JP2001038703A - Manufacturing method of decorative board - Google Patents

Abstract

(57) [Summary] [Purpose] The walls and storage shelves around the kitchen and water are particularly resistant to contamination and damage, providing a clean feeling.
It is an object of the present invention to provide a method of manufacturing a decorative board which can maintain an aesthetic appearance for a long time with high productivity. [Composition] Substrate (1) surface, basis weight 40-1
200 g / m ^{2, and} the thermosetting resin impregnated paper and dried impregnated with a thermosetting resin in the resin-impregnated paper having a thickness of 0.05~0.30mm and (2), at a basis weight 20 to 50 g / m ^2, thickness A surface coated paper (3) having an antifouling resin coating material coating layer made of a water-repellent resin on the surface is sequentially laminated on a thin paper of 0.02 to 0.05 mm, and this is heat-pressed to heat the thermosetting resin impregnated paper. The substrate (1), the thermosetting resin-impregnated paper (2), and the surface-coated paper (3) are integrated with the curable resin, and the backside of the surface-coated paper is reinforced with the thermosetting resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a stain-resistant material which is particularly suitable for use as a wall material for water around kitchens, bathrooms, washrooms, toilets and the like, and surface materials for storage furniture such as cupboards in residential buildings.
The present invention relates to a method for manufacturing a decorative board excellent in various physical properties such as damage resistance, water resistance and hardness with high productivity.

[0002]

2. Description of the Related Art A decorative board excellent in various physical properties such as water resistance, heat resistance, abrasion resistance and hardness has been conventionally used as a wall material around a kitchen or water in a building such as a house. .

[0003] Such a decorative board is prepared by impregnating a printing paper with a thermosetting resin such as a phenol resin, an unsaturated polyester resin, a diallyl phthalate resin, a melamine resin, a benzoguanamine resin, and a urea melamine resin.
A thermosetting resin-impregnated paper obtained by drying in a pre-cured state called a stage is laminated on the surface of the substrate, and the thermosetting resin in the impregnated paper is cured by applying heat and pressure. Are integrally bonded.

[0004] Since the surface of the decorative board is protected by a thermosetting resin-impregnated paper, the above-mentioned properties are provided with excellent properties. Compared with a general decorative board formed by applying a synthetic resin paint to water, like water around the kitchen and around the kitchen,
Used for sites that are easily affected by heat, scratches, etc.

[0005] However, the decorative plate has a problem that it is relatively easy to be stained and hard to fall off. In particular, when used as a wall material around a kitchen or a surface material of a hanging cabinet, there are many opportunities for the stain to adhere. Therefore, there is a problem that the appearance is easily deteriorated.

Further, in order to impart chemical resistance and antifouling property to the decorative board, a decorative board in which a thermoplastic resin film such as polyethylene terephthalate resin (PET resin) is adhered on a thermosetting resin-impregnated paper is used. is there.

However, a resin film having a certain degree of antifouling property, such as the PET resin, is used as a release film when the above-described conventional decorative board is manufactured by hot-pressing the thermosetting resin-impregnated paper with the substrate. And there is almost no adhesion between the impregnated paper and the PET resin film.

For this purpose, a primer treatment must be applied between the impregnated paper and the film, or a corona discharge treatment must be applied to the back surface of the film to improve the adhesion between the two. There was a problem in production that it had to be managed so as not to occur.

[0009]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and particularly, the wall materials and storage shelves around the kitchen and the water have good stain resistance and damage resistance, and have a clean feeling.
An object of the present invention is to provide a method of manufacturing a decorative board that can maintain a beautiful appearance for a long time with high productivity.

[0010]

Means for Solving the Problems In order to achieve the above-mentioned object, the invention according to claim 1 of the present application is directed to a method for manufacturing a semiconductor device comprising the steps of: "adding a substrate having a basis weight of 40 to 100 g / m ² and a thickness of 0.05 to thermosetting resin impregnated paper and dried impregnated with a thermosetting resin in the resin-impregnated paper 0.30mm and [2 (2a)], basis weight 20 to 50 g / m ^2, thickness 0.02~0.05m
m thin paper sequentially laminated with a surface coated paper (3) having an antifouling resin coating material coating layer made of a water-repellent resin on the surface,
The laminate is heated and pressed to obtain a thermosetting resin-impregnated paper [2 (2
a)), the substrate (1), the thermosetting resin-impregnated paper [2 (2a)] and the surface-coated paper (3) are integrated, and the backside of the surface-coated paper (3). Of a decorative board (A) characterized by reinforcing the above with a thermosetting resin.

