JP2016198904A - Melamine decorative board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a melamine decorative board which has excellent durability while keeping a beautiful appearance of a stainless steel material.SOLUTION: The melamine decorative board has a plurality of convex stripe parts or a plurality of concave stripe parts on the surface thereof. When the melamine decorative board is viewed planarly, the plurality of convex stripe parts or the plurality of concave stripe parts are arrayed in one direction. When 60-degree specular glossiness of a plane, on which the plurality of convex stripe parts or the plurality of concave stripe parts are arranged, is measured according to JIS Z 8741:1997 and the 60-degree specular glossiness measured in the direction parallel to the one direction is defined as A and that measured in the direction orthogonal to the one direction is defined as B, A is 10-70%, B is larger than 0% and A/B is equal to or larger than 1.2.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a melamine decorative board.

The wall of buildings, hotels, condominiums, conference rooms, and offices are decorated with decorative panels with patterns such as wood and stone, creating a nice and comfortable space. . Moreover, such a decorative board is used not only for real estate but also as an interior material for vehicles such as trains (see, for example, Patent Documents 1 and 2).

  Among such decorative boards, melamine decorative board is a typical example, and is a decorative board using melamine resin as a surface layer. Due to the characteristics of melamine resin, high surface hardness, wear resistance, heat resistance, heat resistance It has excellent durability such as water resistance, stain resistance, boiling resistance, and light resistance (see, for example, Patent Document 3).

  On the other hand, a hairline stainless steel decorative board provided with a linear straight pattern used for interiors of elevators and the like is used as a high-grade cosmetic material because of its beauty.

Japanese Patent Laying-Open No. 2015-047786 JP 2014-193609 A JP 2013-202906 A

  However, the surface of the stainless steel material of the hairline stainless steel decorative plate is never strong, and the emboss applied to the surface is scratched by contact or the like. On the other hand, a melamine decorative board tends to have high gloss due to its high surface refractive index, and when used on a wall surface, reflection is strongly generated on the decorative board, which may cause discomfort to the observer.

  SUMMARY OF THE INVENTION An object of the present invention is to provide a melamine decorative board having an excellent durability while having the beauty of a stainless steel material.

  The inventor conducted intensive studies aiming to solve the above problems by providing a plurality of ridges or a plurality of ridges on the design surface of a decorative melamine decorative board.

  As a result, on the decorative surface of the melamine decorative board, the glossiness measured in a direction parallel to the plurality of ridges or the plurality of grooves, and the direction perpendicular to the plurality of ridges or the plurality of grooves The present inventors have found that the glossiness to be measured and the relationship between them are important in solving the above problems, and have reached the present invention.

Such an object is achieved by the present invention of the following items (1) to (5).
(1) A melamine decorative board having a plurality of convex strips or a plurality of concave strips on the surface, wherein the plurality of convex strips or the plurality of concave strips when the melamine decorative panel is viewed in plan view, 60 degrees measured in a direction parallel to the one direction in accordance with JIS Z 8741: 1997 with respect to the surface provided with the plurality of ridges or the plurality of ridges. When the specular gloss is A [%] and the 60-degree specular gloss measured in the direction perpendicular to the one direction is B [%], the A is 10% or more and 70% or less, and the B is A melamine decorative board characterized by being greater than 0% and having an A / B of 1.2 or more.

  (2) The melamine decorative board according to (1), wherein the surface roughness Ra defined by JIS B 0601 is 1 μm or more and 10 μm or less with respect to a direction perpendicular to the one direction.

  (3) The distance from one point of any ridge on the surface to one point of another ridge on the shortest distance, or the shortest distance from one point on any ridge on the surface The melamine decorative board according to the above item (1) or (2), wherein the distance to one point of a certain other groove is 15 μm or less.

  (4) The melamine decorative board according to any one of (1) to (3) above, wherein the top surfaces of the plurality of ridges or the bottom surfaces of the plurality of ridges are not flat.

  (5) In any one of the above items (1) to (4), which has at least one core layer selected from the group consisting of glass cloth, glass nonwoven fabric, and a prepreg impregnated with resin. The melamine decorative board as described.

  ADVANTAGE OF THE INVENTION According to this invention, the melamine decorative board which has the beauty which stainless steel has, and has outstanding durability can be provided.

It is sectional drawing which shows typically suitable embodiment of the decorative board of this invention. It is a top view which shows typically suitable embodiment of the decorative board of this invention. It is sectional drawing which shows suitable embodiment of the manufacturing method of the decorative board of this invention. It is sectional drawing which shows other suitable embodiment of the decorative board of this invention. It is sectional drawing which shows other suitable embodiment of the decorative board of this invention.

<< Melamine decorative board >>
Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

  FIG. 1 is a sectional view schematically showing a preferred embodiment of the decorative melamine board of the present invention, and FIG. 2 is a plan view schematically showing a preferred embodiment of the decorative melamine board of the present invention.

  As shown in FIG. 1, the melamine decorative board 100 has a surface layer 11 and a core material layer 12.

<Surface layer>
The surface layer 11 is made of a surface layer material made of a surface layer base material carrying a melamine-based resin on the first surface 111 side serving as a design surface.

