JP2002192657A - Decorative laminated sheet - Google Patents
Decorative laminated sheetInfo
- Publication number
- JP2002192657A JP2002192657A JP2000396339A JP2000396339A JP2002192657A JP 2002192657 A JP2002192657 A JP 2002192657A JP 2000396339 A JP2000396339 A JP 2000396339A JP 2000396339 A JP2000396339 A JP 2000396339A JP 2002192657 A JP2002192657 A JP 2002192657A
- Authority
- JP
- Japan
- Prior art keywords
- decorative
- layer
- resin
- decorative board
- paper
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Landscapes
- Laminated Bodies (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は耐熱性、耐汚染性に
優れ、かつ使用雰囲気の環境変化に対しても極めて良好
な寸法安定性を持つ化粧板に関するものである。具体的
用途としては、例えば、従来高圧メラミン化粧板を表面
化粧材として使用する建材用内装材全般に適用出来、ま
た極めて高い寸法安定性、耐クラック性を活かして高い
耐久性を必要とする車両用内装材にも有効活用が期待出
来る。また、使用部位に応じて化粧板厚みを選択し、か
つ従来のメラミン樹脂化粧板の積層技術を複合させるこ
とで、トイレブース、仕切板等の高剛性や耐水性が要求
される部位でのパネル化材料を提供するものでもある。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board having excellent heat resistance and stain resistance, and having extremely good dimensional stability against environmental changes in a use atmosphere. Specific applications include, for example, vehicles that can be applied to all interior materials for building materials that conventionally use high-pressure melamine decorative boards as surface decorative materials, and that require high durability by taking advantage of extremely high dimensional stability and crack resistance. It can be expected to be used effectively for interior materials. In addition, by selecting the thickness of the decorative board according to the part to be used and combining the conventional laminating technology of melamine resin decorative boards, panels in places where high rigidity and water resistance are required, such as toilet booths and partition boards It also provides chemical materials.
【０００２】[0002]
【従来の技術】従来の主要な内装材料には、メラミン樹
脂化粧板やポリエステル化粧板、塩ビ化粧シート貼り化
粧板等が多用されてきた。中でもメラミン樹脂化粧板
は、その優れた表面硬度、耐汚染性等の表面性能かつ意
匠性でも豊富な色柄が選択出来ることから、表面化粧材
として長年の実績があり、広く使用されて来た。しか
し、こうした優れた表面性能を有する反面、雰囲気湿度
変化に伴う寸法変化が大きく、他の化粧材料に比べ反り
の問題があることや表面が硬くかつ高強度材のため、切
削加工、パネル化接着加工等の２次加工を難しくしてい
る。また、ポリエステル化粧板や塩ビ化粧シート貼り化
粧板も汎用材料として使用されているがメラミン樹脂化
粧板程の表面硬度、耐摩耗性、耐薬品性がなく、耐久性
やメンテナンス性で大きく低下する。さらにベース基材
が合板、パーチクルボードといった木質系基材である場
合、長期耐水性で問題が生じ易くなる欠点があった。2. Description of the Related Art Conventionally, decorative materials such as melamine resin decorative boards, polyester decorative boards, and PVC decorative sheet-attached decorative boards have been widely used as main interior materials. Among them, the melamine resin decorative board has a long track record as a surface decorative material, and has been widely used because its surface properties such as excellent surface hardness and stain resistance and abundant colors and patterns can be selected in design. . However, while having such excellent surface performance, the dimensional change due to changes in atmospheric humidity is large, there is a problem of warpage compared to other decorative materials, and because the surface is hard and high strength material, cutting processing, panel bonding Secondary processing such as processing is difficult. Polyester decorative panels and decorative panels with PVC decorative sheets are also used as general-purpose materials, but they do not have the same surface hardness, abrasion resistance, and chemical resistance as melamine resin decorative panels, and greatly reduce durability and maintainability. Further, when the base material is a wood-based material such as plywood or particle board, there is a disadvantage that long-term water resistance tends to cause a problem.
【０００３】車両用途分野でも、金属ベースメラミン樹
脂化粧板が多用されて来たが、使用環境が過酷であり、
前述した寸法変化に伴う化粧板反り安定性の改善を必要
とする状況にある。また、車両の居住性要求や内装デザ
インの指向変化から曲面加工（特に化粧面を凸とする外
曲げ加工）ｋ要求が高くなり、メラミン樹脂化粧板の代
替材料として塩ビシート、ＦＲＰ成形品等への置き換え
が増えていた。[0003] In the field of vehicle use, metal-based melamine resin decorative boards have been frequently used, but the use environment is harsh.
There is a situation where it is necessary to improve the warpage stability of the decorative board due to the dimensional change described above. In addition, demand for curved surface processing (especially, external bending processing with a convex decorative surface) has increased due to demands for vehicle livability and changes in the orientation of interior design. Replacement was increasing.
