CN114555368A - 树脂浸渍装饰纸、及树脂浸渍装饰板 - Google Patents
树脂浸渍装饰纸、及树脂浸渍装饰板 Download PDFInfo
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- CN114555368A CN114555368A CN202080072131.4A CN202080072131A CN114555368A CN 114555368 A CN114555368 A CN 114555368A CN 202080072131 A CN202080072131 A CN 202080072131A CN 114555368 A CN114555368 A CN 114555368A
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Abstract
使浸渍树脂(5)浸渍于装饰纸(4)而得的树脂浸渍装饰纸(2)。装饰纸(4)具备:原纸(6)、设置在原纸(6)的表面(6a)侧的花纹纹理层(7)、由配置在花纹纹理层(7)的表面(7a)上或花纹纹理层(7)中的发泡剂形成的发泡树脂层(8)、以及设置在发泡树脂层(8)的表面(8a)上的热固性树脂层(9)。热固性树脂层(9)含有环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂中的至少一者。
Description
技术领域
本发明涉及树脂浸渍装饰纸、及树脂浸渍装饰板。
背景技术
以往,提出了一种树脂浸渍装饰板的制造方法,其中,将金属板抵接于浸渍有热固性树脂的树脂浸渍装饰纸与基材的层叠体上并进行加热加压成型,从而获得树脂浸渍装饰纸与基材一体化而成的树脂浸渍装饰板(例如,参照专利文献1)。在专利文献1所记载的树脂浸渍装饰板的制造方法中,在金属板上设置压花形状以对树脂浸渍装饰板的表面赋予凹凸纹理,从而赋予手的触感。此外,也可以通过调整压花形状的粗密度以赋予哑光效果(matt expression)。
然而,在专利文献1所记载的树脂浸渍装饰板的制造方法中,需要为每个想要赋予的凹凸纹理准备金属板,因此可能会增加成本。因此,考虑通过设置发泡树脂层来赋予凹凸纹理。然而,如果不保护凹凸纹理的凸起部,则耐污染性和长期保存后的设计稳定性可能会降低。
现有技术文献
专利文献
专利文献1:日本特开平09-262956号公报
发明内容
[发明所要解决的课题]
本发明是着眼于上述问题而完成的,其目的在于提供在抑制成本的同时哑光效果和手触感优异、且耐污染性和长期保存后的设计稳定性得以提高了的树脂浸渍装饰纸及树脂浸渍装饰板。
[用于解决课题的技术方案]
本发明的一个方式涉及的树脂浸渍装饰纸是使浸渍树脂浸渍于装饰纸而得的树脂浸渍装饰纸,装饰纸具备:原纸、设置在原纸的表面侧的花纹纹理层、由配置在花纹纹理层的表面上或花纹纹理层中的发泡剂形成的发泡树脂层、以及设置在发泡树脂层的表面上的热固性树脂层,热固性树脂层含有环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂中的至少一者。
本发明的其他方式涉及的树脂浸渍装饰板具备:树脂浸渍装饰纸、以及与树脂浸渍装饰纸一体化的基材。
[发明效果]
根据本发明,可以通过加热加压成型使发泡剂发泡,并且可以在树脂浸渍装饰纸的表面适当地形成凹凸纹理。由于不需要为每个凹凸纹理准备金属板,因此可以提供在抑制成本的同时哑光效果和手触感优异的树脂浸渍装饰纸及树脂浸渍装饰板。此外,通过在发泡树脂层的表面上设置含有环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂中的至少一者的热固性树脂层,可以保护凹凸纹理的凸起部。由此,可以提供耐污染性和长期保存后的设计稳定性得以提高了的树脂浸渍装饰纸及树脂浸渍装饰板。
附图说明
[图1]为表示加热加压成型后的树脂浸渍装饰板的剖面图。
[图2]为表示加热加压成型前的树脂浸渍装饰板的剖面图。
具体实施方式
