JPS5933116B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention uses a glass fiber nonwoven fabric impregnated with a diallyl phthalate resin as the surface layer.

The present invention relates to a method for producing a decorative board having improved hardness and wear resistance. Traditionally, diallyl phthalate resin decorative boards have been used for entrance doors, kitchen areas, etc., and have been well received due to their excellent weather resistance, crack resistance, and stain resistance.

However, it is less frequently used for flooring materials, table tops, etc. because it lacks hardness and abrasion resistance. Therefore, some studies have been conducted to use nonwoven fabrics made of organic fibers or resin-impregnated paper fabrics such as high-purity α-cellulose paper as overlay layers in order to improve the apparent abrasion resistance. It is hardly put into practical use because of its poor hardness and low effectiveness in improving hardness and wear resistance.

Further, in the past, the use of glass fibers as woven or non-woven fabrics for overlay layers has been considered. One example is woven glass fiber fabrics used for laminated materials such as printed circuit boards. The disadvantages of using this in the present invention are that the woven pattern of the woven fabric remains on the surface of the decorative board, making it impossible to obtain a smooth decorative surface, and that stress during molding remains, resulting in scratches on the surface layer. It cannot be put to practical use because the overlay layer easily peels off and the transparency is low. The other one utilizes a Surf Ace mat (glass fiber nonwoven fabric) used in unsaturated polyester molding. In this case, since the tensile strength of the mat is low, resin impregnation,
Problems such as cutting occur frequently during the drying process.
Even if a resin-impregnated mat is obtained, the nonwoven fibers flow along the resin flow during molding, causing defects such as an increase in burrs and a decrease in the concentration of glass fibers in the overlay layer, reducing the reinforcing effect. As a result of various studies on such impregnated base materials, the present inventors discovered a method of using a glass fiber nonwoven fabric impregnated with diallyl phthalate resin as an overlay layer of a decorative board, and as a result, the surface hardness and The present invention was achieved by confirming that the wear resistance was significantly improved. The present invention provides a cosmetic base material impregnated with or not impregnated with a diallylphthalate resin.
The surface layer is an unprinted glass fiber nonwoven fabric with a tensile strength of 1.5kg/15n width or more and a basis weight of 10 to 100g/I, and the above diallyl phthalate resin is applied to the nonwoven fabric at a rate of 150 to 150%.
This is a method for producing a diallyl phthalate resin decorative board with improved wear resistance and hardness, which is characterized by stacking sheets impregnated with 500% by weight and performing hot-pressure lamination molding.

The diallyl phthalate resin used in the present invention refers to a diallyl phthalate early polymer having a number average molecular weight of 2,000 to 30,000 alone, a polybasic unsaturated acid such as maleic acid, fumaric acid, and itaconic acid, phthalic anhydride, and isophthalic acid. , a mixture with an unsaturated polyester synthesized from a polybasic saturated acid such as adipic acid and a polyhydric alcohol such as diethylene glycol or propylene glycol, and if necessary, a diallyl phthalate monomer.

The glass fiber nonwoven fabric used in the present invention has a basis weight of 10
-1009/d and a tensile strength of 1.5 kg/15 mm or more and an unprinted material are used.

If the basis weight is less than 109/7r1, the effect of improving abrasion resistance will be low, and if it exceeds 1009/TI, the overlay layer will lack transparency, which is not preferable. Tensile strength 1.5k9/
If the width is less than 15 m1L, the above-mentioned troubles will occur in the impregnation process, molding process, and molded product performance. In carrying out the present invention, impregnating a glass fiber nonwoven fabric with a diallyl phthalate resin is carried out by a conventional method. That is, a resin solution prepared by dissolving and mixing the resin, a polymerization initiator, an internal mold release agent, and other additives in an organic solvent such as acetone, methyl ethyl ketone, toluene, or acetic acid ester is applied to or immersed in the nonwoven fabric, and then dried. After that, a resin-impregnated nonwoven fabric is obtained. The amount of resin attached to the nonwoven fabric is 150-5
00 weight? A range of is appropriate. If it is less than 150% by weight, there is a risk that force deviation may occur on the surface after molding or transparency may be impaired.