【０００４】その一方で、近年、産業廃棄物処理や塩ビ
焼却時のダイオキシン問題に代表される環境保全への社
会ニーズが高まる中で、化粧材料にも新たな対応が求め
られる様になり、一方では低コスト化要求や軽量化対応
が益々強くなっている。そうした市場変化にあって、高
圧メラミン樹脂化粧板の持つ高耐久性が改めて評価され
ている。また、内装材料自体の再資源化（リサイクル
性）も重要視されているが、メラミン樹脂化粧板や金属
ベースメラミン樹脂化粧板では、貼り付けられた合板等
の基板やベース金属板と化粧樹脂層の分別が容易でな
く、マテリアルリサイクルを困難にしている。On the other hand, in recent years, as social needs for environmental protection represented by the dioxin problem at the time of industrial waste treatment and PVC incineration have increased, new measures have been required for cosmetic materials. In response, demands for cost reduction and weight reduction are becoming stronger. Amid such market changes, the high durability of the high-pressure melamine resin decorative board has been evaluated again. Recycling of the interior material itself is also considered important, but in the case of melamine resin decorative boards and metal-based melamine resin decorative boards, substrates such as plywood or base metal sheets that are pasted and the decorative resin layer Is difficult to separate, making material recycling difficult.
【０００５】[0005]
【発明が解決しようとする課題】本発明者は、上記した
ような各種汎用化粧板の持つ欠点を改善し、建材分野、
車両内装用途に好適な化粧材料を開発する目的で、今日
の市場ニーズに合った機能を如何にして付加するかにを
鋭意検討を行った結果、特に耐熱性、寸法安定性、耐汚
染性等の耐久性に優れ、高い意匠性を有する新規な化粧
板を提供するものである。SUMMARY OF THE INVENTION The present inventor has solved the above-mentioned drawbacks of various general-purpose decorative boards,
As a result of intensive studies on how to add functions that meet today's market needs in order to develop cosmetic materials suitable for vehicle interior use, heat resistance, dimensional stability, stain resistance, etc. It is intended to provide a novel decorative board having excellent durability and high designability.
【０００６】[0006]
【課題を解決するための手段】本発明は、（１）化粧板
の最表面層がポリエーテルサルホン樹脂（以下、ＰＥＳ
と略す）層で形成されることを特徴とする厚さ０．３〜
２５ｍｍの化粧板、（２）ＰＥＳ層の厚みが１００〜５
００μｍで、かつガラス転移温度（以下、Ｔｇと略す）
が２００℃以上である第（１）項記載の化粧板、（３）
ＰＥＳ層と意匠を形成する化粧層との接合をポリエステ
ル樹脂、ポリイソシアネート、ポリアクリル酸エステル
から選ばれる１種以上の高分子量樹脂を介して一体成形
されている第（１）又は（２）項記載の化粧板、であ
る。According to the present invention, (1) the outermost surface layer of the decorative plate is made of polyether sulfone resin (hereinafter referred to as PES).
Characterized by being formed of a layer.
(2) The thickness of the PES layer is 100 to 5
00 μm and glass transition temperature (hereinafter abbreviated as Tg)
(3) wherein the temperature is 200 ° C. or more;
Item (1) or (2), wherein the bonding between the PES layer and the decorative layer forming the design is integrally formed via one or more high molecular weight resins selected from polyester resins, polyisocyanates, and polyacrylates. It is a decorative board described.
【０００７】[0007]
【発明の実施の形態】本発明の化粧板は、ＰＥＳを化粧
板の表面層に配置することを特徴とする。ＰＥＳを化粧
板の表面層に配置することにより、メラミン樹脂化粧板
の有する表面硬度、耐熱性、耐汚染性等の長所を保持し
つつ、寸法安定性を改善するものである。本発明ではＰ
ＥＳ層の厚みが１００〜５００μｍで、かつＴｇが２０
０℃以上であることが耐熱性、意匠効果、成形性、コス
ト等の点で好ましい。１００μｍ未満でも本発明の化粧
板として支障はないが、ＰＥＳのＴｇは一般的には高温
であることから厚みの薄いフィルム化が困難であり、大
幅なコストアップになる。５００μｍを越えると透過性
が低下して意匠性の低下につながることがあり、成形条
件の設定が難しくなり、コスト面も障害になる。また、
ＰＥＳのＴｇが２００℃未満であると耐熱性が低下し、
表面硬度の低下につながる傾向がある。本発明で用いる
ＰＥＳは、特に限定されるものではなく、住友化学製の
ビクトレックスＰＥＳ等市販されているものである。DESCRIPTION OF THE PREFERRED EMBODIMENTS The decorative board of the present invention is characterized in that PES is arranged on a surface layer of the decorative board. By arranging PES on the surface layer of the decorative board, the dimensional stability is improved while maintaining the advantages of the melamine resin decorative board such as surface hardness, heat resistance, and stain resistance. In the present invention, P
The thickness of the ES layer is 100 to 500 μm and the Tg is 20
A temperature of 0 ° C. or higher is preferred in terms of heat resistance, design effect, moldability, cost, and the like. Even if the thickness is less than 100 μm, there is no problem as the decorative board of the present invention, but since Tg of PES is generally high temperature, it is difficult to form a thin film, resulting in a significant increase in cost. If it exceeds 500 μm, the transmittance may be reduced, which may lead to a reduction in design properties, which makes it difficult to set molding conditions and also hinders cost. Also,
When Tg of PES is less than 200 ° C., heat resistance is reduced,
It tends to lead to a decrease in surface hardness. PES used in the present invention is not particularly limited, and is commercially available, such as Victrex PES manufactured by Sumitomo Chemical.