以下,参照附图对本发明的实施方式涉及的装饰纸、树脂浸渍装饰纸以及树脂浸渍装饰板进行说明。本发明不限于以下所记载的实施方式,可以基于本领域技术人员的知识来进行设计的改变等修改,进行了这样的修改后的实施方式也包括在本发明的范围内。此外,为了便于理解,适当夸张地显示了各附图。
(构成)
如图1和图2所示,本发明的实施方式涉及的树脂浸渍装饰板1是通过对树脂浸渍装饰纸2与基材3的层叠体进行加热加压成型而使树脂浸渍装饰纸2与基材3一体化而成的装饰板。即,树脂浸渍装饰板1具备:基材3、和设置在基材3的表面3a侧的树脂浸渍装饰纸2。本发明的实施方式涉及的树脂浸渍装饰板1是用于(例如)建筑物的地板、墙壁、天花板等室内装饰;家具、各种橱柜等的表面装饰材料;门窗的表面装饰;车辆内部装饰等的树脂浸渍装饰板。图1示出加热加压成型后的树脂浸渍装饰板1,图2示出加热加压成型前的树脂浸渍装饰板1。
(基材)
基材3的种类没有特别的限制,可以根据作为目标的树脂浸渍装饰板1的用途而使用任意的基材。例如,可以采用单木板、胶合板、层压材料、刨花板、中密度纤维板、硬质纤维板等木质基材;纸板、织布、无纺布、树脂浸渍纸、树脂浸渍布等纤维质基材;石膏板、板岩板、硅酸钙板、矿渣石膏板、木棉水泥板、矿渣水泥板、轻质泡沫混凝土板、玻璃纤维增强混凝土板等无机质基材;钢板、黄铜板、铝板、硬铝板、不锈钢板等金属基材;丙烯酸树脂板、苯乙烯树脂板、ABS(Acrylonitrile butadiene styrene,丙烯腈丁二烯苯乙烯)树脂板、聚碳酸酯树脂板、尼龙树脂板、聚苯乙烯树脂板、聚丙烯树脂板、聚酯树脂板、玻璃纤维增强塑料板等合成树脂基材等;或者选自它们中的2种以上的复合体或层叠体等。
(树脂浸渍装饰纸)
本发明的实施方式涉及的树脂浸渍装饰纸2是通过使浸渍树脂5浸渍于整个装饰纸4、然后干燥而形成的。装饰纸4具备:原纸6、花纹纹理层7、发泡树脂层8、以及热固性树脂层9。花纹纹理层7设置在原纸6的表面6a上。发泡树脂层8由配置在花纹纹理层7的表面7a上、或花纹纹理层7中的发泡剂形成。图1示出了由配置在花纹纹理层7的表面7a上的发泡剂形成发泡树脂层8的例子。热固性树脂层9设置在发泡树脂层8的表面8a上。
(原纸)
作为原纸6,可以使用能够浸渍浸渍树脂5的吸水性良好的纸等纤维质片状体。例如,可以采用薄叶纸、钛纸、上等纸、漂白或未漂白的牛皮纸等。特别是,当考虑到印刷适应性和树脂浸渍适应性这两方面时,钛纸是最合适的。此外,在利用基材3的表面3a的质感的情况下,优选使用具有通过浸渍树脂5的浸渍而变得透明的性质的所谓的透明纸。原纸6的厚度没有特别的限制,优选的是单位面积重量为20g/m2以上200g/m2以下的范围。
(花纹纹理层)
花纹纹理层7是用于对树脂浸渍装饰纸2赋予由花纹纹理带来的设计性的层。花纹纹理层7通过使用印刷油墨等来形成,该印刷油墨是通过将染料或颜料等着色剂与适当的粘合剂树脂一起溶解或分散在稀释溶剂中而得的。印刷油墨的种类没有特别的限定,可以是油性油墨,也可以是水性油墨。即,作为印刷油墨,可以使用不具有疏液性的普通印刷油墨。
特别是,考虑到浸渍树脂5的浸渍适应性,水性油墨是最合适的。与油性油墨相比,水性油墨与浸渍树脂的水溶液具有更好的相容性。因此,在使用水性油墨的情况下,在制造树脂浸渍装饰板1时的浸渍步骤中,可以使浸渍树脂5迅速且均匀地浸渍在装饰纸4中,另外,可以通过与浸渍树脂5的一体化而在优异的花纹纹理层7中展现出强度。此外,水性油墨的种类没有特别的限制,优选为含有以酪蛋白、乳液树脂作为主要成分的粘合剂树脂的油墨。
这样的粘合剂树脂具有在印刷油墨后经过干燥步骤而变得难溶于水的性质。因此,在使用包含这样的粘合剂树脂的粘合剂树脂的情况下,在制造树脂浸渍装饰板1时的树脂浸渍步骤中,花纹纹理层7难以再次溶解在浸渍树脂5的水溶液中,从而可以保持花纹纹理,进而可以防止浸渍树脂5的污染。
作为乳液树脂,例如可以采用丙烯酸类、乙酸乙烯酯类、苯乙烯类、氨基甲酸酯类等。此外,在粘合剂树脂中,除了酪蛋白、乳液树脂以外,还可以一起使用(例如)聚乙烯醇、聚丙烯酰胺等水溶性树脂、以及多糖类、纤维素衍生物等水溶性高分子等以提高油墨的稳定性。
