WO2021085305A1 - 樹脂含浸化粧紙、及び樹脂含浸化粧板 - Google Patents
樹脂含浸化粧紙、及び樹脂含浸化粧板 Download PDFInfo
- Publication number
- WO2021085305A1 WO2021085305A1 PCT/JP2020/039763 JP2020039763W WO2021085305A1 WO 2021085305 A1 WO2021085305 A1 WO 2021085305A1 JP 2020039763 W JP2020039763 W JP 2020039763W WO 2021085305 A1 WO2021085305 A1 WO 2021085305A1
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- WIPO (PCT)
- Prior art keywords
- resin
- layer
- impregnated decorative
- impregnated
- decorative paper
- Prior art date
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- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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- B32B7/04—Interconnection of layers
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Definitions
- the present invention relates to a resin-impregnated decorative paper and a resin-impregnated decorative board.
- a metal plate is brought into contact with a laminate of a resin-impregnated decorative paper impregnated with a thermosetting resin and a base material, and heat-pressurization molding is performed to integrate the resin-impregnated decorative paper and the base material.
- a method for manufacturing a resin-impregnated decorative board for obtaining a resin-impregnated decorative board has been proposed (see, for example, Patent Document 1).
- an embossed shape is provided on the metal plate to give an uneven pattern to the surface of the resin-impregnated decorative board to give a feeling of touch. It is also possible to add a gloss matte expression by adjusting the coarse density of the embossed shape.
- the present invention has been made by paying attention to the above-mentioned problems, and is a resin-impregnated decorative paper which is excellent in gloss matte expression and touch feeling while suppressing cost, and has improved stain resistance and design stability after long-term storage.
- An object of the present invention is to provide a resin-impregnated decorative board.
- the resin-impregnated decorative paper according to one aspect of the present invention is a resin-impregnated decorative paper obtained by impregnating a decorative paper with an impregnated resin, and the decorative paper includes a base paper, a pattern layer provided on the surface side of the base paper, and a pattern.
- a thermosetting resin layer comprising a foamed resin layer formed by a foaming agent arranged on the surface of the pattern layer or in the pattern layer and a thermosetting resin layer provided on the surface of the foamed resin layer. Includes at least one of an epoxy resin, a casein resin, an acrylic resin, and a urethane resin.
- the resin-impregnated decorative board according to another aspect of the present invention includes a resin-impregnated decorative paper and a base material integrated with the resin-impregnated decorative paper.
- the foaming agent can be foamed by heat and pressure molding, and an uneven pattern can be appropriately formed on the surface of the resin-impregnated decorative paper. Since it is not necessary to prepare a metal plate for each uneven pattern, it is possible to provide a resin-impregnated decorative paper and a resin-impregnated decorative plate having excellent gloss matte expression and touch feeling while suppressing the cost. Further, by providing a thermosetting resin layer containing at least one of an epoxy resin, a casein resin, an acrylic resin, and a urethane resin on the surface of the foamed resin layer, the raised portion of the uneven pattern is protected. be able to. Thereby, it is possible to provide a resin-impregnated decorative paper and a resin-impregnated decorative board having improved stain resistance and design stability after long-term storage.
- the resin-impregnated decorative board 1 is formed by heat-press molding a laminate of the resin-impregnated decorative paper 2 and the base material 3, and the resin-impregnated decorative paper 2 is formed. It is a decorative board in which the base material 3 and the base material 3 are integrated. That is, the resin-impregnated decorative board 1 includes a base material 3 and a resin-impregnated decorative paper 2 provided on the surface 3a side of the base material 3.
- the resin-impregnated decorative board 1 according to the embodiment of the present invention is used, for example, for interior decoration of floors, walls, ceilings, etc.
- FIG. 1 shows a resin-impregnated decorative plate 1 after heat-pressurization molding
- FIG. 2 shows a resin-impregnated decorative plate 1 before heat-pressurization molding.
- the type of the base material 3 is not particularly limited, and any base material can be used depending on the intended use of the resin-impregnated decorative board 1.
- wood base materials such as single wood board, plywood, laminated material, particle board, medium density fiber board, hard fiber board, and fibrous base material such as paperboard, woven cloth, non-woven fabric, resin impregnated paper, resin impregnated cloth, etc.
- Inorganic base materials such as gypsum board, slate board, calcium silicate board, slag gypsum board, wood wool cement board, slag cement board, lightweight bubble concrete board, glass fiber reinforced concrete board, steel plate, brass board, aluminum board, duralumin board, Metal base material such as stainless steel plate, acrylic resin plate, styrene resin plate, ABS (Acrylonitrile butadiene styrene) resin plate, polycarbonate resin plate, nylon resin plate, polystyrene resin plate, polypropylene resin plate, polyester resin plate, glass fiber reinforced plastic plate And the like, or two or more kinds of composites or laminates selected from these, etc. can be adopted.