  When the surface layer base material constituting the surface layer 11 contains a melamine resin, the decorative melamine board 100 has particularly excellent hardness and is less likely to be damaged.

  The surface layer 11 is provided with a plurality of convex strip portions 1111 or a plurality of concave strip portions 1112 on the first surface 111 side.

  FIG. 2 is a plan view of the melamine decorative board 100 as viewed from above, and as shown in FIG. 2, a plurality of ridges 1111 or a plurality of concave ridges provided on the surface layer 11 of the melamine decorative board 100. The parts 1112 are arranged in one direction. Arranging in one direction means that a plurality of ridges 1111 or a plurality of ridges 1112 may be arranged in the left-right direction, as shown in FIG. As above, they may be arranged in the vertical direction. Further, the majority of the plurality of ridges 1111 or the plurality of ridges 1112 provided on the surface layer 11 of the melamine decorative board 100 only need to be arranged in one direction, and strictly all the ridges. The portions 1111 or the groove portions 1112 do not need to be arranged in parallel without crossing each other. For example, one certain protrusion portion 1111 or the groove portion 1112 has a certain angle (for example, 1 ° to 10 °), It may intersect with other ridges 1111 or dents 1112.

  And the melamine decorative board 100 has the beauty | look of a hairline stainless steel decorative board like that the protruding strip part 1111 or the concave strip part 1112 satisfies the predetermined conditions as mentioned above.

  That is, the melamine decorative board 100 of the present invention is a melamine decorative board having a plurality of convex strip portions 1111 or a plurality of concave strip portions 1112 on the surface, and the plurality of convex strips when the melamine decorative plate 100 is viewed in plan view. The portion 1111 or the plurality of concave strip portions 1112 are arranged in one direction, and the melamine decorative board of the present invention is provided with the plurality of convex strip portions 1111 or the plurality of concave strip portions 1112 of the melamine decorative plate 100. With respect to the surface (first surface 111), according to JIS Z 8741: 1997, the 60-degree specular gloss measured in a direction parallel to the one direction is A [%], and the direction is perpendicular to the one direction. When the 60 ° specular glossiness measured at 1 is B [%], A is 10% or more and 70% or less, B is greater than 0%, and A / B is 1.2 or more.

  The 60-degree specular gloss may be measured according to JIS Z 8741: 1997, but an LED (wavelength 880 nm) is preferably used as the light source at the time of measurement. More specifically, a gloss meter IG-320 manufactured by Horiba, Ltd. may be used. Since the measurement of the 60-degree specular gloss is measured according to JIS Z 8741: 1997, the standard refractive index of the specular gloss is defined on the glass surface having a constant value of 1.567 over the entire visible wavelength range. Based on the specular gloss at the incident angle θ, this value is expressed as 100%.

  Further, the 60-degree specular gloss measured in a direction parallel to the one direction means that the incident light is melamine decorative board 100 in a direction parallel to the ridge portion 1111 or the ridge portion 1112 as shown in FIG. It is a 60 degree specular gloss measured by applying to the surface. Further, the 60-degree specular gloss measured in a direction perpendicular to the one direction means that the incident light is melamine decorative board 100 in a direction orthogonal to the convex portion 1111 or the concave portion 1112 as shown in FIG. It is a 60 degree specular gloss measured by applying to the surface.

  In the present invention, the 60-degree specular gloss (A) in a direction parallel to the ridges 1111 or the ridges 1112 may be 10% or more and 70% or less, but 15% or more and 70% or less. Is preferable, and it is more preferable to set it to 15% or more and 60% or less. As a result, the effect that the melamine decorative board has excellent durability is exhibited more remarkably while having the aesthetics of the stainless steel described above, and the luxury of the melamine decorative board 100 is particularly excellent. it can.

  In the present invention, the 60-degree specular gloss (B) measured in the direction perpendicular to the one direction is sufficient if B is greater than 0%, but preferably 1% or more and 100% or less. It is more preferable to set it to 10% or more and 80% or less. Thereby, while having the beauty | look which the stainless steel material mentioned above has, the effect which the melamine decorative board has the outstanding durability is exhibited more notably, and the high-class feeling of the melamine decorative board 100 is made especially excellent. There is an effect that can be.

  In particular, the ratio (A / B) between the glossiness in the direction parallel to the ridges or ridges and the glossiness in the direction perpendicular to the ridges (A / B) is necessary for the observer to recognize the anisotropy of the melamine decorative board surface. When this value is not less than the specified value (1.2), a melamine decorative board having the beauty of a hairline stainless decorative board can be provided.

  On the other hand, when the ratio (A / B) of the glossiness in the direction parallel to the ridges or ridges and the glossiness in the direction perpendicular to the ridges is less than a specified value, for example, 1.0 <A / B When <1.2, the surface of the melamine decorative board 100 becomes uniform and the beauty of hairline stainless steel cannot be expressed. For example, when A / B <1.0, it is similar to hairline stainless steel You will never see the design material.

  Furthermore, although A / B should just be 1.2 or more, the direction of 1.4 or more and 70 or less is more preferable, and the direction of 1.6 or more and 50 or less is still more preferable. Thereby, an observer can fully recognize the anisotropy of the surface of the melamine decorative board 100, and can recognize the beauty | look which a stainless material has.