花纹纹理层7的形成方法没有特别的限定,例如可以使用凹版印刷法、胶版印刷法、丝网印刷法、柔版印刷法、凸版印刷法、喷墨印刷法等任意的印刷方法。此外,在花纹纹理层7与原纸6的层间,可以设置用于使基底着色的实地油墨层,在设置实地油墨层的情况下,作为实地油墨层的形成方法,除了上述各种印刷方法以外,还可以使用(例如)辊涂法、凹版涂布法、棒涂法、刮刀涂布法、气刀涂布法、喷涂法、唇涂法、模涂法等任意的涂布方法。
花纹纹理层7所形成的花纹的种类没有特别的限定,根据作为目标的树脂浸渍装饰板1的用途,可以使用任意的花纹。例如,可以采用木纹图案、石纹图案、布纹图案、抽象图案、几何图形、字符、符号、纯色等;或者选自它们中的2种以上的组合等。
(发泡树脂层)
发泡树脂层8是用于通过树脂浸渍装饰纸2的表面的凹凸纹理10来赋予哑光效果和手触感的层。发泡剂的种类没有特别的限定,可以使用任意的发泡剂。例如,可以采用偶氮二羧酸酰胺、偶氮二甲酰胺等偶氮类,氧苯磺酰肼、对甲苯磺酰肼等酰肼类等热分解型的化学发泡剂;微囊发泡剂等。
特别是,微囊发泡剂是最合适的。微囊发泡剂具有囊体、以及封装在该囊体中的挥发性物质。然后,通过挥发性物质挥发使囊体膨胀,从而使得微囊发泡剂成为发泡状态。作为囊体的材料,可以使用(例如)偏二氯乙烯-丙烯腈共聚物等。此外,作为挥发性物质的材料,可以使用(例如)脂肪族烃等。
作为发泡剂,发泡前的平均粒径优选为花纹纹理层7的层厚的2/3倍以上50倍以下。当小于花纹纹理层7的层厚的2/3倍时,哑光感和手触感可能会变弱。另一方面,当大于花纹纹理层7的层厚的50倍时,发泡后的发泡树脂层8可能会从装饰纸4上脱落等,从而耐擦伤性可能会减弱。在此,平均粒径是通过显微镜观察得到的平均粒径。通过显微镜观察得到的平均粒径可以通过(例如)在显微镜下观察发泡剂并采用图像处理软件等测定100个由显微镜观察到的发泡剂的粒径、然后以个数为基准对测定结果进行平均而得到。需要说明的是,作为发泡剂的粒径,可以采用发泡剂粒子的长轴径和短轴径的平均值。
作为发泡剂,发泡后的平均粒径优选为15μm以上250μm以下。当小于15μm时,哑光感和手触感可能会变弱。另一方面,当大于250μm时,发泡后的发泡树脂层8可能会从装饰纸4上脱落等,从而耐擦伤性可能会减弱。更优选为30μm以上200μm以下。在此,与发泡前的发泡剂的平均粒径同样地,发泡后的发泡剂的平均粒径也是通过显微镜观察得到的平均粒径。此外,作为用于获得平均粒径的发泡后的发泡剂的粒径,可以采用通过发泡剂的发泡而形成的空隙的长轴径和短轴径的平均值。
此外,发泡剂的发泡起始温度优选为100℃以上220℃以下。当低于100℃时,开始发泡的时间点较早,因此发泡后的发泡树脂层8被加热加压的时间变长,发泡后的发泡树脂层8可能被压碎,从而哑光感和手触感可能会变弱。另一方面,当高于220℃时,在制造树脂浸渍装饰板1时,由于通过与金属板(镜面板)抵接而进行的加热加压成型,使得发泡树脂层8不能充分地发泡,从而哑光感和手触感可能会变弱。更优选为120℃以上200℃以下。
发泡后的发泡树脂层8所形成的凹凸纹理10的种类没有特别的限制,可以与花纹纹理层7所形成的花纹设计性地同步,也可以不同步。特别是,当考虑到获得设计性优异的树脂浸渍装饰板1时,最优选的是与花纹纹理层7所形成的花纹设计性地同步。在使花纹纹理层7所形成的花纹与凹凸纹理10设计性地同步的情况下,使发泡树脂层8的配置位置与花纹纹理层7所形成的花纹同步。即,在花纹纹理层7所形成的花纹当中,将发泡树脂层8配置在想要表现出消光状质感的部位之上。例如,将发泡树脂层8以覆盖花纹纹理层7所形成的花纹当中的、亮度相对于该花纹的其他部分而言更低的暗色部分的方式配置在花纹纹理层7的表面上。由发泡树脂层8覆盖的面积占暗色部分的面积的比率优选为70%以上。特别是,最优选为90%以上。在将花纹纹理层7的花纹设为木纹理的情况下,将发泡树脂层8配置成与花纹纹理层7的木纹理设计性地同步的导管纹理状。发泡树脂层8的颜色没有特别的限定,可以是无色的,也可以是有色的。
