JPS59209864A - 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 pack 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 of the decorative board, and a lack of transparency due to the color problem of phenolic resin. [Objective of the Invention] The present invention was made in view of the above circumstances, and aims to provide a decorative panel with excellent transparency, depth, and depth, and which is inexpensive and has excellent performance. [Disclosure of the Invention] In order to achieve the above-mentioned object, the present invention aims to provide a method for manufacturing decorative boards that can mass-produce boards. A first prepreg obtained by secondly impregnating the impregnated long strip base material with a transparent thermosetting resin, and a transparent thermosetting resin on the printed transparent long strip base material. The required number of second prepregs each impregnated with a synthetic resin are laminated, the heat molding is continuously performed under no pressure, and the obtained strip-shaped laminated cured product is cut into a desired length. Its gist is the manufacturing method of decorative laminates. 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 base paper, and linter paper, and cloth base materials such as nonwoven fabrics made from glass fibers and polyester fibers 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 the 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 have high permeability to cellulose and are compatible with paper, and among these, it is most preferable to use melamine resin. Melamine resins may be those commonly used for decorative boards, or those for paints, adhesives, and the like. 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 diallylphthalate monomers are suitable as the crosslinking agent. As a polymerization initiator for polyester resin, benzoyl peroxide (BPO), which has a fast decomposition rate, is preferably used since a continuous method is used. As the acrylic resin, those commonly used as acrylic resins such as polymethyl methacrylate and glycidyl methacrylate 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 polyester resins, which are used for secondary impregnation, are compatible with the base material (permeability, chemical bonding, etc.).
Therefore, if a prepreg in which the base material is impregnated with polyester etc. alone, the adhesion strength between the prepregs will decrease and the resulting decorative board will have quality problems such as heat resistance and water resistance. be. In addition, instead of impregnating the base material with the resin for the primary impregnation, paper made by making a mixture containing the resin and fibers for the primary impregnation, such as melamine resin sand-infused paper, is used. You can do it like this. The resin content of the base material containing the resin for primary impregnation is preferably in the range of 3 to 50%. 3%
If it is less than that, the effect of primary impregnation (lining effect) is small,
In terms of the quality of the decorative board obtained, it tends to be almost the same as that using prepreg impregnated with polyester etc. alone, and on the other hand, if it exceeds 50%, the quality of the decorative board obtained when using melamine resin tends to be almost the same. A chip on the board. Cracks, warping, etc. tend 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 g/rd transparent paper is used. As the transparent thermosetting resin, the same resin as mentioned above for the first prepreg is used.

This second prepreg is also preferably impregnated with a resin that has an affinity for the base material, as described above, before being impregnated with a transparent thermosetting resin. The content of this primary impregnating resin is preferably 3 to 50%.

After successively laminating the required number of long strip-shaped first prepregs and similarly long strip-shaped second prepregs,
A long decorative board (laminated cured product) is produced by continuous heat forming under no pressure using a heating furnace (hardening furnace) or the like. Next, the long decorative board is cut into desired dimensions to form the decorative board of 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. Substrates 1' 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 and assembled by the assembly roll 8.8. The laminate 9 is produced by integrating. After laminating the air-blocking film 10 made of polyethylene (PE) or polypropylene (PP) on the upper and lower surfaces of the laminate 9, a curing furnace (heating furnace) in which the temperature can be adjusted within the range of room temperature to about 150°C is used. ) 11 through the laminate 9,
Heat molding (curing) is performed continuously. After thermoforming, the air-blocking film 10 is removed, and the obtained long decorative board 12 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. If the long decorative board is too thick to be rolled up, or even if it can be rolled up, it may be cut to a desired length without being wound up 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 facilitated because long strips of prepreg are used and laminated and heated in succession. It's easy to do. Since heat molding is carried out under pressureless conditions without applying pressure, the manufacturing equipment becomes simple and mass production becomes easier. Furthermore, by using the first and second prepregs as described above, it is possible to obtain a decorative board that has excellent transparency, depth, and solidity, and has 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/nr) and bleached kraft base paper (125 g/nr)
g/rrr), an aqueous solution of methylolmelamine resin obtained by condensation at a ratio of F/M = 2.3 as a pretreatment.
Subsequent impregnation was carried out to give a resin content of 12% and a volatile content of 3.0%, respectively. 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, polyester resin was used as the resin for secondary impregnation, and the resin content of both base materials 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 cured by heating without pressure under curing conditions of 60 to 70°C. The composition of the polyester resin is as follows.

Unsaturated polyester resin 100 parts by weight (average molecular weight 1400-2300) Styrene monomer 70 parts by weight Benzoyl peroxide 2.0 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 7I 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: 100 parts by weight of unsaturated polyester resin (average molecular weight 14
00-2300) Diaryl phthalate monomer 60 parts by weight Benzoyl peroxide 2.0 parts by weight Qr (50% paste) [Comparative example] Oat \-lay paper (printing linter paper) for decorative boards printed with a marble pattern and bleached kraft base paper A decorative board was prepared by winding it up into a roll without performing any pretreatment for resin impregnation, and then performing the same operations as in Example 1.

The decorative boards obtained in Example 1.2 were superior to those obtained in Comparative Examples in terms of transparency, depth, and solid feel.

For the decorative boards obtained in Example 1.2 and Comparative Example, boiling resistance (JIS method), heat resistance 1 surface hardness (JAS method),
Impact resistance and stain resistance (JtS method) were examined. However, heat resistance is determined by using a steel plate with a diameter of IQ cm and a thickness of 1 cm that is equipped with an electric heater and whose temperature can be controlled, and whether or not there is any abnormality 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 and,
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, O
indicates good quality, △ indicates normal 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 the decorative laminate as described above, so that it has a transparent feel.

It is easy to mass-produce a decorative board with excellent depth and depth, low cost, and excellent performance.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an explanatory diagram of an embodiment of the decorative board manufacturing method according to the present invention. 5... Second prepreg 6... First prepreg 8... Laminated roll 11... Curing furnace 12... Long decorative board (laminated cured body) Agent Patent attorney Takehiko Matsumoto

Claims (1)

[Scope of Claims] (11) A first prepreg formed by secondly impregnating a long strip-shaped base material with a resin having affinity for the base material and secondly impregnating it with a thermosetting resin having transparency; and a second prepreg made by impregnating a transparent long strip-shaped base material with a transparent thermosetting resin are laminated in the required number, and are continuously heat-formed under no pressure. conduct,
A method for producing a decorative board, which comprises cutting the obtained strip-shaped cured laminate into 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.