  In the present invention, the surface roughness Ra of the melamine decorative board 100 can be 1 μm or more and 10 μm or less with respect to the direction perpendicular to the one direction, and more preferably 2 μm or more and 8 μm or less. As a result, the observer can sufficiently recognize the anisotropy of the surface of the melamine decorative board 100, and the aesthetics of the stainless steel can be recognized more clearly.

  In the present invention, the distance from one point of any ridge 1111 on the surface to one point of the other ridge 1111 at the shortest distance, or 1 of any ridge 1112 on the surface. The distance from the point to one point of the other concave portion 1112 at the shortest distance is preferably 15 μm or less, and more preferably 1 μm or more and 10 μm or less. Thereby, when manufacturing the melamine decorative board 100, manufacturing time, such as a hot press molding, can be shortened, and productivity becomes excellent.

  The cross-sectional shape of the ridge portion 1111 or the ridge portion 1112 is not particularly limited, and may be any shape such as a rectangular shape, a semicircular shape, a semi-elliptical shape, a triangular shape, etc. In particular, a plurality of ridge shapes It is preferable that the upper surface of the portion 1111 or the bottom surfaces of the plurality of concave strip portions 1112 is not flat. The shape in which the top surface of the plurality of ridge portions 1111 or the bottom surface of the plurality of ridge portions 1112 is not flat is, for example, the cross-sectional shape of the ridge portion 1111 or the ridge portion 1112 is the vertex of the ridge portion or the ridge portion. And a cross-sectional shape that continuously changes in the thickness direction of the melamine decorative board (for example, a semicircular shape, a semielliptical shape, and a triangular shape). Thereby, the appearance of the design surface of the melamine decorative board becomes sharp, and the melamine decorative board becomes closer to the appearance of the stainless steel material.

  In the present embodiment, the surface layer 11 is made of a material containing a melamine resin. Thereby, the melamine decorative board 100 has moderate elasticity and rigidity, and is excellent in handleability (ease of handling). Further, since the melamine-based resin has a high surface hardness and is excellent in scratch resistance and antifouling property (hardness of adhesion of dirt), from the viewpoint of aesthetics and durability of the melamine decorative board 100 as well. preferable.

  A melamine-based resin is a resin obtained by reacting a melamine compound and an aldehyde compound as constituent components.

  The melamine compound is a compound having a 1,3,5-triazine skeleton, in which three amino groups are introduced into the triazine ring.

  As a preferable structure of a melamine compound, what is represented by following formula (1) etc. are mentioned, for example.

(In formula (1), R ¹ , R ³ and R ³ are each independently a hydrogen atom or a hydrocarbon group having 1 to 4 carbon atoms which may have a substituent.)

As the melamine compound, a compound (melamine) in which R ¹ , R ³ and R ³ in formula (1) are all hydrogen atoms is particularly preferable. Thereby, the hardness of the melamine decorative board 100 can be made more excellent. Moreover, the synthesis | combination of the melamine type resin which comprises the melamine decorative board 100 can be performed more efficiently.

  The aldehyde compound only needs to have an aldehyde group (—CHO) in the molecule, and examples thereof include those represented by the following formula (2).

(In the formula (2), R is a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms which may have a substituent.)

  As the aldehyde compound, formaldehyde is particularly preferable. Thereby, the hardness of the melamine decorative board 100 can be made more excellent. Moreover, the synthesis | combination of the melamine type resin which comprises the melamine decorative board 100 can be performed more efficiently.

  The melamine-based resin only needs to contain a melamine compound and an aldehyde compound as constituent components, but may further contain a guanamine compound as a constituent component in addition to the melamine compound and aldehyde compound. Thereby, while making the hardness of the melamine decorative board 100 sufficiently excellent, the workability of the melamine decorative board 100 can be made particularly excellent.

  A guanamine compound is a compound having a 1,3,5-triazine skeleton, in which two amino groups are introduced into the triazine ring.

  As a preferable structure of the guanamine compound, for example, one represented by the following formula (3) can be mentioned.

(In Formula (3), R is a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms which may have a substituent.)

  As the guanamine compound, a compound (acetoguanamine) in which R in formula (3) is a methyl group is particularly preferable. Thereby, the hardness and workability of the melamine decorative board 100 can be made compatible at a higher level. Moreover, the synthesis | combination of the melamine type resin which comprises the melamine decorative board 100 can be performed more efficiently.

  The melamine resin is not particularly limited, and for example, a resin obtained by reacting a melamine compound and an aldehyde compound in a neutral or weak alkali can be used.

  The reaction molar ratio of the aldehyde compound to the melamine compound (the value of (molar amount of aldehyde compound) / (molar amount of melamine compound), hereinafter simply referred to as “reaction molar ratio”) is not particularly limited. 1.0 or more and 4.0 or less is preferable, 1.0 or more and 2.0 or less is more preferable, and 1.1 or more and 1.8 or less is more preferable. When the reaction molar ratio is within the above range, unreacted components are reduced, the storage stability is excellent, the cost is reduced, and the resin flexibility after curing is excellent. In addition, when a guanamine compound is applied, the input amount can be appropriately adjusted according to the number of functional groups.