The invention according to claim 2 of the present application is characterized in that, in the structure of claim 1 of the present application, the thermosetting resin-impregnated paper [2 (2b)] is also laminated on the back surface of the substrate (1). To produce a decorative board (A).

Further, the invention according to claim 3 of the present application is:
"A thermosetting resin is applied to one or both of the surface of the substrate (1) and the back surface of the surface coated paper (3) having the antifouling resin coating material coating layer according to claim 1 on the surface and dried. After that, the substrate (1) and the surface-coated paper (3) are laminated, and the laminate is heated and pressed to integrate the substrate (1) and the surface-coated paper (3) with the thermosetting resin. And a method of manufacturing a decorative board (A) characterized in that the back side of the front coated paper (3) is reinforced with the thermosetting resin.

Further, the invention according to claim 4 of the present application is directed to the decorative board (A) according to the third aspect of the present invention, wherein a thermosetting resin is also applied to the back surface of the substrate (1). Manufacturing method ”.

Further, the invention according to claim 5 of the present application is characterized in that, in each of the constitutions of claims 1 to 4 of the present application, the “substrate (1) is
Method for producing decorative board (A), which is an inorganic substrate having a specific gravity of 0.6 to 0.9 ”.

[0015] The invention according to claim 6 is based on claim 1.
In each of the structures (1) to (5), “a decorative board according to any one of (1) to (4), wherein at least one of the thin paper constituting the surface coated paper and the antifouling resin coating material coating layer is subjected to a flame retardant treatment. A) Manufacturing method ”is provided.

According to the invention of claim 1 of the present application, because of the above-mentioned structure, the substrate (1) is provided with a thin thermosetting resin impregnated paper [2 (2a)] and a thin surface. The surface coating paper (3) having an anti-fouling resin coating material coating layer is integrated with them simply by hot-pressing them, whereby the decorative board (A) is manufactured.

The surface coated paper (3) is much thinner than the resin impregnated paper (2),
The thermosetting resin in (2) flows, and the substrate (1) and the resin-impregnated paper
(2) The resin-impregnated paper (2) and the back side of the surface-coated paper (3) can be firmly adhered to each other, and the surface-coated paper (3) can be reinforced and strengthened, and it has water resistance, heat resistance, and hardness. ,
The antifouling property and the damage resistance are remarkably improved without lowering the peeling resistance and the like.

According to the invention of claim 2 of the present application, the backside of the substrate (1) also has a thick thermosetting resin-impregnated paper [2 (2b)]
Is laminated, so that the decorative board (A) to be manufactured does not warp and, for example, when the door is opened when used as a door surface material of a kitchen hanging door, the board (1) is not exposed and the appearance is beautiful. In addition, water resistance, abrasion resistance, damage resistance, and the like are imparted to such a back surface.

According to the invention of claim 3 of the present application, the surface of the substrate (1) or the back of the surface coated paper (3) having the antifouling resin coating material coating layer according to claim 1 on the surface. After applying and drying either one or both of the thermosetting resin, the decorative board (A) is manufactured by laminating the substrate (1) and the surface-coated paper (3) and applying heat and pressure. It will be.

According to the invention of claim 4 of the present application, since the thermosetting resin is also applied to the back surface of the substrate (1), for example, when the door is opened when the door is used as a door surface material of a kitchen hanging door. Also, the substrate (1) is not exposed and the appearance is good, and water resistance, abrasion resistance, damage resistance and the like are imparted to such a back surface.

According to the invention of claim 5 of the present application, since an inorganic plate having a specific gravity of 0.6 to 0.9 is used for the substrate (1),
In particular, it is suitable for fire prevention around the kitchen and is easy to handle because of its light weight as an inorganic plate, and the relatively rough surface of the surface of such an inorganic plate is coated with a thermosetting resin layer. By providing the layer, the layer has mirror smoothness and sufficient hardness.

According to the invention of claim 6 of the present application, since flame retardancy can be imparted to the surface-coated paper, it is possible to impart fire-resistance such as making it difficult to ignite the surface.