【０００８】本発明の化粧板において、化粧板として必
要な意匠性は、ＰＥＳ層の直下にある化粧層により発現
させ、ＰＥＳ層と化粧層との接合をポリエステル樹脂、
ポリイソシアネート、ポリアクリル酸エステルから選ば
れる１種以上の高分子量樹脂を介して一体成形されてい
ることを特徴のひとつとする。これらの高分子量樹脂が
ＰＥＳとの相溶性ないし密着性に優れるからである。こ
れらの中でもポリエステルフィルムが最も安定した積層
成形が達成されるため、最も好ましい。ポリエステルフ
ィルムは、特に限定されるものではなく、東亞合成製の
ＰＥＳ−１２０ＥＦ等市販されているものである。ポリ
エステルフィルムのＴｇは、化粧板の耐熱性の点から１
００℃以上が好ましく、成形温度で軟化ないし溶融し化
粧原紙中に浸入するものが好ましく使用される。また、
ポリエステルフィルムの厚みは、化粧板の耐熱性及び化
粧層との密着性の点から３０〜２００μｍが好ましい。
３０μｍ未満では化粧層とＰＥＳ層の密着性が不十分と
なることがあり、２００μｍを越えると耐熱性が低下す
るようになる。また、ＰＥＳの裏面に化粧印刷を施し、
バインダーを介してコア層と積層成形する方法も採用さ
れうる。In the decorative panel of the present invention, the design required for the decorative panel is expressed by a decorative layer immediately below the PES layer, and the bonding between the PES layer and the decorative layer is made of a polyester resin.
One of the features is that they are integrally formed via at least one kind of high molecular weight resin selected from polyisocyanate and polyacrylate. This is because these high molecular weight resins are excellent in compatibility or adhesion with PES. Among these, a polyester film is most preferable because the most stable lamination molding is achieved. The polyester film is not particularly limited, and is commercially available such as PES-120EF manufactured by Toagosei. The Tg of the polyester film is 1 from the viewpoint of the heat resistance of the decorative board.
It is preferably at least 00 ° C., and those which soften or melt at the molding temperature and penetrate into decorative base paper are preferably used. Also,
The thickness of the polyester film is preferably from 30 to 200 μm from the viewpoint of the heat resistance of the decorative board and the adhesion to the decorative layer.
If it is less than 30 μm, the adhesion between the decorative layer and the PES layer may be insufficient, and if it exceeds 200 μm, the heat resistance will be reduced. Also, make a decorative print on the back of the PES,
A method of lamination molding with a core layer via a binder can also be adopted.
【０００９】本発明の化粧板は、表面層にはＰＥＳを配
置するが、コア層には通常化粧板に用いられているもの
を使用する。コア層はそのプライ数により化粧板を所定
の厚みに形成するものである。コア層としては、フェノ
ール樹脂含浸紙、アクリル樹脂含浸紙、ジアリルフタレ
ート樹脂含浸紙等が挙げられる。また、車両内装用途に
は金属板をコア層とすることが強度、耐久性、難燃性、
曲げ加工性の点で好ましく、一般建材用途には、低コス
ト化等のために、必要に応じて無機ボード、木質系基材
等をコア層とすることができる。このコア層の両面又は
片面には化粧層をバインダーを介して積層成形する。バ
インダーとしては、前記のポリエステル、ポリイソシア
ネート、アクリル酸エステルから選ばれる１種以上の高
分子量樹脂が好ましく使用される。これらの樹脂は、コ
ア層との密着性に優れるからである。コア層からの影響
により化粧外観に隠蔽ムラが生じる場合には、化粧層と
コア層との境界面に下地色を遮蔽するためのバリア層を
挿入することも可能である。[0009] In the decorative board of the present invention, PES is disposed on the surface layer, and the core layer used is usually that used for decorative boards. The core layer forms the decorative board to a predetermined thickness according to the number of plies. Examples of the core layer include phenol resin impregnated paper, acrylic resin impregnated paper, diallyl phthalate resin impregnated paper, and the like. In addition, for vehicle interior use, it is necessary to use a metal plate as the core layer for strength, durability, flame retardancy,
It is preferable from the viewpoint of bending workability. For general building materials, an inorganic board, a wood-based substrate, or the like can be used as a core layer as necessary for cost reduction and the like. On both sides or one side of the core layer, a decorative layer is laminated and formed with a binder interposed therebetween. As the binder, one or more high molecular weight resins selected from the above-mentioned polyesters, polyisocyanates and acrylates are preferably used. This is because these resins have excellent adhesion to the core layer. When hiding unevenness occurs in the cosmetic appearance due to the influence of the core layer, it is also possible to insert a barrier layer for shielding the base color at the interface between the decorative layer and the core layer.
【００１０】本発明の化粧板の構成例を以下に示す。一
般建材用途では、例えば、ＰＥＳフィルム、ポリエステ
ルフィルム、印刷化粧原紙、ポリエステルフィルム、及
び複数枚のフェノール樹脂含浸紙をこの順序に重ね合わ
せ、加熱加圧して得られる。フェノール樹脂含浸紙の全
部又は一部を無機ボード、木質系基材等に置き換えるこ
ともできる。。また、車両内装用途のための金属ベース
化粧板は、例えば、ＰＥＳフィルム、ポリエステルフィ
ルム、印刷化粧原紙、ポリエステルフィルム、及びアル
ミ板を積層成形して得られる。An example of the structure of the decorative board of the present invention is shown below. In general building material applications, for example, a PES film, a polyester film, a printing decorative base paper, a polyester film, and a plurality of phenolic resin-impregnated papers are laminated in this order and heated and pressed. All or a part of the phenolic resin-impregnated paper can be replaced with an inorganic board, a wood-based substrate, or the like. . Further, a metal-based decorative board for vehicle interior use is obtained by, for example, laminating a PES film, a polyester film, a printing base paper, a polyester film, and an aluminum plate.