  In addition, as a melamine-type resin, what is contained individually by 1 type can also be used, and what contains 2 or more types of melamine-type resins in which reaction molar ratios, weight average molecular weights, etc. differ can be used. it can.

  Moreover, as melamine-type resin, commercially available things, such as Sumitomo Chemical Co., Ltd. melamine resin, can also be used, for example.

  The content of the melamine resin in the resin supported on the first surface 111 side of the surface layer 11 is not particularly limited, but is preferably 80% by mass or more and 100% by mass or less, and more preferably 95% by mass or more and 100% by mass. % Or less is more preferable. Thereby, the effects as described above are more remarkably exhibited.

  The surface layer base material constituting the surface layer 11 preferably supports a thermoplastic resin on the second surface 112 side facing the core material layer 12. Thereby, the adhesion between the surface layer 11 and the core material layer 12 can be made particularly excellent, the durability of the melamine decorative board 100 can be made particularly excellent, and the melamine decorative board 100 Workability can be made particularly excellent.

  In the following description, the case where the surface layer base material supports the thermoplastic resin on the second surface 112 side will be mainly described.

  In the present specification, the surface layer base material carrying the resin means that the resin adheres to the surface of the base material (carrier) or is impregnated in the voids inside the base material, and after the surface layer material is molded. It means that it is in a state that makes it possible to develop the performance of the supported resin. In addition, resin does not need to be uniformly distributed on the surface of a base material and the inside of a base material.

  The thermoplastic resin carried on the second surface 112 side is not particularly limited, but is preferably a solid content of a thermoplastic resin emulsion in which the thermoplastic resin is dispersed in a solvent to be in an emulsion state. Thereby, the thermoplastic resin emulsion is easily impregnated into the voids inside the base material of the surface layer, and the productivity is excellent.

  The solid content of the thermoplastic resin emulsion means a component obtained by removing the solvent from the thermoplastic resin emulsion.

  The solid content of the thermoplastic resin emulsion includes components present as emulsion resin particles, has adhesive properties with metals and various materials, and imparts flexibility to the melamine decorative board 100. As a result, the adhesive strength between the surface layer 11 and the core material layer 12 can be improved, and the bending workability of the melamine decorative board 100 can be improved.

  The solid content of the thermoplastic resin emulsion is not particularly limited. For example, heat such as acrylic resin, urethane resin, vinyl acetate copolymer, urethane acrylic composite particles, styrene butadiene rubber (SBR), nitrile rubber (NBR), etc. The emulsion particle | grains of a plastic resin are mentioned. Among these, urethane acrylic composite particles are preferable.

  In the present specification, the urethane-acrylic composite particles mean those having a heterogeneous structure of an acrylic resin and a urethane resin in a single particle.

  Since each of the urethane resin and the acrylic resin has high adhesive strength with the core material layer 12, good adhesive strength with the core material layer 12 can be expressed by using urethane acrylic composite particles. Furthermore, the urethane resin is particularly excellent in toughness, elasticity, and flexibility, and the acrylic resin is particularly excellent in transparency, durability, weather resistance, chemical resistance, and film forming property.

  In the present specification, “heterophasic structure” means a structure in which a plurality of phases composed of different types of resins exist in one particle, and examples thereof include a core-shell structure, a localized structure, and a sea-island structure. It is done.

  Moreover, the arrangement | sequence state between particle | grains when the said urethane acryl composite particle is carry | supported by the 2nd surface 112 side of the surface layer 11 is not specifically limited, For example, a linear structure etc. are mentioned. The structure of the particles and the arrangement state between the particles can be confirmed by, for example, a scanning electron microscope (SEM).

  Among the foregoing, the urethane acrylic composite particles are particularly preferably an aqueous clear type having a core-shell structure in which an acrylic component is a core and a urethane component is a shell.

  When the urethane-acrylic composite particles have the above-described core-shell structure, the surface outline becomes a urethane composition when supported on the second surface 112 side of the surface layer 11, so the second surface 112 side of the surface layer 11 is While having the properties of both a urethane resin and an acrylic resin, the properties of the urethane resin are imparted to the outer shell.

  In the present specification, “aqueous clear” means that the resin liquid is water-soluble, the coating film after removing the water is non-aqueous, and transparent enough to clearly distinguish the underlying pattern. It means an aqueous resin solution.

  Since the resin carried on the second surface 112 side of the surface layer 11 is an aqueous clear type, the influence of the surface layer on the color tone of the design surface can be suppressed.

  In addition, as solid content of a thermoplastic resin emulsion, what contained 1 type in the above-mentioned independently can also be used, and what contains 2 or more types of different thermoplastic resins in mixture can also be used. .

  In addition to the thermoplastic resin emulsion particles, the solid content of the thermoplastic resin emulsion may contain a small amount of a thickener, a penetration enhancer, an antifoaming agent, and the like as necessary.

  The solid content of the thermoplastic resin emulsion preferably includes emulsion resin particles having an average particle size of 30 nm to 100 nm, and the average particle size of the emulsion resin particles is more preferably 60 nm to 90 nm. As a result, when the surface layer substrate is composed of a material containing a fibrous substance, the impregnation property between the fibers of the emulsion resin particles is improved, and the emulsion resin extends to a deeper portion of the surface layer substrate. Since the particles can be impregnated, the flexibility of the surface layer 11 can be made particularly excellent.