需要说明的是,在将发泡树脂层8配置在花纹纹理层7中的情况下,将发泡树脂层8混入至花纹纹理层7所形成的花纹当中的、亮度相对于该花纹的其他部分而言更低的暗色部分中而配置在花纹纹理层7中。发泡树脂层8的体积在暗色部分的体积与发泡树脂层8的体积的总体积中所占的比率优选为70%以上。特别是,最优选为90%以上。
发泡树脂层8的配置方法没有特别的限定,例如可以采用在花纹纹理层7上印刷通过将发泡树脂层8与适当的粘合剂树脂一起分散在稀释溶剂中而得的印刷油墨的方法。作为粘合剂树脂,可以使用(例如)二液固化型氨基甲酸酯树脂等具有氨基甲酸酯键的热固化型树脂;电离放射线固化性树脂等固化性树脂;以酪蛋白、乳液树脂为主要成分的树脂。作为热固化型树脂,可以采用(例如)三聚氰胺类树脂、环氧类树脂、尿素类树脂、酚醛类树脂、不饱和聚酯类树脂、邻苯二甲酸二烯丙基酯类树脂、苯并胍胺类树脂、氨基甲酸酯类树脂、氨基醇酸类树脂、有机硅类树脂等。此外,作为电离放射线固化性树脂,例如可以采用(甲基)丙烯酸酯类树脂、不饱和聚酯类树脂等。
此外,与花纹纹理层7同样地,发泡树脂层8的印刷油墨的印刷方法没有特别的限定,可以使用(例如)凹版印刷法、胶版印刷法、丝网印刷法、柔版印刷法、凸版印刷法、喷墨印刷法等任意的印刷方法。
(热固性树脂层)
作为热固性树脂层9,可以使用公知的在制造树脂浸渍装饰板时所使用的热固性树脂。例如,可以使用:环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂、三聚氰胺类树脂、邻苯二甲酸二烯丙基酯类树脂、苯并胍胺类树脂、醇酸类树脂、不饱和聚酯类树脂、酚醛类树脂、尿素类树脂等。特别是,优选含有环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂中的至少一者。
与花纹纹理层7同样地,热固性树脂层9的印刷方法没有特别的限定,可以使用(例如)凹版印刷法、胶版印刷法、丝网印刷法、柔版印刷法、凸版印刷法、喷墨印刷法等任意的印刷方法。
热固性树脂层9的厚度优选为1μm以上15μm以下。当热固性树脂层9的厚度小于1μm时,树脂浸渍装饰纸2的耐擦伤性和耐污染性可能会降低。另一方面,当热固性树脂层9的厚度超过15μm时,树脂浸渍装饰纸2的设计性和长期保存后的设计稳定性可能会降低。更优选为5μm以上10μm以下。
热固性树脂层9设置在发泡树脂层8的表面积当中的30%以上的范围内。当热固性树脂层9在小于发泡树脂层8的表面积的30%的范围内时,树脂浸渍装饰纸2的耐擦伤性可能会降低。更优选为50%以上。
热固性树脂层9含有着色油墨。作为着色油墨的展色剂(vehicle),可以使用:将氯化聚乙烯、氯化聚丙烯等氯化聚烯烃、聚酯、由异氰酸酯和多元醇形成的聚氨酯、聚丙烯酸酯、聚乙烯乙酸酯、聚氯乙烯、氯乙烯-乙酸乙烯酯共聚物、纤维素类树脂、聚酰胺类树脂等中的一种或二种以上混合使用,并在其中添加颜料、溶剂、各种助剂等以进行油墨化而得的材料。
(树脂浸渍装饰板的制造方法)
接下来,对本发明的实施方式涉及的树脂浸渍装饰板1的制造方法进行说明。
首先,通过在原纸6的表面6a上设置花纹纹理层7、在花纹纹理层7的表面7a上设置发泡树脂层8、并在发泡树脂层8的表面8a上设置热固性树脂层9来形成装饰纸4。然后,将装饰纸4浸渍在通过使浸渍树脂5溶解或分散在水中而得的水系浸渍液中,从而使浸渍树脂5浸渍于装饰纸4。
作为浸渍树脂5,可以使用公知的在制造树脂浸渍装饰板时所使用的热固性树脂。例如可以使用:三聚氰胺类树脂、环氧类树脂、邻苯二甲酸二烯丙基酯类树脂、苯并胍胺类树脂、氨基甲酸酯类树脂、醇酸类树脂、不饱和聚酯类树脂、酚醛类树脂、尿素类树脂等。浸渍树脂5的浸渍可以从装饰纸4的形成有花纹纹理层7的表面侧进行,也可以从相对面的那一侧进行。此外,可以分两次地逐个对单个表面进行浸渍,或者也可以同时对两个表面进行浸渍。浸渍树脂5的浸渍率(浸渍树脂的质量在浸渍后的树装饰纸4的质量中所占的比率)优选为20%以上80%以下。特别是,最优选为40%以上70%以下。此外,为了获得物理性能优异的树脂浸渍装饰板1,重要的是使浸渍树脂5均匀地浸渍于整个原纸6。