【００１１】本発明の化粧板は、上記の各素材を重ね合
わせ、通常のメラミン樹脂化粧板と同様の加熱加圧条件
で、積層成形することにより製造することができる。本
発明の化粧板において、前記した成形方法は、従来のメ
ラミン樹脂化粧板のようなメラミン樹脂含浸化粧紙を使
用する方法と異なり、積層成形する際に加える圧力と熱
を利用して、各層間に配するバインダーを化粧原紙中に
圧し込む方法である。他の方法として、単に従来の高圧
メラミン樹脂化粧板の構成上にバインダーを介してＰＥ
Ｓ層を形成することも可能である。しかしながら、この
場合、加熱硬化の際にメラミン樹脂含浸化粧紙から放出
する反応縮合水や含浸紙作成時に残留している揮発分
が、ＰＥＳと化粧層との接合力を大幅に低下させる要因
となるため、バインダーの性状や形態が大きく制限され
るという欠点がある。化粧原紙をバインダーで挟み込む
形で積層成形する前者の方法は、こうした水分の影響が
無く層間接合を容易にする効果と、メラミン樹脂を化粧
原紙に含浸する必要がなく生産工程を簡素化できるメリ
ットもある。The decorative board of the present invention can be produced by laminating the above-mentioned materials and laminating them under the same heating and pressurizing conditions as for a normal melamine resin decorative board. In the decorative board of the present invention, the above-mentioned forming method is different from a method using a melamine resin impregnated decorative paper such as a conventional melamine resin decorative board, by utilizing pressure and heat applied during laminating and forming each interlayer. Is a method of pressing a binder to be disposed into a decorative base paper. Another method is to simply provide PE on a conventional high-pressure melamine resin decorative board structure via a binder.
It is also possible to form an S layer. However, in this case, the reaction condensed water released from the melamine resin-impregnated decorative paper at the time of heat curing and the volatile matter remaining during the preparation of the impregnated paper are factors that greatly reduce the bonding strength between the PES and the decorative layer. Therefore, there is a disadvantage that the properties and form of the binder are greatly restricted. The former method, in which the decorative base paper is sandwiched between binders, has the advantage of facilitating interlayer bonding without the influence of moisture and the advantage of simplifying the production process without the need to impregnate the melamine resin into the decorative base paper. is there.
【００１２】本発明を考案するに当たり、幾つかの重要
なポイントがあった。 （１）まず、表面層に構成する材料の選択である。最表
面にＰＥＳ層を配置する本発明の化粧板は、雰囲気湿度
変化に対して極めて高い寸法安定性を実現する。また、
表面硬度、耐汚染性、耐熱性等も、従来の高圧メラミン
樹脂化粧板比較して遜色ないものが達成された。 （２）次はバインダーの選択である。バインダーは表面
ＰＥＳ層とコア材のそれぞれに相溶性がある事が基本に
なり、ＰＥＳに対するバインダーの親和性によって層間
強度が決定される。種々のバインダー材料を検討した結
果、ポリエステル樹脂、ポリイソシアネート、及びポリ
アクリル酸エステルが使用可能であり、中でも、ポリエ
ステルフィルムが最も安定した積層成形が達成された。
また、バインダー層の種類、厚み等により、リサイクル
に必要な化粧層とコア層又は基板との分離・分別を容易
に行えるような技術開発も可能となる。There are several important points in devising the present invention. (1) First, selection of a material constituting the surface layer. The decorative plate of the present invention in which the PES layer is disposed on the outermost surface realizes extremely high dimensional stability against changes in atmospheric humidity. Also,
Surface hardness, stain resistance, heat resistance, and the like were also comparable to those of the conventional high-pressure melamine resin decorative board. (2) Next is the selection of the binder. The binder is based on compatibility between the surface PES layer and the core material, and the interlayer strength is determined by the affinity of the binder for PES. As a result of examining various binder materials, polyester resins, polyisocyanates, and polyacrylates can be used, and among them, the most stable lamination molding of polyester films has been achieved.
Further, depending on the type and thickness of the binder layer, it is also possible to develop a technology that can easily separate and separate the decorative layer and the core layer or the substrate required for recycling.
【００１３】本発明に用いられる化粧板総厚みは、使用
用途、適用部位別に要求される板厚に調整される。建材
用途、車両用途では０．６〜１５．０ｍｍが選択され、
汎用品では、０．８〜１．２ｍｍが多用されている。６
ｍｍ越える厚物化粧板が必要な用途には、間仕切板、ト
イレブース等がある。製品厚みの調整方法については、
通常、メラミン樹脂化粧板の製造手段と同様の方法で良
く、コア層であるフェノール樹脂含浸紙のプライ数にて
所定の厚みを形成する。フェノール樹脂含浸紙の代わり
にアクリル樹脂含浸紙、ジアリルフタレート含浸紙等を
用いても良い。或いは、金属板、無機ボード、木質系基
材をコア層とし、この両面又は片面に前記した化粧層を
バインダーを介して積層成形する方法もある。また、コ
ア層からの影響により化粧外観に隠蔽ムラが生じる場合
には、化粧層とコア層との境界面に下地色を遮蔽するた
めのバリア層を挿入することも可能である。The total thickness of the decorative board used in the present invention is adjusted to the required board thickness for each application and application site. 0.6-15.0mm is selected for construction materials and vehicles.