  In the present invention, the average particle diameter means a volume-based average particle diameter unless otherwise specified.

  Here, the particle diameter can be measured by dispersing the target particles in water by ultrasonic treatment for 1 minute using a laser diffraction particle size distribution analyzer SALD-7000.

  The solid content of the thermoplastic resin emulsion is preferably water-insoluble. As a result, the solid content of the thermoplastic resin emulsion moves to the first surface 111 side of the surface layer 11 and is mixed with the melamine-based resin carried on the first surface 111 side. It can prevent more effectively that the surface performance by the 111 side melamine resin is impaired.

  In this specification, water-insoluble means that the solubility in water at 25 ° C. is less than 0.5 g / 100 g water, and water-soluble means that the solubility in water at 25 ° C. is 0.5 g. / 100g refers to water or more.

  The surface layer base material is a sheet-like base material in which a ridge 1111 is formed on the first surface 111 side. The material of the surface layer substrate is not particularly limited, and for example, pulp, linter, synthetic fiber, glass fiber, or the like can be used. Moreover, the titanium oxide containing decorative paper etc. which contain pigments, such as a titanium oxide, can be used as needed.

The basis weight of the surface layer substrate is not particularly limited, is preferably 40 g / ^{m 2} or more 150 g / ^{m 2} or less.

  When the basis weight is less than the lower limit, the surface layer base material absorbs the resin, and the coating process is difficult due to the problem of cutting and wrinkling in the step of impregnating the surface layer base material with the resin. In addition, it is difficult to adjust the amount of resin impregnation carried on each of the first surface and the second surface.

  On the other hand, when the basis weight exceeds the above upper limit, in the case where the surface layer base material absorbs the resin, the impregnation amount of the resin carried by the surface layer base material becomes uneven, and the flexibility of the melamine decorative board 100 is increased. As well as lowering productivity and increasing costs.

<Core material layer>
In addition to the surface layer 11, the melamine decorative board 100 of this embodiment further includes a core material layer 12. Thereby, the shape stability and durability of the melamine decorative board 100 are particularly excellent.

  The core material layer 12 is bonded to the second surface 112 side of the surface layer 11.

  The core material layer 12 is not particularly limited, but a glass cloth or a glass nonwoven fabric, a prepreg based on a glass cloth or a glass nonwoven fabric, a fiber base material such as kraft paper and a prepreg impregnated with a phenol resin and a prepreg are laminated. And a laminate composed of a core material layer made of a slurry-carrying glass nonwoven fabric, glass cloth or glass nonwoven fabric, or a prepreg based on glass cloth or glass nonwoven fabric gives a surface shape. It is particularly preferable from the viewpoints of ease in the process to be performed, press moldability, and incombustibility. Thereby, the heat resistance of the melamine decorative board 100, rigidity, etc. can be made especially excellent.

  Examples of the glass cloth include, but are not limited to, glass woven fabrics such as plain weave, twill weave, satin weave, leopard weave, imitation weave, oblique pattern weave, double weave, etc. The glass woven fabric is preferable.

  Moreover, as glass which comprises a glass cloth, E glass, C glass, A glass, S glass, D glass, NE glass, T glass, H glass etc. are mentioned, for example. Among these, T glass is preferable. Thereby, the thermal expansion coefficient of a glass cloth can be made small.

The weight of the glass cloth is not particularly limited, but if it is necessary to satisfy the “combustible cracks / penetration after combustion” requirement of Article 2-9 of the Building Standards Act The basis weight is preferably 100 g / m ² or more. Moreover, although the upper limit of a weight does not require a restriction | limiting especially, the basic weight of 250 g / m < ² > or less is preferable from the surface of material cost and workability.

  The prepreg is not particularly limited, and for example, the prepreg may be obtained by impregnating the above-mentioned glass cloth with a resin composition containing a thermoplastic resin, a thermosetting resin, or the like.

  The content of the resin composition contained in the prepreg is not particularly limited as long as the interlayer adhesion strength with the surface layer 11 is sufficient to form the melamine decorative board 100, but a thermoplastic resin is used as the resin composition. When using, it is preferable to contain 1 to 20 mass% by solid content in a prepreg, and it is more preferable to contain 1 to 10 mass%. Moreover, when using a thermosetting resin as a resin composition, it is preferable to contain 1 to 20 mass% by solid content in a prepreg, and it is more preferable to contain 2 to 10 mass%. Thereby, the interlayer adhesive strength of the surface layer 11 and the core material layer 12 can be improved.

  Examples of the thermoplastic resin include acrylic resin, urethane resin, ethylene vinyl acetate resin, styrene butadiene rubber (SBR), and the like. Among these, it is preferable to use an acrylic resin and / or a urethane resin.

  Examples of the thermosetting resin include phenol resin, epoxy resin, oxetane resin, (meth) acrylate resin, unsaturated polyester resin, diallyl phthalate resin, urea resin, maleimide resin, and the like. Among these, a phenol resin is preferable from the viewpoint of nonflammability, heat resistance, and adhesion. These resins can be used alone or in combination.