接下来,将浸渍有浸渍树脂5的装饰纸4干燥,从而得到树脂浸渍装饰纸2。随后,将树脂浸渍装饰纸2放置在基材3上(图2),使金属板(镜面板)与树脂浸渍装饰纸2的形成有发泡树脂层8和热固性树脂层9的面抵接,对树脂浸渍装饰纸2与基材3的层叠体进行加热加压成型以使树脂浸渍装饰纸2与基材3一体化,从而获得树脂浸渍装饰板1。此时,发泡剂通过加热加压成型时的热量而发泡,配置有发泡树脂层8的位置凸起而形成凹凸纹理10(图1)。然后,通过所形成的凹凸纹理10,使树脂浸渍装饰板1展现出哑光感和手触感。
需要说明的是,在基材3与树脂浸渍装饰纸2之间可以***粘接剂等,也可以不***粘接剂等。此外,根据需要,与公知的三聚氰胺树脂装饰板所采用的方法同样地,也可以***芯纸。作为芯纸,可以使用(例如)通过将未固化状态的热固性树脂浸渍在钛纸、漂白或未漂白的牛皮纸、玻璃纤维无纺布等适当的原纸中而得的材料。此外,热固性树脂可以根据作为目标的树脂浸渍装饰板1所要求的物性等而使用任意的热固性树脂。例如,可以采用三聚氰胺类树脂、环氧类树脂、邻苯二甲酸二烯丙基酯类树脂、苯并胍胺类树脂、氨基甲酸酯类树脂、醇酸类树脂、不饱和聚酯类树脂、酚醛类树脂、尿素类树脂等。作为芯纸的例子,可列举出以往已被广泛用作三聚氰胺树脂装饰板的芯纸的酚醛树脂浸渍牛皮纸。
作为用于将树脂浸渍装饰纸2以层叠的状态粘接在基材3上的加热加压成型方法,例如可以使用将金属板抵接以进行平压压制的方法、圆压式的连续层压方式等。特别是,优选使用金属制环形带的连续层压方式。通过连续层压方式,可以高速且连续地制造表面没有翘曲或起伏等、并且层间密合性良好且致密地固化并一体化的高品质树脂浸渍装饰板1。
在使用连续层压方式的情况下,树脂浸渍装饰板1的表面形状成为在连续层压方式中使用的金属板或金属制环形带、由固化型树脂等制作的压花片的表面形状直接赋予的形状。因此,通过使用表面已被平滑地研磨成镜面状等的材料作为金属板或金属制环形带、由固化型树脂等制作的压花片,可以获得表面光泽度及平滑性优异的树脂浸渍装饰板1。
当然,根据需要,通过使用所需的任意的消光状或质地状的金属板或金属制环形带、由固化型树脂等制作的压花片,也能够根据作为目标的树脂浸渍装饰板1的用途而获得任意的表面为成品状态的树脂浸渍装饰板1。
本发明的树脂浸渍装饰板1不限于上述详细说明的实施方式,在不脱离本发明主旨的范围内,也可以进行各种变形后实施。
如上所述,本发明的实施方式涉及的树脂浸渍装饰纸2为使浸渍树脂5浸渍于装饰纸4而得的,装饰纸4具备:原纸6、花纹纹理层7、发泡树脂层8、以及热固性树脂层9。花纹纹理层7设置在原纸6的表面6a侧。发泡树脂层8由配置在花纹纹理层7的表面7a上、或花纹纹理层7中的发泡剂形成。热固性树脂层9含有环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂中的至少一者,该热固性树脂层9设置在发泡树脂层8的表面8a上。由此,可以通过加热加压成型使发泡剂发泡,从而可以在树脂浸渍装饰纸的表面适当地形成凹凸纹理。此外,由于不需要为每个凹凸纹理10准备金属板,因此可以在抑制成本的同时提供哑光效果和手触感优异的树脂浸渍装饰纸2及树脂浸渍装饰板1。此外,可以通过热固性树脂层9保护凹凸纹理10的凸起部,从而可以提供耐污染性和长期保存后的设计稳定性得以提高了的树脂浸渍装饰纸2及树脂浸渍装饰板1。
此外,将热固性树脂层9的厚度设为1μm以上15μm以下。由此,可以提供抑制了设计性劣化、且耐久性和长期保存后的设计稳定性得以提高了的树脂浸渍装饰纸2及树脂浸渍装饰板1。
此外,将热固性树脂层9的厚度设为5μm以上10μm以下。由此,可以提供抑制了设计性劣化、且耐久性和长期保存后的设计稳定性得以进一步提高了的树脂浸渍装饰纸2及树脂浸渍装饰板1。
此外,将热固性树脂层9设置在发泡树脂层8的表面积当中的30%以上的范围内。由此,可以提供耐擦伤性和设计性降低得以抑制了的树脂浸渍装饰纸2及树脂浸渍装饰板1。