[0023]

BEST MODE FOR CARRYING OUT THE INVENTION The substrate (1) used in the present invention is a wood board such as plywood, particle board, MDF, hard board having a thickness of about 6 mm to 15 mm, hard cement calcium silicate board, gypsum slag. An inorganic plate such as a plate, a calcium silicate plate, an inorganic multilayer plate (manufactured by Daiken Kogyo Co., Ltd., trade name: Dylite), a flexible board, or the like can be used.

In particular, when used for walls around water or kitchens, or as a storage space, as described in claim 5 of the present application, an inorganic plate having a specific gravity of about 0.6 to 0.9 is lightweight and has good workability.
Further, it is suitably used in that it has good fire protection.

The thermosetting resin-impregnated paper [2 (2a) (2b)] used in the present invention is obtained by adding a resin-impregnated paper to diallyl phthalate resin, phenol resin, unsaturated polyester resin, melamine resin, urea resin. A material impregnated with a thermosetting resin such as a melamine resin or a benzoguanamine resin and dried and precured to a so-called B stage can be suitably used. The thermosetting resin-impregnated paper [2 (2a) (2b)] may be one having a printed pattern printed on the surface.

The impregnated paper having the resin impregnating property includes:
For example, titanium paper or kraft paper, etc., and the basis weight is 40 to
100 g / m ² and a thickness of 0.05 to 0.30 mm are selected.
When the grammage is less than 40 g / m ² or the thickness is less than 0.05 mm, the thermosetting resin-impregnated paper (2) obtained by impregnating the same with water-resistant, heat-resistant, It is not preferable because wear resistance and hardness are insufficient. Conversely, the grammage is 100 g / m
^{When the} thickness exceeds ² , or when the thickness exceeds 0.30 mm, it is not preferable because it is heavy and expensive, and practical advantages are poor.

The amount of the thermosetting resin impregnated into the resin-impregnated paper is determined by the obtained thermosetting resin-impregnated paper [2 (2a) (2b)]
Is selected in the range of 40-70% by weight. If the content is less than 40% by weight, the resulting thermosetting resin-impregnated paper [2 (2a) (2b)] is not preferable because of insufficient water resistance, heat resistance, abrasion resistance, hardness and the like. On the other hand, if it exceeds 70% by weight, it is not preferable because it is heavy and expensive, and practical advantages are poor.

Surface coated paper used in the present invention
(3) is composed of a thin paper having a basis weight of 20 to 50 g / m ² and a thickness of 0.02 to 0.05 mm, and an antifouling resin coating material coating layer made of a water-repellent resin applied to the thin paper.

When the thickness of the thin paper is less than 0.02 mm, the strength becomes weak. When the thickness exceeds 0.05 mm, unevenness occurs in the backside reinforcement by the thermosetting resin in the impregnated paper at the time of hot pressing.
It is not preferable because there is a fear that the hardness and the damage resistance may be reduced or the peeling may be easily performed. In addition, a flame-retardant one or a flame-retardant one may be used for the thin paper.

The coating layer of the antifouling resin coating material is composed of a coating material containing a water repellent resin, and further prepared by optionally adding a coloring agent and inorganic powder such as flame-retardant alumina and silica. You. At least one of a fluororesin and a silicone resin is selected as the water-repellent resin. The addition of the inorganic powder is preferable from the viewpoint of improving wear resistance.

The thermosetting resin-impregnated paper [2 (2a) (2
b)), if a printed pattern is formed, use a transparent coating material, while the thermosetting resin impregnated paper [2 (2a) (2
When it is desired to conceal the color of b)), a coating material having concealment properties can be used.

The above-mentioned coating material is usually applied at a solid content of 3 to 20 g / m ² , but is not particularly limited thereto.

The method for producing a decorative board (A) of the present invention comprises the steps of: drying the substrate (1) on the thermosetting resin-impregnated paper [2 (2a)] and the surface-coated paper (3) Are sequentially placed, and are laminated under heat and pressure. At this time, part of the resin of the thermosetting resin-impregnated paper [2 (2a)] migrates to the surface-coated paper (3), and the surface-coated paper (3) itself is reinforced. In addition, the condition of the said heat pressure is
Although it is appropriately selected depending on the type of the substrate (1) and its thickness, it is usually performed at 120 to 140 ° C. and about 5 to ²⁰ kg / m ² .