Further, for impregnating a paper cloth or a wooden veneer with a resin as a base material for surface decoration, the resin liquid may be used for impregnation, or a commercially available resin-impregnated paper cloth or the like may be used. In either case, the amount of resin deposited is preferably in the range of 50 to 150% by weight based on the weight of the paper cloth or wood veneer. In some cases, it is also possible to use paper cloth or wood veneer that is not impregnated with resin. In this case, the paper cloth or wood veneer may be bonded in advance to a predetermined substrate via an adhesive and then subjected to molding. Although ordinary cellulose-based paper cloth can be used, olefin-based synthetic paper is particularly suitable. The wood veneer may be any tree species commonly used in wood-plastic ivy composites, such as cedar, paulownia, lauan, beech, birch, cherry tree, etc., sliced into 0.1 to 3 mm pieces. As the substrate, wooden boards such as hardboard, particle board, and plywood, metal boards such as steel plates, stainless steel boards, and aluminum boards, and inorganic boards such as calcium silicate boards and asbestos cement boards are used. In the molding of the present invention, a normal hot-hot molding method can be adopted.

That is, a resin-impregnated glass fiber non-woven fabric, a resin-impregnated paper cloth or wood veneer, and a substrate are laminated in this order, or a resin-impregnated glass fiber non-woven fabric, an unimpregnated paper cloth or a wood veneer is laminated in this order, and these are laminated in this order. Insert the cushion and mirror surface into a suspended hot press machine and press under pressure of 5 to 50 kg/d for 3 to 30 minutes.
A decorative board is obtained by pressing for 20 minutes. The appropriate heating plate temperature at this time is 120 to 1800C. Also,
The present invention can also be applied to the production of laminated sheets without using a substrate.

That is, resin-impregnated glass fiber nonwoven fabric, one or more sheets of resin-impregnated paper cloth, or wood veneer are stacked together, inserted into a press through a mirror surface, and a laminated sheet is produced by hot-hot or cold-hot cold molding. be done.
The molded product obtained by the present invention can be applied to fields of use that require hardness and abrasion resistance, such as table tops and flooring materials, which could not be used with conventional diallylphthalate resin decorative boards. The present invention will be explained below with reference to Examples. Examples 1 to 4, Comparative Examples 1 to 4 Two types of impregnating resin liquids shown in Table 1 were prepared.

The overlay and cosmetic base material shown in Table 2 were impregnated thereon by immersion, respectively, to obtain resin-impregnated sheets that did not have tackiness after drying. Next, 15m1! Using thick plywood (Japan Agricultural Standards Class 1), layer the plywood, resin-impregnated decorative base material, and resin-impregnated overlay in this order, insert it into a heat press with a hot platen temperature of 140C, and remove the cushion and matte duralumin mirror plate. A decorative board was obtained by pressing for 10 minutes under a pressure of 13 kg/0171. In Examples 3 and 4, a non-resin-impregnated decorative base material was adhered to the plywood, and then a resin-impregnated overlay was layered and pressed in the same manner. Table 3 shows the properties and performance of the decorative board obtained. In addition, as a comparative example, basis weight 59/I,
Resin impregnation was carried out using a glass fiber nonwoven fabric with a tensile strength of 0.6k9/15 mm width, but the glass fibers were severely cut and impregnation was not possible.

Claims (1)

[Claims] 1 A tensile strength of 1.5 kg as a surface layer on a cosmetic base material impregnated with diallelphthalate resin or not impregnated with diallelphthalate resin.
An unprinted glass fiber nonwoven fabric with a width of 15 mm or more and a basis weight of 10 to 100 g/m^2 is impregnated with 150 to 500% by weight of the above diallyl phthalate resin to the nonwoven fabric, and then hot-pressure lamination molding is performed. A method for producing a decorative diallyl phthalate resin board having improved wear resistance and hardness.