JPS6153949B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a decorative material that has good peeling resistance and is used as a building material.

Decorative materials used as interior materials for houses are made by gluing paper-like sheets with a surface decoration onto a base material such as plywood. There were problems such as peeling. Therefore, there are methods to improve interpaper strength by coating paper-like sheets with urethane-based or aminoalkyd resins using gravure coating, etc., or impregnating paper-like sheets with diallyl phthalate resins, polyester resins, etc. and bonding them with the base material by thermocompression. There are known methods to do this. However, in the former method, the amount of added resin must be considerably increased in order to obtain sufficient paper separation, but in this case, the paper quality is significantly hardened, which significantly impairs processing suitability for subsequent processes such as printing and coating. lose a lot of money. On the other hand, since the latter method uses a hot plate at a temperature of 150° C. or higher, there is a problem in that the added synthetic resin hinders mold release.

The present invention was made in view of the above circumstances, and its purpose is to provide a method for producing a decorative material that has high peel strength and adhesion to a base material, and has good dimensional stability. It's about doing.

That is, the present invention uses a paper-like sheet with a surface decoration and internally added with a resin having active hydrogen or hydroxyl groups, a hydrophilic emulsion with a resin solution having active hydrogen or hydroxyl groups and POVAL as a protective colloid, and polyisocyanate. The present invention provides a method for manufacturing a decorative material, which is characterized in that it is pressed and integrated onto a decorative material base material using an adhesive made of a mixed solution of a decorative material.

The surface-decorated paper sheet (or decorative paper) used in this invention is made of wood pulp or synthetic resin pulp (e.g. vinylon, nylon, etc.).
It is made from polypropylene (polypropylene), and resin is added internally during paper manufacturing. As the internally added resin, it is preferable to use a resin having active hydrogen or a hydroxyl group, such as an acrylic resin, a vinyl acetate resin, a vinyl chloride resin, a chlorinated rubber resin, or a melamine resin. Furthermore, the density of this resin-coated paper is preferably 0.7 or less. The surface decorative layer to be applied on this internal paper sheet can be one in which a desired pattern is printed with ink and then a top coat made of polyvinyl chloride or the like, or a thermosetting material such as aminoalkyd or urethane can be used as the top coat. A material using a resin or a surface decorative layer having an uneven pattern can be used as appropriate.

Next, as mentioned above, the adhesive used in this invention includes a resin solution having active hydrogen or a hydroxyl group,
It consists of a mixture of three components, a hydrophilic emulsion using POVAL as a protective colloid, and a polyisocyanate, in which three components are uniformly dispersed. A synthetic resin having active hydrogen or hydroxyl groups such as resin, vinyl chloride resin, chlorinated rubber resin, or melamine resin dissolved in a solvent containing a polar solvent, such as a ketone solvent or an ester solvent can be used. . In addition, especially preferred as this polar solvent are ester solvents such as ethyl acetate and butyl acetate. Next, as a hydrophilic emulsion containing POVAL as a protective colloid, a protective colloid solution containing POVAL of any synthetic resin such as styrene-butadiene rubber, ethylene vinyl acetate resin, or acrylic resin can be used. As the polyisocyanate, conventionally known polyisocyanates can be used as appropriate.

The mixing ratio of the resin solution having active hydrogen or hydroxyl groups, the hydrophilic emulsion, and the polyisocyanate is 30 to 70 parts by weight of the resin solution and 6 to 10 parts by weight of the polyisocyanate per 100 parts by weight of the hydrophilic emulsion. It is preferable to do so. If the proportion of the resin solution added is 70 parts by weight or more, the POVAL protective colloid may be destroyed. Further, even if the proportion of polyisocyanate added is 10 parts by weight or more, it is unnecessary because it does not contribute to the curing reaction with other materials. Note that the lower limit of these additives is the limit necessary to achieve the purpose of addition.

Various types of plywood, hardboard,
Particle board, inorganic board, etc. can be used as appropriate, and there are no particular limitations.

As a method of pressing and integrating a paper-like sheet with resin embedded on a decorative material base material, only the back side of the paper-like sheet is
Alternatively, apply the above adhesive in an appropriate amount, for example, 100 to 180 g/ ^m2 , only on the surface of the base material, or on both the back surface of the paper sheet and the surface of the base material, using any coating means such as a roll. After that, the base material, adhesive and resin-incorporated paper-like sheet were polymerized, and then pressed with a flat plate press at a pressure of 5 to 10 kg/cm ² .
Pressing is performed at room temperature or 80 to 120°C for 5 to 30 minutes, followed by curing for 24 to 48 hours. In addition, instead of a flat plate press, a continuous roll press (3~
6 passes) under the same conditions as above.