- Metal base material such as stainless steel plate, acrylic resin plate, styrene resin plate, ABS (Acrylonitrile butadiene styrene) resin plate, polycarbonate resin plate, nylon resin plate, polystyrene resin plate, polypropylene resin plate, polyester resin plate, glass fiber reinforced plastic plate
- the resin-impregnated decorative paper 2 is formed by impregnating the entire decorative paper 4 with the impregnated resin 5 and then drying the decorative paper 2.
- the decorative paper 4 includes a base paper 6, a pattern layer 7, a foamed resin layer 8, and a thermosetting resin layer 9.
- the pattern pattern layer 7 is provided on the surface 6a of the base paper 6.
- the foamed resin layer 8 is formed by a foaming agent arranged on the surface 7a of the pattern layer 7 or in the pattern layer 7.
- FIG. 1 shows an example in which the foamed resin layer 8 is formed by a foaming agent arranged on the surface 7a of the pattern layer 7.
- the thermosetting resin layer 9 is provided on the surface 8a of the foamed resin layer 8.
- Base paper As the base paper 6, a fibrous sheet-like body such as paper having good water absorption capable of being impregnated with the impregnating resin 5 can be used. For example, thin paper, titanium paper, woodfree paper, bleached or unbleached kraft paper and the like can be adopted. In particular, titanium paper is the most suitable in consideration of both printability and resin impregnation suitability. Further, when utilizing the texture of the surface 3a of the base material 3, it is preferable to use so-called transparent paper having a property of becoming transparent by impregnation with the impregnating resin 5.
- the thickness of the base paper 6 is not particularly limited, but is preferably in the range of 20 g / m 2 or more and 200 g / m 2 or less in basis weight.
- the pattern pattern layer 7 is a layer for imparting a design property by a pattern to the resin-impregnated decorative paper 2.
- the pattern layer 7 is formed by using a printing ink or the like in which a colorant such as a dye or a pigment is dissolved or dispersed in a diluting solvent together with an appropriate binder resin.
- the type of printing ink is not particularly limited, and may be an oil-based ink or a water-based ink. That is, as the printing ink, a normal printing ink having no liquid repellency can be used. In particular, considering the impregnation suitability of the impregnated resin 5, the water-based ink is the most suitable.
- the water-based ink has better compatibility with the aqueous solution of the impregnated resin than the oil-based ink. Therefore, when the water-based ink is used, the impregnated resin 5 can be quickly and uniformly impregnated into the decorative paper 4 in the impregnation step at the time of manufacturing the resin-impregnated decorative plate 1, and further, an excellent pattern is excellent due to the integration with the impregnated resin 5. Strength can be exhibited in the pattern layer 7.
- the type of water-based ink is not particularly limited, but one containing casein or a binder resin containing an emulsion resin as a main component is preferable.
- Such a binder resin has a property of becoming poorly water-soluble by undergoing a drying step after printing the ink. Therefore, when a binder resin containing such a binder resin is used, the pattern layer 7 is difficult to redissolve in the aqueous solution of the impregnated resin 5 in the resin impregnation step during the production of the resin-impregnated decorative plate 1, and the pattern is retained. It is possible to prevent the impregnated resin 5 from being contaminated.
- the emulsion resin for example, acrylic type, vinyl acetate type, styrene type, urethane type and the like can be adopted.
- binder resins include, for example, water-soluble resins such as polyvinyl alcohol and polyacrylamide, and water-soluble polymers such as polysaccharides and cellulose derivatives in order to improve the stability of ink. May be used together.
- the method for forming the pattern layer 7 is not particularly limited, and any printing method such as a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a letterpress printing method, or an inkjet printing method is used. be able to.
- a solid ink layer for the purpose of coloring the base may be provided between the pattern layer 7 and the base paper 6, and when the solid ink layer is provided, in addition to the above-mentioned various printing methods, for example, as a method for forming the solid ink layer, for example.
- Roll coating method, gravure coating method, rod coating method, knife coating method, air knife coating method, spray coating method, lip coating method, die coating method and the like can also be used.
- the type of the pattern formed by the pattern pattern layer 7 is not particularly limited, and any pattern can be used depending on the intended use of the resin-impregnated decorative board 1.
- any pattern can be used depending on the intended use of the resin-impregnated decorative board 1.
