JPS60172512A - Manufacture of laminate - 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 heat and pressure hardened laminate and a laminate secured by a curvature.

The build-up, which hardens by heat and pressure, generally comprises a core phase consisting of a paper sheet impregnated with a number of phenolic resins, a decorative sheet impregnated with melamine-formaldehyde resin, and optionally a top sheet impregnated with melamine-formaldehyde resin. Made by using These laminates are widely used in home and industrial applications as structural materials, ie, wall panels, counter tops, etc. These are unique 18! It can be manufactured to perform well in various applications, and can be manufactured with glossy, matte and endless surfaces. In the past, they could be formed into steps by the application of heat, and they could be cut and handled in the same way as other building materials.

Although the above-mentioned laminates have proven to be very successful over the past 40 years, there are consistent concerns that the yuzu laminates and/or their manufacturing methods should be completely improved. Therefore, there is a great deal of research focused on achieving such a first-class score.

One property of heat and pressure hardened laminates that is constantly being researched to improve is the dark edge lines that are present in all laminates made from phenolic resins. ).

(b) Dark-colored crease lines that are noticeable when cutting or using regular laminates have been a particular problem.When the resin impregnated into the center sheet is a phenolic resin, when exposed to light, it has a dark color. For example, even if a water-clear phenolic resin is used as the center flank, photo-ulf coloring of the edges exposed to light will occur over time. When a water-clear cameramine/formaldehyde resin is used in place of the phenolic resin, the laminates made therefrom are high pressure decorative laminates).
@Does not meet the characteristics of the IVEMA standards required for objects.

Accordingly, the dark color edge line of the device l1li layered material is improved, lJlchishi: The color of the soldier sheet and the designer.
If it is possible to select the desired color and 1lij, I"L:,l, the 92 requirements for long fenestrations have been satisfied.

Decorative lamination! In the center sheet of the proboscis, the use of formaldehyde oil containing polymethylolketone as a component allows for a laminate with edge portions of colors that complement the color of the decorative mounting surface, including white and various nosostere colors. Manufacturing of EJ
make it possible. The polymethylolketone-modified melamine-formaldehyde decomposition system provides toughness, dimensional stability, and dimensional stability that pass NEKIA standards for pressure-sensitive decorative laminates made with phenolic resin-impregnated center sheets. It is possible to obtain a surface effect without any interference. If the centerpiece is preferably four-colored with the same color as the C1 backing sheet, the colorized centerpiece is fade-resistant when exposed to artificial or natural UV light (one of the gustel hues). There can be 14 cases, including one.

Formula (+) c, r, H,, -, o・<cR, oH), 1/(1) [
where X is an integer from 3 to 6, and y is an integer from 1 to 6.
! ! The corresponding dark color caused by and in place of the phenol-formaldehyde individual fat that is usually used in the production of oil can be improved.

The polymethylol ketone of the above formula (1) contains 1 to 6 moles of formaldehyde, 2C, H, and 0 (however, 2 is the same as above).
reaction product with a ketone.

Here are some suitable ketones for A1! 1t is one in which X is 3, that is, the hydrogen atoms present are 1 to 61 [! First, it is an acetone reaction product that is leaked through the aldehyde door, which is derived from the reaction between solid and formaldehyde. A further preferred option is one prepared from acetone and 4 moles of formaldehyde.

The polymethylol ketone used in the present invention generally has one hydrogen atom bonded to an α-carbon atom, as described above.
~611...1 with diformaldehyde or formaldehyde:j-b crude agent or donor in an aqueous system with a pB value of about 10 or less and in the presence of a tertiary amine catalyst. In particular, they are produced by the reaction between acetone and formaldehyde, which produces a hydrogen atom of 6 (R + 1). The G1 method is C1ar, which is cited as an A4 document in this book.
p country% of k C/Lemical C″orp = 1
It is described in Publication No. GB2.077.256A.