In general-purpose products, 0.8 to 1.2 mm is frequently used. 6
Applications requiring a thick decorative board exceeding mm include a partition board, a toilet booth, and the like. For how to adjust the product thickness,
Usually, a method similar to the method for manufacturing a melamine resin decorative board may be used, and a predetermined thickness is formed by the number of plies of the phenol resin-impregnated paper as the core layer. Instead of the phenol resin-impregnated paper, an acrylic resin-impregnated paper, diallyl phthalate-impregnated paper or the like may be used. Alternatively, there is a method in which a metal plate, an inorganic board, or a wood-based substrate is used as a core layer, and the decorative layer is laminated and formed on both sides or one side of the core layer with a binder interposed therebetween. In addition, when hiding unevenness occurs in the cosmetic appearance due to the influence of the core layer, it is possible to insert a barrier layer for shielding the base color at the interface between the decorative layer and the core layer.
【００１４】以下、本発明の化粧板について、一例を図
面により説明する。図１において、ＰＥＳフィルム１、
バインダーとしてポリエステルフィルム２、化粧原紙３
をもって表面化粧層１０を形成し、更にバインダー層４
（前述のポリエステル２を使用することができる）を介
して、コア層５及び必要によりバック層６の順に積層す
る。ＰＥＳフィルム１は、印刷色、図柄を表現する上で
透明度を必要とする。フィルムの厚さは、前述のように
１００〜５００μｍとすることが好ましい 化粧原紙３は、厚み選択が重要となる。化粧原紙３を上
下からバインダーで挟み、成形時の熱と圧力で原紙内部
に圧し込む方式では、化粧原紙３は米坪の小さいものが
好ましく、２０〜６０ｇ／ｍ2 が望ましい。６０ｇ／ｍ
2 を越えてくると、バインダーの種類によっては原紙補
強が不十分となり原紙の層内剥離や耐水性が問題になる
恐れがある。Hereinafter, an example of the decorative board of the present invention will be described with reference to the drawings. In FIG. 1, PES film 1,
Polyester film 2 and base paper 3 as binder
To form a surface decorative layer 10, and further, a binder layer 4
(The above-mentioned polyester 2 can be used), the core layer 5 and, if necessary, the back layer 6 are laminated in this order. The PES film 1 needs transparency in expressing a printing color and a design. As described above, the thickness of the film is preferably set to 100 to 500 μm. The thickness of the decorative base paper 3 is important. In a method in which the decorative base paper 3 is sandwiched between binders from above and below and pressed into the base paper by heat and pressure during molding, the decorative base paper 3 preferably has a small rice yard and preferably 20 to 60 g / m 2 . 60g / m
If it exceeds 2 , the reinforcement of the base paper may become insufficient depending on the type of the binder, and the peeling in the base paper and the water resistance may become a problem.
【００１５】[0015]
【実施例】以下、本発明について実施例にて具体的に説
明する。ここで、「％」は「重量％」を示す。EXAMPLES Hereinafter, the present invention will be described specifically with reference to Examples. Here, “%” indicates “% by weight”.
【００１６】実施例１ 表面に置くＰＥＳフィルム１は、厚さ４００μｍでＴｇ
２２５℃、バインダーには厚さ８０μｍでＴｇ１２０℃
のポリエステルフィルム２を使用した。化粧原紙３は、
米坪３０ｇ／ｍ2 の薄葉紙に図柄印刷した化粧紙を使用
した。化粧原紙３の下に前記ポリエステルフィルム２を
配置し、その下に厚さ２０μｍのアルミ箔４を配置し
た。更にその下にコア層として米坪１４５ｇ／ｍ2 の未
晒しクラフト紙に、以下に示すフェノール樹脂（ａ）を
含浸した樹脂量４８％、揮発分５％のフェノール樹脂含
浸紙５、及び米坪１９０ｇ／ｍ2 の未晒しクラフト紙
に、以下に示すフェノール樹脂（ｂ）を含浸した樹脂量
３０％、揮発分７％に調整したフェノール含浸紙６を配
置した。次に、艶消しステンレス板の間に、前記化粧板
の素材セットを２組ずつ挿入した。このとき、ステンレ
ス板とＰＥＳフィルム１が接触する様に、かつ、２組の
素材セットを背中合わせにしその間に離形フィルムを挟
んで組み込んだ。プレスは、圧力１００ｋｇ／ｃｍ2 に
保持したままで加熱・冷却した。熱盤温度を１６０℃と
し、製品最高温度が１３８℃〜１４３℃の範囲に入る様
に加熱した後、４０℃まで冷却し、厚さ０．８ｍｍの意
匠性化粧板（図１）を得た。接着用フェノール樹脂
（ａ）ワニスの調製：フェノールに対するホルムアルデ
ヒドのモル比１．２５にて反応し脱水濃縮した粘度１２
０ｃｐｓ／２０℃のレゾール型フェノール樹脂ワニス
を、メタノールにより粘度２７ｃｐｓ／３５℃に調整し
た。含浸用フェノール樹脂（ｂ）ワニスの調製：フェノ
ールに対するホルムアルデヒドのモル比１．３にて反応
した粘度３８ｃｐｓ／２０℃の水溶性レゾール型フェノ
ール樹脂を、メタノールにより粘度１９ｃｐｓ／３４℃
に調整した。Example 1 A PES film 1 placed on the surface was 400 μm thick and had a Tg film thickness of 400 μm.