  The prepreg can be produced by a conventionally known method. For example, the prepreg can be obtained by impregnating a glass cloth similar to the glass cloth described above with a varnish obtained by dissolving a resin in a solvent and drying the glass cloth.

  Further, the core layer material further improves the adhesive strength by supporting the resin (solid content) constituting the thermoplastic resin emulsion on the surface side in contact with the surface layer 11, and near room temperature (25 ° C.). The bending workability of can be made particularly excellent. The solid content of the thermoplastic resin emulsion to be carried on the surface in contact with the surface layer 11 of the core material layer material is not particularly limited as long as it imparts flexibility and does not interfere with the calorific value and gas toxicity during combustion. The average particle diameter of the emulsion resin particles contained in the solid content of the thermoplastic resin emulsion is not particularly limited, and may be water-soluble or water-insoluble.

  The thickness of the core material layer 12 is preferably 100 μm or more. Thereby, sufficient heat resistance and nonflammability can be imparted to the melamine decorative board 100. Further, the upper limit of the thickness is not particularly limited, but the thickness and weight of the melamine decorative board 100 increase and the cost increases as the thickness increases. The thickness is preferably 350 μm or less.

  The melamine decorative board 100 preferably has an overall thickness (average thickness) of 0.1 mm or more and 2 mm or less, and more preferably 0.1 mm or more and 1.2 mm or less. Accordingly, the melamine decorative board 100 can be easily bent while having sufficient mechanical strength and the like.

<< Manufacturing method of decorative board >>
Next, the manufacturing method of the decorative board mentioned above is demonstrated.

  FIG. 3 is a cross-sectional view showing a preferred embodiment of the method for producing a decorative board of the present invention.

  First, the first layer 11 ′ composed of the surface layer material described above is formed (see FIG. 3 (1 a)). The first layer 11 ′ is a layer that becomes the surface layer 11 described above.

  The first layer 11 ′ carries a resin containing a melamine resin on one surface of the surface layer base material (the first surface 111 serving as a design surface) (application step), and the other surface is a thermoplastic resin. It is formed by supporting the solid content of the emulsion.

  As a method for supporting a resin containing a melamine resin on a surface layer base material, for example, a resin composition containing a melamine resin is used using a known device such as a spray device, a shower device, a kiss coater, or a comma coater. The method of giving etc. are mentioned.

  Examples of the method of supporting the solid content of the thermoplastic resin emulsion on the surface layer substrate include a method of applying the thermoplastic resin emulsion using a known device such as a spray device, a shower device, a kiss coater, or a comma coater. Can be mentioned.

  Next, the base body 12 'made of a core material layer material prepared separately is disposed so as to face the surface of the first layer 11' to which the resin composition containing the melamine resin is applied ( (Refer FIG. 3 (1b)). The base body 12 ′ is a layer that becomes the core material layer 12 described above.

  Next, the base 12 ′ is disposed on the support member 20 and heated while pressing the first layer 11 ′ with the pressing member 30 in a state where the first layer 11 ′ and the base 12 ′ are in contact with each other. (See FIG. 3 (1c)). As a result, the first layer 11 ′ and the base 12 ′ are thermocompression bonded to obtain a melamine decorative board 100 having the surface layer 11 and the core material layer 12 (see FIG. 3 (1 d)).

  At this time, the pressing member 30 has an inverted shape corresponding to the protruding strip portion 1111 or the recessed strip portion 1112 to be formed on the surface thereof (the surface in contact with the first layer 11 ′), the groove 31 or the protruding portion of the pattern. The one provided with is used. Thereby, the groove | channel 31 or convex part which the press member 30 has is transcribe | transferred, and the convex shape part 1111 or the concave line part 1112 of a desired shape and pattern can be formed easily and reliably.

  The pressing member 30 (a member provided with a groove 31 or a convex portion corresponding to the convex strip portion 1111 or the concave strip portion 1112) is, for example, a member having a high surface smoothness (for example, a member having a mirror finish). It can be suitably manufactured by moving the pressing member 30 in one direction while preparing and pressing the polishing paper or the like on its surface. In particular, the pressing member 30 can be suitably manufactured by changing conditions such as the count of the abrasive paper, the feeding speed, and the polishing time.

  As the support member 20, a member having a smooth surface and excellent shape stability, for example, a member made of various metal materials such as stainless steel can be suitably used.

  Further, by this heating, the resin composition containing the melamine resin contained in the first layer 11 ′ is polymerized and cured (curing step). Thereby, the hardness and durability of the melamine decorative board 100 are particularly excellent.

  The heating conditions are not particularly limited, but the heating temperature is preferably 130 ° C. or higher and 150 ° C. or lower, and the pressure is preferably 1 MPa or higher and 8 MPa or lower. The heating time is preferably 10 minutes or more and 90 minutes or less.

  By satisfying the above-described conditions, it is possible to easily and reliably form the convex strips 1111 or the concave strips 1112 having a desired shape and pattern.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention. It is.