此外,将热固性树脂层9设置在发泡树脂层8的表面积当中的50%以上的范围内。由此,可以提供耐擦伤性和设计性降低得以更有效地抑制了的树脂浸渍装饰纸2及树脂浸渍装饰板1。
此外,在热固性树脂层9中含有着色油墨。由此,可以提供抑制了由发泡树脂层8引起的白化、且设计性得以提高了的树脂浸渍装饰纸2及树脂浸渍装饰板1。
此外,发泡树脂层8在发泡后的平均粒径设为15μm以上250μm以下、发泡起始温度设为100℃以上220℃以下。因此,将发泡树脂层8在发泡后的平均粒径和发泡起始温度设为适当的数值,因此通过以往的树脂浸渍装饰板的制造方法,可以在加热加压成型时使发泡树脂层8发泡,从而可以在树脂浸渍装饰板1的表面适当地形成凹凸纹理10。由此,树脂浸渍装饰板1可以展现出哑光感和手触感。此外,通过调整装饰纸4中的发泡树脂层8的配置位置,可以在树脂浸渍装饰板1的表面赋予任意的凹凸纹理10,并且不需要为每个凹凸纹理10准备金属板。因此,可以在抑制成本的同时提供能够形成哑光效果和手触感优异的树脂浸渍装饰板1的装饰纸4。
此外,发泡树脂层8在发泡后的平均粒径为15μm以上250μm以下,发泡树脂层8的发泡起始温度为100℃以上220℃以下,因此可以形成适当的凹凸纹理10,并且可以提供哑光感、手触感、耐擦伤性优异的装饰纸4。
另外,在本发明的实施方式涉及的装饰纸4中,由于花纹纹理层7所形成的花纹与发泡树脂层8的配置位置同步,因此可以形成花纹纹理层7所形成的花纹与树脂浸渍装饰板1表面的凹凸纹理10设计性地同步的树脂浸渍装饰板1。
此外,在本发明的实施方式涉及的装饰纸4中,发泡树脂层8在发泡前的平均粒径为花纹纹理层7的层厚的2/3倍以上50倍以下。因此,可以形成适当的凹凸纹理10,并且可以提供哑光感、手触感、耐擦伤性优异的树脂浸渍装饰板1。
此外,将本发明的实施方式涉及的树脂浸渍装饰板1设置为具备:树脂浸渍装饰纸2、以及与树脂浸渍装饰纸2一体化的基材3。因此,可以在抑制成本的同时提供哑光效果和手触感优异的树脂浸渍装饰板1。
实施例
以下,对本发明涉及的树脂浸渍装饰板1的实施例和比较例进行说明。需要说明的是,本发明不限于下述的实施例。
(实施例1)
首先,作为原纸6,准备了吸水性良好的装饰纸用钛纸。随后,采用以酪蛋白为主要成分的水性油墨在原纸6的表面6a上印刷木纹纹理,形成了层厚为10μm的花纹纹理层7。作为印刷方法,使用了凹版印刷方式。接下来,采用含有发泡剂的以环氧树脂为主要成分的水性油墨,在花纹纹理层7的表面7a上印刷了与花纹纹理层7的木纹纹理设计性地同步的导管纹理,从而将发泡树脂层8配置成导管纹理状。作为印刷方法,使用了直接凹版印刷方式。作为发泡树脂层8,使用了发泡前的平均粒径为100μm(花纹纹理层7的层厚的10倍)、发泡后的平均粒径为120μm且发泡起始温度为180℃的发泡树脂层。
接下来,在发泡树脂层8的表面8a上印刷作为外涂层的热固性树脂层9,形成了装饰纸4。作为印刷方法,使用凹版印刷方式,并且热固性树脂层9使用了环氧类树脂。将热固性树脂层9的厚度设为0.5μm,将设置热固性树脂层9的范围设为发泡树脂层8的表面积当中的25%。即,有多个发泡树脂层8,但是在其全部中的每一个中,表面积的25%的范围被热固性树脂层9覆盖。接下来,使浸渍树脂5浸渍于装饰纸4后,在烘箱中干燥,从而形成了树脂浸渍装饰纸2。作为浸渍树脂5,使用了水性三聚氰胺类树脂液。接下来,将树脂浸渍装饰纸2放置在基材3上。作为基材3,使用了刨花板基材。接下来,在约160℃下,对树脂浸渍装饰纸2的形成有发泡树脂层8和热固性树脂层9的面进行热压,对树脂浸渍装饰纸2与基材3的层叠体进行加热加压成型,以使树脂浸渍装饰纸2与基材3一体化,从而形成了实施例1的树脂浸渍装饰板1。热压时的板使用了平板。在树脂浸渍装饰板1中,在花纹纹理层7当中,没有发泡树脂层8和热固性树脂层9的区域具有光泽,有发泡树脂层8和热固性树脂层9的区域具有哑光效果。
(实施例2)
在实施例2中,使用酪蛋白类树脂作为热固性树脂层9。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例3)