225 ° C, Tg 120 ° C with a thickness of 80 μm for the binder
Was used. The decorative base paper 3
A decorative paper pattern-printed on thin paper of 30 g / m 2 of rice tsubo was used. The polyester film 2 was disposed under the decorative base paper 3, and an aluminum foil 4 having a thickness of 20 μm was disposed under the polyester film 2. More unbleached kraft paper of basis weight 145 g / m 2 as a core layer thereunder, impregnated resin amount of 48% of phenol resin (a) shown below, the volatile content of 5% phenolic resin impregnated paper 5, and Beitsubo A phenol-impregnated paper 6 having a resin content of 30% impregnated with a phenol resin (b) shown below and a volatile content of 7% adjusted to 190 g / m 2 of unbleached kraft paper was placed. Next, between the matte stainless steel plates, two sets of the above-described decorative plate material sets were inserted. At this time, the two sets of materials were back-to-back so that the stainless steel plate and the PES film 1 were in contact with each other, and a release film was sandwiched between the sets. The press was heated and cooled while maintaining the pressure at 100 kg / cm 2 . The hot platen temperature was set to 160 ° C, and the product was heated so that the maximum product temperature was in the range of 138 ° C to 143 ° C, and then cooled to 40 ° C to obtain a decorative decorative board (Fig. 1) having a thickness of 0.8 mm. . Preparation of adhesive phenolic resin (a) varnish: Formaldehyde to phenol molar ratio of 1.25 reacted and dehydrated and concentrated to a viscosity of 12
The viscosity of the resol type phenol resin varnish of 0 cps / 20 ° C. was adjusted to 27 cps / 35 ° C. with methanol. Preparation of impregnating phenolic resin (b) Varnish: water-soluble resol type phenolic resin having a viscosity of 38 cps / 20 ° C. reacted at a molar ratio of formaldehyde to phenol of 1.3 was converted to a viscosity of 19 cps / 34 ° C. with methanol.
Was adjusted.
【００１７】実施例２ 実施例１と同様に最表面に厚さ２００μｍでＴｇ２２５
℃のＰＥＳフィルム１、次にバインダーとして厚さ８０
μｍでＴｇ１２０℃のポリエステルフィルム２、更に米
坪３０ｇ／ｍ2 の薄葉紙に図柄印刷した化粧原紙３、前
記ポリエステルフィルム２を順次重ね合わせた後に、コ
ア層として片面がサンディング処理された厚さ１．２ｍ
ｍのアルミ板７（ＪＩＳ Ｈ４０００に規定されるＡ３
００３ＰＨ２４）を配置した以外は実施例１と同様の方
法にて加圧成形し、製品厚さ１．５ｍｍの金属ベース化
粧板（図２）を得た。Example 2 As in Example 1, a 200 μm thick Tg 225 was formed on the outermost surface.
C. PES film 1 and then a thickness of 80 as a binder
A polyester film 2 having a Tg of 120 ° C. and a decorative base paper 3 having a pattern printed on thin paper of 30 g / m 2 in U.S.M. 2m
m aluminum plate 7 (A3 specified in JIS H4000)
(003PH24) except that 003PH24) was placed, to obtain a metal-based decorative board (FIG. 2) having a product thickness of 1.5 mm in the same manner as in Example 1.
【００１８】実施例３ コア層として、米坪１００ｇ／ｍ2 の酸化チタン２０％
混抄した晒パルプに、下記の含浸用メラミン樹脂ワニス
（ａ）を含浸した樹脂量４５％、揮発分６％のメラミン
樹脂含浸紙８の２枚と、その間に実施例１で用いたフェ
ノール樹脂含浸紙６を５枚毎に交互反転しながら計６０
枚を配置した。この両面に上下面が対称となるように、
実施例１で使用したものと同じポリエステルフィルム
２、化粧原紙３、ポリエステルフィルム２、及び ＰＥ
Ｓフィルム１と順次重ね合わせた。プレスは、圧力１０
０ｋｇ／ｃｍ2 に保持したままで加熱・冷却した。熱盤
温度を１６０℃とし、製品最高温度が１４５℃〜１５５
℃の範囲に入る様に加熱した後、４０℃まで冷却し、厚
さ１３．２ｍｍの厚物化粧板（図３）を得た。含浸用メ
ラミン樹脂ワニス（ａ）の調整：メラミンに対するホル
ムアルデヒドのモル比１．７にて反応した粘度４５ｃｐ
ｓ／２０℃の水溶性メラミン樹脂を水により粘度２３ｃ
ｐｓ／３０℃に調整し、硬化触媒を添加した。Example 3 As a core layer, 20% of titanium oxide of 100 g / m 2 of rice tsubo was used.
The mixed bleached pulp was impregnated with the following melamine resin varnish (a) for impregnation, and two sheets of melamine resin-impregnated paper 8 having a resin content of 45% and a volatile content of 6% were impregnated with the phenol resin used in Example 1 therebetween. A total of 60 sheets of paper 6 alternately inverted every 5 sheets
Were placed. So that the upper and lower surfaces are symmetrical on both sides,
Polyester film 2, decorative base paper 3, polyester film 2, and PE same as those used in Example 1.