Melamine-formaldehyde OJ l
Examples of polymethylolketones that can be used in combination with lj are dimethylolacetone, 1,1゜1-trimethylolacetone, l,1,3-1-limethylolacetone, sym, tetramethylolacetone, ), 1,
Includes 1.3-tetramethylolacetone, pentamethylolacetone, hexamethylolacetone, etc. Although acetone is the most easily available ketone, it will be appreciated that other ketones such as methyl ethyl ketone can also be obtained. Similarly, the use of formaldehyde or paraformaldehyde in water can be easily applied to the floor.
It will be appreciated that other sources of formaldehyde can also be used, such as formaldehyde donors or generators, such as Palau formaldehyde.

For the purposes of the invention mentioned above, tetramethio-ruacetone C", Il, tno (C1l, U).

is a suitable ingredient. This is produced by the method described in Example 1 of the above-mentioned British Ith1% publication.

Compositions useful in the production of laminates of the present invention include: 1) the above formula (
Polymethylol ketone represented by 1) and 2)
It is made from a mixture of melamine and formaldehyde fat. This mixture is about 10 to 5
0%, preferably about 20-40%, most preferably f
It will have about 20 to 3051 parts of polymethylolketone. This cutting mixture is made of 1 to 2
about 30 to 7011 i-J, i
It is a liquid with a total solids content of 101%.

Melamine-7 mixed with polymethylolketone (lumaldehyde)
The normal, well-known fcsl+1 ratio in humans is from 1:1 to about 1:4.

Melamine-formaldehyde resin is a lower alkanol,
For example, it can be completely or partially etherified with methanol.

melamine-formaldehyde resin and 71 trimethy,
, Mu1. ＋小n゛，“、・6も・、目むらぎりお −
Made with a 45% solids aqueous resin mixture comprising 75% ragso formaldehyde resin and 25% tetramethylolacetone and having a pH value of 9.5 to 9.9 and a viscosity of about a 5 cps at 25°C. .

A mixture of melamine-formaldehyde resin and polymethylol ketone may be used to impregnate cellulosic paper sheets according to the present invention in an amount of about 25 to about 60 parts by weight based on the pattern of the sheet being impregnated. can.

The above side 11M 戊1j戊(The proboscis is used to impregnate the cellulosic sheet, and then this sheet is used as the center material in the manufacture of the #t)@ product. This resin mixture is
It is used in place of the phenolic resin commonly used in the center sheet of decorative laminates.

The center layer of such sheets is usually made from a plurality of paper sheets, ie from 2 to 12 or more such sheets, impregnated with a phenolic resin as described above. Phenol cutting gives the laminate a dark edge line that is observed in the 1/ifi: section of the laminate when the laminate is cut for use. The center sheet can be stretchable or non-stretchable, or can be used as a ridged sheet set, 14t to 1j.

The 4 generations of these crafts are unfinished (214 white kraft, -H kraft, 214 white kraft, -H kraft, 214 white kraft, 1 color kraft, and 4 white kraft paper). Sheets made from other known pulp products, ie, cotton, rayon, etc., can also be produced in about 4-3 hours per year.

Center sort phenolse 1 fat (1) instead of Qin')
When using a polymethylolketone/melamine-formaldehyde resin mixture according to I3 Ming and coloring the center sheet to match the color of the decorative sheet, the dark colored edges that appear at the edges of the normal laminate Lines or bands are removed. When cutting the laminate to size, the cut laminate edges appear in a color that complements the color of the laminate surface from the decorative sheet, and the edges are beveled or fastened (to hide dark edge lines). The Ushima product can be manufactured without the need for splicing. The properties of the resulting laminate are measured and the required NEM
Play according to A standard. Furthermore, the cut edges of such laminates do not appreciably tremble when exposed to ultraviolet light, which prevails in direct sunlight, i.e., the color remains the same as the surface even with long-term exposure or has other desired properties. Retains the original and intended center color. If it is necessary to precisely match the colors of table (6), the center sheet may be made of the same cellulose product and pigments as the decorative sheet, and if necessary the alpha-cellulose can be placed on top. It may be contained in

The following examples are presented for illustrative purposes only and should not be considered as limiting the invention.

All parts and fractions are by weight unless otherwise specified.

