaluation was made by examining the Then, the steel plate was held at a constant temperature, and if there was no abnormality at all for 60 seconds, this temperature was considered OK. The results are shown in Table 1. In the table, ○ indicates good quality, △ indicates fair quality, and × indicates poor quality.

(The following is a blank space) Table 1 From Table 1, the decorative boards obtained in Examples 1 and 2 have superior boiling resistance and heat resistance, as well as surface hardness and It can be seen that the impact resistance and stain resistance are also at the same level. [Effects of the Invention] The decorative laminate manufacturing method according to the present invention produces a decorative laminate in step 7 as described above, so that it has a transparent feel.

It is easy to mass-produce decorative laminates that have excellent depth and solidity, and are inexpensive and have excellent performance.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic explanatory diagram of an embodiment of the method for manufacturing a decorative board according to the present invention. 5... Second prepreg 6... First prepreg 8... Assemblage roll 11... Hot pressure roll 12...
・Long decorative board (laminated hardened body) Agent: Patent attorney Takehiko Matsumoto

Claims (5)

[Claims] (1) Two transparent thermoplastic resins are applied to a long strip-shaped base material that has been primarily impregnated with a resin that has an affinity for the base material.
Next, the required number of the first prepreg made by impregnating the substrate and the second prepreg made by impregnating a printed transparent long strip base material with a transparent thermosetting resin are laminated and heated. A method for manufacturing a decorative board, which comprises continuously performing pressure forming and cutting the obtained strip-shaped cured laminate to a desired length. (2) The method for manufacturing a decorative laminate according to claim 1, wherein the resin having an affinity for the base material is an amino resin. (3) The decorative board according to claim 1 or 2, wherein the transparent thermosetting resin is at least one selected from the group consisting of polyester resin, melamine resin, and acrylic resin. manufacturing method. (4) The method for manufacturing a decorative board according to any one of claims 1 to 3, wherein the base material of the first prepreg is transparent. (5) A plurality of first prepregs serve as a core, and a second prepreg is superimposed on the surface of the core, and a first prepreg having a transparent base material is further superimposed on the surface of the core. A method for manufacturing a decorative board according to any of items up to 4.