It superposed sequentially with S film 1. Press the pressure 10
And heating and cooling while maintaining the 0 kg / cm 2. The hot platen temperature is 160 ° C, and the maximum product temperature is 145 ° C to 155
After heating so as to fall within the range of ° C., it was cooled to 40 ° C. to obtain a thick decorative board having a thickness of 13.2 mm (FIG. 3). Preparation of impregnating melamine resin varnish (a): viscosity 45 cp reacted at a molar ratio of formaldehyde to melamine of 1.7
s / 20 ° C water-soluble melamine resin with water, viscosity 23c
The temperature was adjusted to ps / 30 ° C., and a curing catalyst was added.
【００１９】比較例１ 通常行う高圧メラミン樹脂化粧板の製造方法に準じて、
米坪１００ｇ／ｍ2 の酸化チタン２６％混抄した晒パル
プに柄模様が印刷された化粧印刷紙に、下記の含浸用メ
ラミン樹脂ワニス（ｂ）を含浸して樹脂量５５％、揮発
分６．４％のメラミン樹脂含浸化粧紙９を得た。実施例
１で用いたフェノール樹脂含浸紙６を５枚を重ね合わ
せ、実施例１と同様に、ステンレス板間に、前記化粧板
の素材セットを２組ずつ挿入した。このとき、２組の素
材セットを背中合わせにし離形フィルムを挟んで組み込
んだ。プレスは、圧力１００ｋｇ／ｃｍ2 に保持したま
まで加熱・冷却した。熱盤温度を１６０℃とし、製品最
高温度が１４２℃に達するまで加熱した後、４０℃まで
冷却し、厚さ１．１５ｍｍの高圧メラミン樹脂化粧板
（図４）を得た。含浸用メラミン樹脂ワニス（ｂ）の調
整：メラミンに対するホルムアルデヒドのモル比１．７
にて反応した粘度４５ｃｐｓ／２０℃の水溶性メラミン
樹脂を水により粘度２１ｃｐｓ／３０℃に調整し、硬化
触媒、内部離形剤、添加フィラー剤を添加した。Comparative Example 1 In accordance with the method for producing a high-pressure melamine resin decorative board usually performed,
The decorative print paper pattern pattern has been printed on the basis weight 100 g / m 2 of titanium dioxide 26%混抄the bleached pulp, impregnated with a resin amount of 55% of the impregnating melamine resin varnish described below (b), volatiles 6. 4% melamine resin impregnated decorative paper 9 was obtained. Five sheets of the phenolic resin-impregnated paper 6 used in Example 1 were overlapped, and two sets of the decorative board material set were inserted between stainless steel plates in the same manner as in Example 1. At this time, the two material sets were back-to-back and incorporated with a release film in between. The press was heated and cooled while maintaining the pressure at 100 kg / cm 2 . The hot platen temperature was set to 160 ° C., and the product was heated until the maximum product temperature reached 142 ° C., and then cooled to 40 ° C. to obtain a 1.15 mm-thick high-pressure melamine resin decorative board (FIG. 4). Preparation of melamine resin varnish (b) for impregnation: molar ratio of formaldehyde to melamine 1.7
The water-soluble melamine resin having a viscosity of 45 cps / 20 ° C. reacted with the above was adjusted to a viscosity of 21 cps / 30 ° C. with water, and a curing catalyst, an internal mold release agent, and an additive filler were added.
【００２０】比較例２ 実施例２で得た金属ベース化粧板と比較するため、比較
例１と同様の方法にて金属ベース高圧メラミン樹脂化粧
板を作成した。構成は比較例１で使用したメラミン樹脂
含浸化粧紙９の下にフェノール樹脂含浸紙６を１枚を配
置し、アルミ板との接着のために実施例１で使用したフ
ェノール樹脂含浸紙５を１枚挿入し、実施例２で使用し
たものと同じアルミ板（片面サンディング処理、板厚
１．２ｍｍ）をサンディング面がフェノール樹脂含浸紙
５と接する様に重ね合わせた。比較例１と同様に、ステ
ンレス板間に、前記化粧板の素材セットをアルミ板が背
中合わせになる様に２組ずつ組み込んだ。プレスは、製
品最高温度が１４０〜１４５℃の温度範囲になる様に加
圧成形し、厚さ１．６２ｍｍの金属ベースメラミン樹脂
化粧板（図５）を得た。Comparative Example 2 For comparison with the metal-based decorative panel obtained in Example 2, a metal-based high-pressure melamine resin decorative panel was prepared in the same manner as in Comparative Example 1. The configuration is such that one phenolic resin-impregnated paper 6 is placed under the melamine resin-impregnated decorative paper 9 used in Comparative Example 1, and one phenolic resin-impregnated paper 5 used in Example 1 is used for bonding to an aluminum plate. Then, the same aluminum plate (single-side sanding treatment, plate thickness 1.2 mm) as that used in Example 2 was overlapped so that the sanding surface was in contact with the phenolic resin-impregnated paper 5. As in the case of Comparative Example 1, two sets of the above-described decorative plate material set were incorporated between the stainless steel plates so that the aluminum plates were back to back. The press was press-formed so that the maximum product temperature was in the temperature range of 140 to 145 ° C. to obtain a 1.62 mm-thick metal-based melamine resin decorative board (FIG. 5).
【００２１】各実施例及び比較例にて得られた化粧板に
ついて特性を測定した。その結果を表１に示す。The characteristics of the decorative boards obtained in the respective Examples and Comparative Examples were measured. Table 1 shows the results.