According to this invention, since the decorative paper-like sheet contains a polar solvent as an adhesive with the decorative material base material,
The adhesive has a high penetration power into the decorative paper-like sheet and the base material, and the resin added to the paper-like sheet, the active hydrogen present in the resin in the resin solution, and the poval, the functional hydroxyl group and the isocyanate are crosslinked. Because the reaction occurs and hardens, the paper peel strength is significantly strengthened. Furthermore, if the base material is wood, a hardening reaction occurs between the hydroxyl groups in the cellulose in the wood fibers and the isocyanate in the adhesive, resulting in a paper-like sheet. The peel strength with the base material also increases. In addition, the resin in the top coat layer of the paper-like sheet (if it has active hydrogen or functional hydroxyl groups) is also affected by the impregnated adhesive, and a part of it hardens, improving the adhesiveness of the paper-like sheet. do.

Furthermore, according to the present invention, when press-integrating a paper-like sheet with a decorative material base material, there is no need for high temperature and high pressure as in the conventional method using a hot press, and the hardened additive resin suppresses expansion and contraction. In addition, water resistance is added to the curing reaction, resulting in extremely good dimensional stability of the product.

Example 1 A paper with a basis weight of 50 g/m ² containing 10% by weight of methylolated melamine resin was coated with a PVC foam paste layer with a pattern made with polyvinyl chloride resin (PVC) ink, and Using a decorative paper with a PVC clear paste layer applied on top of it, this was polymerized onto a wood plywood substrate whose top surface had been coated with adhesive in advance using a roll coater, and then applied using a flat plate press to a pressure of 7 kg/cm ² for 15 minutes at room temperature. After pressing, it was taken out, tightened with turnbuckles, and cured for 2 days to obtain a decorative board.

In this example, 60 parts by weight of POVAL protective colloid of styrene-butadiene rubber and 40 parts of ethyl acetate solution (30%) of acrylic resin were used as adhesives.
A mixture of 6 parts by weight of polyisocyanate and 6 parts by weight of polyisocyanate was used and coated onto the above substrate at a rate of 180/m ² .

As a result of a peel test of the resulting decorative board, no peeling occurred between the sheets or the decorative paper and the substrate, but destruction of the plywood material or destruction of the PVC foam layer occurred. Or, the dimensional change rate of this decorative board is 0.1 ~
It was around 0.2%.

Example 2 As decorative paper, a thin paper with a basis weight of 30 g/m ² to which 10% by weight of acrylic resin was added was dry-coated with an aminoalkyd paint at 10 g/m ² . In addition, 30 parts by weight of an emulsion containing ethylene vinyl acetate/acrylic copolymer as an adhesive and POVAL as a protective colloid, 3 parts by weight of polyisocyanate, and acetic acid containing vinyl chloride/vinyl acetate/acrylic copolymer with an average degree of polymerization of 500 to 1000. A mixed solution consisting of 20 parts by weight of a solution dissolved in a mixed solution of butyl and toluene (5:1) was used.

This adhesive was applied to the surface of lauan plywood (2.7 mm thick) at a rate of 150 g/m ² using a roll coater, then the above decorative paper was polymerized, and a continuous roll press (5 passes) was used at a roll pressure of 5 kg/cm. , temperature 60~100℃
The decorative board was then deposited and cured for 48 hours. As a result, a decorative board having peel strength and dimensional stability similar to those of Example 1 was obtained.

Claims (1)

[Scope of Claims] 1. A paper-like sheet with surface decoration and internally added with a resin having active hydrogen or hydroxyl groups is treated with a hydrophilic emulsion containing a resin solution having active hydrogen or hydroxyl groups and poval as a protective colloid. 1. A method for producing a decorative material, which comprises pressing and integrating the decorative material onto a base material using an adhesive made of a liquid mixture with polyisocyanate. 2 The resin having active hydrogen or hydroxyl group is acrylic resin, vinyl acetate resin, vinyl chloride resin,
The method for producing a decorative material according to claim 1, wherein the decorative material is selected from chlorinated rubber resins and melamine resins. 3 The mixing ratio of the resin solution, hydrophilic emulsion, and polyisocyanate is the same as that of the hydrophilic emulsion.
2. The method for producing a decorative material according to claim 1, wherein the resin solution is in a range of 30 to 70 parts by weight and the polyisocyanate is in a range of 6 to 10 parts by weight based on 100 parts by weight.