Reference Example A To a suitable reaction vessel were added 435 parts (7.5 mmol) of acetone, 2432 m (30 mol) of 37% aqueous formaldehyde and 0.25 mol of hydryethylamine. 1<
Stir the mixed ingredients, heat to 50℃, and heat to 50℃ for 1 hour.
Moe 1 was saved. An additional 0.5 mole of triethylamine was added and the mixture was allowed to flow under atmospheric pressure for 45 minutes and then cooled to room temperature II. The raw material that was given 4t is solid gold.
Fi: 53%, viscosity 32 cps and pB 8.75. Rhinoceros production, proboscis, tetramethylolacetone,
2% unreacted formaldehyde, 1.1340
I shouldered Ohitun.

Nuclear Example B Tetramethylolacetone product made in Reference Example A (8o oi"ii1 53% solids) gold, 42% solids commercially available melamine-formaldehyde side JIii' 24
00 parts of melamine-formaldehyde resin mixed with 75 parts
A composition containing a heavy polymer head and 25 tetramethylolacetone heavy phases was obtained. The solids content of this mixture was 45%.

Example 1 A sheet of white decorative sheet impregnated with melamine-formaldehyde resin R and 7 white 1581/m2 kraft paper sheets with a combination of Al fat mixed proboscis of Reference Example B with a thickness of 1. A three-rib decorative laminate was produced. (I) The recovered items are all IVEMA for decorative laminates.
I met the standards. The edges of this product were white when cut and did not exhibit dark bands. The edges of the laminate did not exhibit any appreciable discoloration when the edges were exposed to a fade meter according to the IVEMA standard light fastness test method. The manufacturing details of the laminate I snout are as follows: Resin-impregnated sheet , the top decorative sheet, the 7 center sheets,
This process was repeated upwards and downwards, and the IntIn was inserted between metal press plates to form a combined product. A release sheet was placed between the decorative surface and the press board. Some of these combined products were placed on the press platen 11j of a rili layer press. , the press was closed and pressure was applied with the onset of heating. The pressure should be at least 3.4
It was 5 MPα, and the good price was about 9.67 iUpα.

The pressure platen of the press was heated to about 25° C. for about 25 minutes, maintained at about 125° C. for about 26 minutes, and then cooled to below 100° C. while maintaining the pressure. This cycle photon lJ! J opened the press, took out the combined product from the press, and removed it from between the sheets of the now (I!1.! layered laminate) and the metal pressure plate.Excluding the release sheet, the circumference of the image 1 layer +]fJ Any uncured bite was removed from the back side of the 44:I layer's proboscis. Promotes contact/arching of the laminate to the substrate during manufacturing.
To do this, I lightly roughened it with sand.

Example 2 The method of Example 1 was followed except that the back of the Noteke center sheet was used as part of the center sheet instead of one of the center sheets. This sheet is an exact replica of the decorative sheet and has been impregnated with the same resin as the auxiliary sheet. The folded laminate showed excellent properties and was similar to IVEMA in Example 1.
A total of 4 tons were used for the light resistance test.

Examples 3 to 10 Tetramethylolacetone of Reference Example A ((U in Table 1 below)
Other 1? Rough adjustment of IJ methylol ketone
□- The method of Example 2 was repeated except without.゛Each? In all cases, the laminates passed IVEMA standards, including lightfastness tests, and exhibited edge colors that were practically suitable for decorative surfaces.

Claims (1)

[Scope of Claims] 1. In the context of a military match, a laminated composite of a center sheet of paper with rJ number of 7 sides fat-containing paper, a resin-impregnated cover sheet B, and a top sheet that is cut and impregnated as needed. 2) a melamine-formaldehyde resin having a molar ratio of melamine to formaldehyde in the range of about 1:1 to about 1:4; wherein X is an integer from 3 to 6, and y is an integer from 1 to 6.
A method for producing a heat and pressure hardened laminate containing from θ% to about 50%. 2. The method according to claim 1, wherein the resin-impregnated decorative sheet and the center sheet are colored in the same color. 3. The method according to claim 1, wherein the decorative sheet impregnated with an absorbent resin is electrodynamically colored in a color different from that of the central sheet. 4. The method according to claim 1 ++g, in which the yI''r-rimethylolketone is diluted with trimethylol acetone. 5. The method according to claim 1, wherein the polymethylol ketone is trinonalol acetone. Luxury with the method shown
46; 1Ω object.