The decorative board (A) obtained as described above is
Since a thermosetting resin-impregnated paper [2 (2a)] having an appropriate thickness is laminated, water resistance, heat resistance, damage resistance, hardness and the like are imparted, and the resin-impregnated paper [2 (2a)) and the surface-coated paper (3), which is integrated by heat and pressure, with resin-impregnated paper [2 (2
a)), the substrate (1) and the resin-impregnated paper [2] are coated in one shot without applying an adhesive to the precured resin-impregnated paper [2 (2a)]. 2 (2
a)] can be integrally and well bonded.

The resin in the thermosetting resin-impregnated paper [2 (2a)] in the pre-cured state not only adheres the resin-impregnated paper to the surface-coated paper (3), but also adheres to the surface-coated paper (3). The resin impregnated paper (2 (2a)) can be reinforced by reinforcing it with water, heat resistance, damage resistance, and the like. Can be improved.

A relatively light substrate (1), for example, having a specific gravity of 0.6
Conventionally, a decorative sheet or printing paper is stuck on the surface of the substrate, and a synthetic resin paint is applied on it to form a decorative board, which may result in insufficient damage resistance. However, in the present invention, since the relatively light-weight substrate (1) is laminated and integrated with a relatively thick resin-impregnated paper [2 (2a)], damage resistance and hardness can be improved. I have.

Further, in the method for manufacturing the decorative board (A) of the present invention, the resin-impregnated paper [2 (2b)] may be integrated with the back surface by heat and pressure. Also in this case, the resin-impregnated paper [2 (2a)] and the surface-coated paper (3) on the front surface and the resin-impregnated paper [2 (2b)] on the rear surface can be integrated by heat and pressure in one shot.

Further, on the front or back surface of the substrate (1), an underlayer coated with a sealer or putty of acrylic resin or the like is formed, and the substrate (1) and the resin-impregnated paper [2 (2a) (2b) ] Can be improved.

[Examples] The present invention will be described below with reference to examples and drawings, but the present invention is not limited thereto.

As the substrate (1), an inorganic multilayer plate (trade name: DAILIGHT, manufactured by Daiken Kogyo Co., Ltd.) having a thickness of 15 mm and a specific gravity of 0.7 was prepared. / m ² titanium paper impregnated with diallyl phthalate resin at a rate of 80 g / m ² , and dried and precured in the state of B stage for the front side (2a) and the back side (2b ) Was prepared.

The surface-coated paper (3) in which the thermosetting resin-impregnated paper (2a) is disposed on the surface of the substrate (1), and a fluororesin-based coloring paint is applied thereon at 6 g / m ^{2 in} terms of solid content. The thermosetting resin-impregnated paper (2b) is disposed on the back surface of the substrate (1), and is heat-pressed at 130 ° C. and 12 kg / cm ² for 12 minutes to integrate them. A plate (A) was obtained.

Comparative Example 1 A decorative plate of Comparative Example 1 was obtained in the same manner as in the above example except that the surface-coated paper was not used.

[Comparative Example 2] A commercially available diallyl phthalate resin decorative board having a smooth surface was used.

A stain resistance test was performed on the decorative boards of the above Examples and Comparative Examples. Table 1 shows the results. In the stain resistance test, the stain was brought into contact with a decorative board, heated at 100 ° C. for 24 hours, washed, and the state of the stain was observed. The contaminants are as shown in Table 1. In Table 1, ◎ indicates no contamination, は indicates slight contamination, Δ indicates considerable contamination, and × indicates strong contamination.

[0045]

[Table 1]

From the above results, it can be seen that the decorative plate obtained by the method of the present invention has excellent antifouling properties.

[0047]

According to the invention of claim 1 of the present application,
A decorative board can be manufactured with high productivity simply by laminating and hot-pressing a thick thermosetting resin-impregnated paper and a surface-coated paper having a thin and antifouling resin coating material coating layer on the surface. be able to.

Also, the surface-coated paper is much thinner than the thermosetting resin-impregnated paper, and the thermosetting resin in the thermosetting resin-impregnated paper flows at the time of hot pressing, and the substrate and the resin-impregnated paper, The resin-impregnated paper and the backside layer of the surface-coated paper can be firmly adhered to each other, and the surface-coated paper can be reinforced.Water resistance, heat resistance, peeling resistance, without reducing the hardness, antifouling properties, Damage resistance can be significantly improved.