在实施例3中,使用丙烯酸类树脂作为热固性树脂层9。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例4)
在实施例4中,使用氨基甲酸酯类树脂作为热固性树脂层9。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例5)
在实施例5中,将热固性树脂层9的厚度设为1μm。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例6)
在实施例6中,将热固性树脂层9的厚度设为5μm。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例7)
在实施例7中,将热固性树脂层9的厚度设为7μm。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例8)
在实施例8中,将热固性树脂层9的厚度设为10μm。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例9)
在实施例9中,将热固性树脂层9的厚度设为15μm。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例10)
在实施例10中,使热固性树脂层9的范围增加5%,成为发泡树脂层8的表面积的30%。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例11)
在实施例11中,使热固性树脂层9的范围增加25%,成为发泡树脂层8的表面积的50%。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例12)
在实施例12中,使热固性树脂层9的范围增加35%,成为发泡树脂层8的表面积的60%。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例13)
在实施例13中,使热固性树脂层9的范围增加55%,成为发泡树脂层8的表面积的80%。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例14)
在实施例14中,使热固性树脂层9的范围增加75%,成为发泡树脂层8的表面积的100%。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(实施例15)
在实施例15中,在热固性树脂层9中添加着色油墨。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(比较例1)
在比较例1中,省略了热固性树脂层9。除此以外,以与实施例1相同的材料和步骤制作了树脂浸渍装饰板1。
(性能评价)
对实施例1~15、比较例1的树脂浸渍装饰板1进行了如下所示的性能评价。
(横切试验)
在横切(crosscut)试验中,使用切割工具在树脂浸渍装饰板1上进行横切,评价是否发生剥离。将横切时无明显剥离的情况设为“○”,将有显著剥离的情况设为“×”。
(污染试验)
在污染试验中,用黑色蜡笔和红色油墨被覆树脂浸渍装饰板1,1小时后用酒精擦拭,评价擦拭残留程度。将擦拭残留程度小于30%的情况设为“○”,将擦拭残留程度为30%以上且小于70%的情况设为“△”,将擦拭残留程度为70%以上的情况设为“×”。
(触感评价)
在触感评价中,作为官能试验,用10名试验员进行了评价。将评价为良好的人为7~10名的情况设为“○”,将评价为良好的人为1~6名的情况设为“△”,将评价为良好的人为0人的情况设为“×”。
(设计评价)
在设计评价中,作为官能试验,用10名试验员进行了评价。将评价为良好的人为7~10名的情况设为“○”,将评价为良好的人为1~6名的情况设为“△”,将评价为良好的人为0人的情况设为“×”。
(长期环境试验)
在长期环境试验中,将树脂浸渍装饰板1在温度40℃、湿度90%的环境下放置2个月后,作为关于设计变化的官能试验,用10名试验员进行了评价。将评价为良好的人为7~10名的情况设为“○”,将评价为良好的人为1~6名的情况设为“△”,将评价为良好的人为0人的情况设为“×”。