【００２２】[0022]
【表１】 [Table 1]
【００２３】（測定方法） １．寸法変化率 ：ＪＩＳ Ｋ ６９０２の寸法変化率試
験に準ずる。 ２．耐摩耗性試験：ＪＩＳ Ｋ ６９０２の摩耗性性試験
に準ずる。 ３．耐汚染性試験：ＪＩＳ Ｋ ６９０２の耐汚染性試験
に準ずる。 ４．屈曲性試験 ：ＪＩＳ Ｋ ６９０２の車両用化粧板
の屈曲性試験による。(Measurement method) Dimensional change rate: According to the dimensional change rate test of JIS K6902. 2. Abrasion resistance test: According to JIS K 6902 abrasion resistance test. 3. Stain resistance test: In accordance with the JIS K 6902 stain resistance test. 4. Flexibility test: According to a flexural test of a decorative board for a vehicle according to JIS K6902.
【００２４】[0024]
【発明の効果】以上の説明から明らかなように、本発明
の化粧板は、表面層がポリエーテルサルホン樹脂層で形
成されることにより、従来の高圧メラミン樹脂化粧板の
優れた表面性能を保持しながら、高い寸法安定性と耐熱
性を示すと共に、従来の製法に比較して簡易な製造をも
可能とするものである。また、バインダー層の種類、厚
み等により、リサイクルに必要な化粧層とコア層又は基
板との分離・分別を容易に行えるような技術開発も可能
となる。As is clear from the above description, the decorative board of the present invention has excellent surface performance of the conventional high-pressure melamine resin decorative board by forming the surface layer with a polyether sulfone resin layer. While maintaining, it shows high dimensional stability and heat resistance, and also enables simpler production than conventional production methods. Further, depending on the type and thickness of the binder layer, it is also possible to develop a technology that can easily separate and separate the decorative layer and the core layer or the substrate required for recycling.
【図１】 実施例１にて得られた化粧板の構成を示す断
面図。FIG. 1 is a cross-sectional view showing a configuration of a decorative board obtained in Example 1.
【図２】 実施例２にて得られた化粧板の構成を示す断
面図。FIG. 2 is a cross-sectional view illustrating a configuration of a decorative board obtained in Example 2.
【図３】 実施例３にて得られた化粧板の構成を示す断
面図。FIG. 3 is a cross-sectional view illustrating a configuration of a decorative board obtained in Example 3.
【図４】 比較例１にて得られた化粧板の構成を示す断
面図。FIG. 4 is a cross-sectional view showing a configuration of a decorative board obtained in Comparative Example 1.
【図５】 比較例２にて得られた化粧板の構成を示す断
面図。FIG. 5 is a cross-sectional view illustrating a configuration of a decorative board obtained in Comparative Example 2.
１ ＰＥＳフィルム ２ ポリエステルフィルム（バインダー） ３ 化粧原紙 ４ アルミ箔 ５ フェノール樹脂含浸紙（接着用） ６ フェノール樹脂含浸紙 ７ アルミ板（片面サンディング） ８ メラミン樹脂含浸紙（下地色隠蔽用） ９ メラミン樹脂含浸化粧紙 DESCRIPTION OF SYMBOLS 1 PES film 2 Polyester film (binder) 3 Decorative base paper 4 Aluminum foil 5 Phenol resin impregnated paper (for bonding) 6 Phenol resin impregnated paper 7 Aluminum plate (single-sided sanding) 8 Melamine resin impregnated paper (for concealing undercolor) 9 Melamine resin Impregnated decorative paper
Claims (3)
ン樹脂層で形成されることを特徴とする化粧板。1. A decorative board, wherein the outermost surface layer of the decorative board is formed of a polyether sulfone resin layer.
０〜５００μｍで、かつガラス転移温度が２００℃以上
である請求項１記載の化粧板。2. A polyether sulfone resin having a thickness of 10
The decorative board according to claim 1, which has a glass transition temperature of 0 to 500 µm and a glass transition temperature of 200 ° C or higher.
る化粧層との接合をポリエステル樹脂、ポリイソシアネ
ート、ポリアクリル酸エステルから選ばれる１種以上の
高分子量樹脂を介して一体成形されている請求項１又は
２記載の化粧板。3. The bonding between the polyethersulfone layer and the decorative layer forming a design is integrally formed via one or more high molecular weight resins selected from polyester resins, polyisocyanates and polyacrylates. Item 3. The decorative plate according to item 1 or 2.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000396339A JP2002192657A (en) | 2000-12-27 | 2000-12-27 | Decorative laminated sheet |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2000396339A JP2002192657A (en) | 2000-12-27 | 2000-12-27 | Decorative laminated sheet |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JP2002192657A true JP2002192657A (en) | 2002-07-10 |
Family
ID=18861651
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2000396339A Pending JP2002192657A (en) | 2000-12-27 | 2000-12-27 | Decorative laminated sheet |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2002192657A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013199003A (en) * | 2012-03-23 | 2013-10-03 | Sumitomo Bakelite Co Ltd | Incombustible decorative panel |
| JP2016144950A (en) * | 2016-05-16 | 2016-08-12 | 住友ベークライト株式会社 | Incombustible decorative panel |
-
2000
- 2000-12-27 JP JP2000396339A patent/JP2002192657A/en active Pending
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2013199003A (en) * | 2012-03-23 | 2013-10-03 | Sumitomo Bakelite Co Ltd | Incombustible decorative panel |
| JP2016144950A (en) * | 2016-05-16 | 2016-08-12 | 住友ベークライト株式会社 | Incombustible decorative panel |
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