  For example, the decorative board of the present invention is not limited to the form of the melamine decorative board 100 shown in FIG. 1, and when it is desired to impart mechanical strength or the like, as shown in FIG. Furthermore, another core material layer material may be laminated and two core material layers may be laminated to form a three-layer structure of the surface layer 11, the core material layer 12, and the core material layer 14. Moreover, you may have another layers other than a surface layer and a core material layer, for example, as shown in FIG. 5, it has the protective layer 15 in the outermost layer by the side of a design surface, or a core material layer side The support layer 16 may be provided as the outermost layer.

The protective layer 15 is not particularly limited. For example, a paper substrate having a basis weight of 10 g / m ² or more and 50 g / m ² or less, a melamine resin alone, or a melamine resin, aluminum hydroxide, magnesium hydroxide, Or it can obtain by impregnating the resin composition containing the inorganic filler chosen from silica, and drying this.

  The support layer 16 is not particularly limited. For example, a base material similar to that used for the surface layer base material is impregnated with a resin that can be used on the first surface side or the second surface side of the surface layer. Prepregs, metal foils, and the like can be used.

  In the present invention, the decorative board may have an intermediate layer between the surface layer and the core material layer.

  The decorative board of the present invention may not have a core layer, for example.

  In the above-described embodiment, the surface layer is representative of a case where the surface layer is composed of a surface layer material composed of a surface layer base material carrying a solid content of a thermoplastic resin emulsion in addition to a resin containing a melamine resin. However, for example, a thermoplastic resin emulsion that does not contain a solid content may be used.

  In the above-described embodiment, the case where the decorative board is made of a material containing a melamine-based resin has been mainly described. However, the decorative board of the present invention satisfies the predetermined condition as described above. Any material may be used as long as it has a ridge or a groove and satisfies a predetermined condition with respect to the glossiness, and its constituent material is not particularly limited.

  Moreover, in embodiment mentioned above, although demonstrated as what forms the convex strip part 1111 or the concave strip part 1112 which a decorative board has by a transfer method, the convex strip part 1111 or the concave strip part 1112 which a decorative board has is transfer method. Other methods may be used. For example, the convex strip portion 1111 or the concave strip portion 1112 may be formed by directly machining the surface of the decorative plate. In such a case, for example, the ridge portion 1111 or the ridge portion 1112 is formed in a state where the curable resin constituting the portion to be the surface layer of the decorative board is partially cured, and then, The curing reaction of the curable resin may be advanced. Thus, the convex strip portion 1111 or the concave strip portion 1112 having a desired shape can be easily and reliably formed, and the strength and durability of the decorative board finally obtained are particularly excellent. it can.

  Even when the transfer method is adopted, a master mold is prepared, the surface shape of the mold is transferred, and a mold for manufacturing a decorative board is manufactured. You may manufacture a decorative board (formation of a convex part or a concave part) using a shaping | molding die. Thereby, the lifetime of a shaping | molding die can be aimed at and it can manufacture, suppressing the dispersion | variation in quality about more decorative boards. Further, by adopting the above-described method (two-step transfer method), the shape or pattern of the ridge portion 1111 or the ridge portion 1112 that the decorative plate to be manufactured should have is the ridge portion that the master has or Since it becomes the same as the concave stripe portion and does not have an inverted shape, the shape and pattern of the convex stripe portion or the concave stripe portion can be easily managed.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail based on an Example and a comparative example, this invention is not limited to this.

Example 1
[1] Production of resin composition Melamine-based resin obtained by condensation reaction of melamine (M) and formaldehyde (F) at a reaction molar ratio (F / M) = 1.7: Resin solid containing 100 parts Minute: 50% by mass of melamine resin varnish, thermal latent acid catalyst (“Catanit” manufactured by MRC Unitech): 0.9 part by mass, release agent (“Separ 328” manufactured by Chukyo Yushi Co., Ltd.): 0. 2 parts by mass was added and stirred at 23 ° C. for 10 minutes to obtain a resin composition (varnish).

[2] Production of surface layer material Using a titanium oxide-containing decorative paper having a basis weight of 80 g / m ² as the surface layer base material, the resin composition (varnish) obtained in [1] is used as the surface layer base material. On both sides, it was coated by dip coating and then dried to obtain a surface layer material having a melamine resin content of 50% by mass and a volatile content of 6% by mass with respect to the entire surface layer material.

[3] Manufacture of Core Material Layer Material Unbleached kraft paper having a basis weight of 190 g / m ² was prepared as a core material layer base material. Resol-type phenolic resin obtained by reacting phenol (P) and formaldehyde (F) at a reaction molar ratio (F / P) = 1.3: Resole containing 100 parts by mass of resin solid content: 50% by mass The phenolic resin varnish was applied to the core layer base material and then dried to obtain a core layer material having a phenol resin content of 35% by mass and a volatile content of 6% by mass with respect to the entire core material.

[4] Manufacture of decorative board Four core material layers obtained in [3] are placed on a support member made of stainless steel with a smooth surface, and further, on [2], The obtained surface layer materials were superposed.

  Thereafter, the outer surface of the surface layer material was pressed and heated with a pressing member under the conditions of pressure: 8 MPa, heating temperature: 140 ° C., and heating time: 60 minutes to obtain a decorative board having a thickness of 1.2 mm.