(综合判定)
通过上述横切试验、污染试验、触感评价、设计评价、长期环境试验这五个项目进行了综合的评价。将特别优异的设为“◎”,将优异的设为“○”,将几乎没有问题的设为“△”,将有问题的设为“×”。
(评价结果)
这些评价结果示于表1。
[表1]
如表1所示,在横切试验中,实施例1~15、及比较例1中均未观察到剥离,密合性没有问题。然而,与省略了热固性树脂层9的比较例1相比,在设置有热固性树脂层9的实施例1~15中,耐污染性和长期保存后的设计稳定性得以提高。特别是,如实施例1~4的评价结果所示,使用了环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂作为热固性树脂9的实施例,关于耐污染性和长期保存后的设计稳定性,是优异的、或者几乎没有问题。此外,如实施例5~9的评价结果所示,热固性树脂层9越厚,耐擦伤性越得以提高,但是设计性倾向于降低。此外,如实施例10~14的评价结果所示,热固性树脂层9的涂布面积越增加,耐污染性越得以提高,但是设计性倾向于降低。另外,如实施例15的评价结果所示,通过在热固性树脂层9中添加着色油墨,不仅可以提高设计展现的自由度,还能抑制发泡树脂层8的白化,提高设计性。作为综合判定,实施例6、7、12、15的树脂浸渍装饰板1特别优异。在实施例5~14中,虽然使用了环氧类树脂作为热固性树脂层9,但是即使使用酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂等来代替环氧类树脂,基本的物性也没有太大的差别,可以得到大致相同的结果。
以上,参照有限数量的实施方式进行了说明,但是权利范围不限于它们,基于上述公开的实施方式的改变对于本领域技术人员来说是显而易见的。
符号的说明
1…树脂浸渍装饰板、2…树脂浸渍装饰纸、3…基材、3a…表面、4…装饰纸、5…浸渍树脂、6…原纸、6a…表面、7…花纹纹理层、7a…表面、8…发泡树脂层、8a…表面、9…热固性树脂层、10…凹凸纹理
Claims (10)
1.一种树脂浸渍装饰纸,其为使浸渍树脂浸渍于装饰纸而得的树脂浸渍装饰纸,特征在于,
所述装饰纸具备:
原纸、
设置在所述原纸的表面侧的花纹纹理层、
由配置在所述花纹纹理层的表面上或所述花纹纹理层中的发泡剂形成的发泡树脂层、以及
设置在所述发泡树脂层的表面上的热固性树脂层,
所述热固性树脂层含有环氧类树脂、酪蛋白类树脂、丙烯酸类树脂、氨基甲酸酯类树脂中的至少一者。
2.根据权利要求1所述的树脂浸渍装饰纸,其特征在于,
所述热固性树脂层的厚度为1μm以上15μm以下。
3.根据权利要求2所述的树脂浸渍装饰纸,其特征在于,
所述热固性树脂层的厚度为5μm以上10μm以下。
4.根据权利要求1至3中任一项所述的树脂浸渍装饰纸,其特征在于,
所述热固性树脂层设置在所述发泡树脂层的表面积当中的30%以上的范围内。
5.根据权利要求4所述的树脂浸渍装饰纸,其特征在于,
所述热固性树脂层设置在所述发泡树脂层的表面积当中的50%以上的范围内。
6.根据权利要求1至5中任一项所述的树脂浸渍装饰纸,其特征在于,
所述热固性树脂层含有着色油墨。
7.根据权利要求1至6中任一项所述的树脂浸渍装饰纸,其特征在于,
所述发泡剂在发泡后的平均粒径为15μm以上250μm以下,发泡起始温度为100℃以上220℃以下。
8.根据权利要求1至7中任一项所述的树脂浸渍装饰纸,其特征在于,
所述花纹纹理层所形成的花纹与所述发泡树脂层的配置位置同步。
9.根据权利要求1至8中任一项所述的树脂浸渍装饰纸,其特征在于,
所述发泡剂在发泡前的平均粒径为所述花纹纹理层的层厚的2/3倍以上50倍以下。
10.一种树脂浸渍装饰板,其特征在于,具备:
权利要求1至9中任一项所述的树脂浸渍装饰纸、以及与所述树脂浸渍装饰纸一体化的基材。
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