According to the invention of claim 2 of the present application, since a thick thermosetting resin-impregnated paper is also laminated on the back surface of the substrate, the decorative board obtained does not warp and, for example, a kitchen hanging door When the door is opened, the substrate is not exposed even when the door is opened, and the aesthetic appearance is good, and water resistance, abrasion resistance, damage resistance and the like can be imparted to such a back surface.

According to the invention of claim 3 of the present application, in addition to the effect obtained by the above-mentioned claim 1, a thermosetting resin impregnated paper is not required, which further improves productivity and reduces production cost. Can be reduced.

According to the invention of claim 4 of the present application, the same effect as that of claim 2 can be obtained because the thermosetting resin is also applied to the back surface of the substrate.

According to the invention of claim 5 of the present application, since an inorganic plate having a specific gravity of 0.6 to 0.9 is used for the substrate, it is suitable for fire prevention especially around a kitchen and is lightweight as an inorganic plate, so that it can be handled easily. It is easy, and since the surface coating layer is provided on the relatively rough surface of the surface of such an inorganic plate via a thermosetting resin layer, it has mirror smoothness and sufficient hardness. A decorative board can be manufactured.

According to the invention of claim 6 of the present application, since flame retardancy can be imparted to the surface-coated paper, it is possible to impart fire resistance such as making surface ignition difficult.

[Brief description of the drawings]

FIG. 1 is a structural explanatory view of an example of a decorative board manufactured by the method of the present invention.

[Explanation of symbols]

 (A) ... decorative board (1) ... substrate (2) (2a) (2b) ... thermosetting resin impregnated paper (3) ... surface coated paper

 ────────────────────────────────────────────────── ─── Continuation of front page (72) Inventor Ikuo Kawahara 1-5-1, Kobashiyamahoncho, Tarumi-ku, Kobe-shi, Hyogo F-term (reference) 2G002 AA01 AA04 BA01 BB04 BB12 DA02 DA06 2B250 AA06 AA09 AA11 BA05 BA06 BA07 DA04 EA02 EA11 FA21 FA31 FA33 FA37 FA45 GA03 HA01 4F100 AA00A AK01B AK01C AK17C AK41B AT00A BA03 BA07 BA08 BA10A BA10C CA13C CC00C DG10B DG10C EH012 EH46C EH461 EJ051 EJ082 EJ172 EJ422 EJ641 EJ861 GB08 JA13A JA13B JA13C JB06 JB06C JB10B JJ07B JK12 JK14 JL02 JL06 JL06C YY00A YY00B YY00C

Claims (6)

[Claims] 1. A substrate having a basis weight of 40 to 100 g / m ² on a substrate surface.
A thermosetting resin-impregnated paper dried by impregnating a thermosetting resin into a resin-impregnated paper having a thickness of 0.05 to 0.30 mm and a basis weight of 20 to 50 g /
m ^2, and the sequentially laminating a surface coating paper having antifouling resin coating material coated layer made of water-repellent resin to the thin thickness 0.02~0.05mm the surface, the thermosetting of the laminated body by heating and pressing The thermosetting resin in the resin-impregnated paper integrates the substrate, the thermosetting resin-impregnated paper, and the surface-coated paper, and the backside of the surface-coated paper is reinforced with the thermosetting resin. Plate manufacturing method. 2. The method for manufacturing a decorative board according to claim 1, wherein a thermosetting resin-impregnated paper is also laminated on the back surface of the substrate. 3. A thermosetting resin is applied to one or both of the front surface of the substrate and the back surface of the surface coated paper having the antifouling resin coating material coating layer according to claim 1, and dried. The substrate and the surface-coated paper are laminated, and the laminate is heated and pressed to integrate the substrate and the surface-coated paper with the thermosetting resin, and the backside of the surface-coated paper is coated with the thermosetting resin. A method of manufacturing a decorative board, wherein the decorative board is reinforced. 4. The method for manufacturing a decorative board according to claim 3, wherein a thermosetting resin is also applied to the back surface of the substrate. 5. The method for producing a decorative board according to claim 1, wherein the substrate is an inorganic substrate having a specific gravity of 0.6 to 0.9. 6. The method according to claim 1, wherein at least one of the thin paper constituting the surface-coated paper and the antifouling resin coating material coating layer is subjected to a flame retardant treatment. Manufacturing method of decorative board.