  The pressing member is a plate made of stainless steel, and the mirror-finished polishing paper is mirror-finished under predetermined conditions (for example, abrasive paper count # 150, feed rate 3 cm / s, etc.). It was manufactured by polishing in one direction on the applied surface side, and used was provided with a groove satisfying a predetermined condition (a groove corresponding to a protruding portion to be formed). Moreover, when the shape which should be formed on the surface of a melamine decorative board is a concave part, the press member transcribe | transferred with the scissors was used for the press member obtained by the above-mentioned.

(Examples 2 to 4)
The decorative board is made in the same manner as in Example 1 except that the conditions of the ridges formed on the decorative board are changed as shown in Table 1 by changing the conditions of the grooves of the pressing member used in the curing step. Manufactured.

(Examples 5-7)
By changing the condition of the groove of the pressing member used in the curing step, the condition of the ridge formed on the decorative plate was changed as shown in Table 1, and the core material layer obtained in [3] A decorative board was produced in the same manner as in Example 1 except that the four materials were changed to glass cloth having a thickness of 0.2 mm (“WEA 7628” manufactured by Nanya Plastic Co., Ltd.).

(Comparative Example 1)
A decorative board was produced in the same manner as in Example 1 except that the pressing member used in the curing step was a member having no groove on the surface.

(Comparative Examples 2 and 3)
The decorative board is the same as in Example 1 except that the conditions of the ridges formed on the decorative board are changed as shown in Table 1 by changing the conditions of the grooves of the pressing member used in the curing step. Manufactured.

(Reference Example 1)
A commercially available hairline stainless steel decorative board (manufactured by Tsukisei Art Industry Co., Ltd., HL material) was used.

  With respect to the surface provided with the convex strips or concave strips of the decorative plates of the respective examples and comparative examples, the values of 60 ° specular glossiness (A and B) measured according to JIS Z 8741: 1997 are obtained. Table 1 summarizes the results. In the measurement of the 60-degree specular gloss, a gloss meter IG-320 (light source: LED) manufactured by Horiba, Ltd. was used.

  Moreover, the surface roughness Ra prescribed | regulated by JISB0601 in the surface in which the convex part or the concave part was provided is measured about the surface of the predetermined range using a laser microscope (the Keyence company make, VK-9700). Was determined by

[3] Evaluation The following evaluations were performed on the decorative plates of Examples, Comparative Examples, and Reference Examples manufactured as described above.

[3.1] Appearance The hairline stainless steel decorative board (manufactured by Tsukisei Art Industry Co., Ltd., HL material, Reference Example 1) was compared with the manufactured decorative board, and the appearance was evaluated according to the following criteria.
A: It looks almost the same as the hairline stainless steel decorative board itself.
B: Although it is not invisible to the hairline stainless steel decorative board, it has a dull appearance.
C: It cannot be seen at all on the hairline stainless steel decorative board.

[3.2] Durability A wear amount and a wear value measured by a method based on a wear resistance test of JIS K6902 were confirmed, and evaluation was performed according to the following criteria.
Wear amount ○: 0.1 g / 100 or less ×: Greater than 0.1 g / 100 Wear value ○: Vertical plane: 150 or more, horizontal plane: 300 or more ×: Vertical plane: smaller than 150, horizontal plane: smaller than 300

  These results are shown together in Table 2 together with the results of the hairline stainless steel decorative board.

  As can be seen from Table 2, the decorative board of the present invention had an excellent durability while having the beauty of a stainless steel material. On the other hand, in the comparative example, a satisfactory result was not obtained. Further, the hairline stainless steel decorative plate was inferior in durability.

DESCRIPTION OF SYMBOLS 100: Melamine decorative board 11 ': 1st layer 11: Surface layer 111: 1st surface 1111: Convex strip part 1112: Concave strip part 112: 2nd surface 12': Base | substrate 12: Core material layer 14: Core Material layer 15: Protective layer 16: Support layer 20: Support member 30: Pressing member 31: Groove

Claims (5)

A melamine decorative board having a plurality of ridges or a plurality of grooves on the surface,
When the plan view of the melamine decorative board, the plurality of ridges or the plurality of ridges are arranged in one direction,
For the surface provided with the plurality of ridges or the plurality of ridges, a 60-degree specular gloss measured in a direction parallel to the one direction according to JIS Z 8741: 1997 is A [%]. When the 60-degree specular gloss measured in a direction perpendicular to the one direction is B [%],
A is 10% or more and 70% or less,
B is greater than 0%,
A melamine decorative board, wherein A / B is 1.2 or more.   2. The melamine decorative board according to claim 1, wherein the surface roughness Ra defined by JIS B 0601 of the surface is 1 μm or more and 10 μm or less with respect to a direction perpendicular to the one direction.   The distance from one point of any ridges on the surface to one point of the other ridges at the shortest distance, or another point at the shortest distance from one point of any ridges on the surface The melamine decorative board according to claim 1 or 2, wherein the distance to one point of the concave strip is 15 µm or less.   The melamine decorative board according to any one of claims 1 to 3, wherein the top surfaces of the plurality of ridge portions or the bottom surfaces of the plurality of ridge portions are not flat. The melamine decorative board according to any one of claims 1 to 4, which has at least one core material layer selected from the group consisting of glass cloth, glass nonwoven fabric and prepreg impregnated with resin.