- a wood grain pattern, a stone grain pattern, a cloth pattern, an abstract pattern, a geometric figure, a character, a symbol, a solid color, etc., or a combination of two or more selected from these can be adopted.
- the foamed resin layer 8 is a layer for imparting a gloss matte expression and a feeling of touch by the uneven pattern 10 on the surface of the resin-impregnated decorative paper 2.
- the type of foaming agent is not particularly limited, and any foaming agent can be used.
- azo-based chemical foaming agents such as azodicarbonamide and azobisformamide
- hydrazide-based chemical foaming agents such as oxybenzenesulfonyl hydrazide and paratoluenesulfonyl hydrazide
- microcapsule foaming agents are most suitable.
- the microcapsule foaming agent has a capsule and a volatile substance encapsulated in the capsule. Then, the microcapsule foaming agent is brought into a foamed state by volatilizing the volatile substance and expanding the capsule.
- a vinylidene chloride-acrylonitrile copolymer or the like can be used as the material of the capsule.
- the material of the volatile substance for example, an aliphatic hydrocarbon or the like can be used.
- the foaming agent preferably has an average particle size before foaming that is 2/3 times or more and 50 times or less the layer thickness of the pattern layer 7. If it is less than 2/3 times the layer thickness of the pattern layer 7, the gloss matte feeling and the touch feeling may be weakened. On the other hand, if the thickness of the pattern layer 7 is larger than 50 times, the foamed resin layer 8 after foaming may fall off from the decorative paper 4 and the scratch resistance may be weakened.
- the average particle size is the average particle size obtained by microscopic observation.
- the average particle size obtained by microscopic observation can be obtained, for example, by observing the foaming agent under a microscope, measuring 100 particle sizes of the foaming agent observed under a microscope using image processing software, and averaging the number of measurement results.
- the average value of the major axis diameter and the minor axis diameter of the particles of the foaming agent can be adopted.
- the foaming agent preferably has an average particle size of 15 ⁇ m or more and 250 ⁇ m or less after foaming. If it is less than 15 ⁇ m, the gloss matte feeling and the touch feeling may be weakened. On the other hand, if it is larger than 250 ⁇ m, the foamed resin layer 8 after foaming may fall off from the decorative paper 4 and the scratch resistance may be weakened. More preferable is 30 ⁇ m or more and 200 ⁇ m or less.
- the average particle size of the foaming agent after foaming is the average particle size obtained by microscopic observation, similarly to the average particle size of the foaming agent before foaming. Further, as the particle size of the foaming agent after foaming used for obtaining the average particle size, the average value of the major axis diameter and the minor axis diameter of the voids formed by the foaming of the foaming agent can be adopted.
- the foaming start temperature of the foaming agent is preferably 100 ° C. or higher and 220 ° C. or lower. If the temperature is lower than 100 ° C., the timing of starting foaming is early, so that the time for heating and pressurizing the foamed resin layer 8 after foaming becomes long, the foamed resin layer 8 after foaming is crushed, and a gloss matte feeling and a feel are felt. May be weakened.
- the foamed resin layer 8 is not sufficiently foamed by the heat and pressure molding performed by abutting the metal plate (mirror surface plate) during the production of the resin-impregnated decorative plate 1, and the foamed resin layer 8 is not sufficiently foamed, resulting in a gloss matte feeling and a touch.
- the feeling may be weakened. More preferable is 120 ° C. or higher and 200 ° C. or lower.
- the type of the concavo-convex pattern 10 formed by the foamed resin layer 8 after foaming is not particularly limited, and may or may not be in sync with the pattern formed by the pattern pattern layer 7. ..
- the one that is design-synchronized with the pattern formed by the pattern pattern layer 7 is most preferable.
- the arrangement position of the foamed resin layer 8 is synchronized with the pattern formed by the pattern layer 7. That is, the foamed resin layer 8 is arranged on the portion where the matte texture is desired to be expressed in the pattern formed by the pattern pattern layer 7.
- the foamed resin layer 8 is arranged on the surface of the pattern pattern layer 7 so as to cover a dark-colored portion having a relatively lower brightness than the other parts of the pattern in the pattern formed by the pattern pattern layer 7. To do.
- the ratio of the area covered by the foamed resin layer 8 to the area of the dark-colored portion is preferably 70% or more. In particular, 90% or more is most preferable.
- the pattern of the pattern layer 7 is a wood grain pattern
- the foamed resin layer 8 is arranged in a conduit pattern that is design-synchronized with the wood grain pattern of the pattern layer 7.
- the color of the foamed resin layer 8 is not particularly limited, and may be colorless or colored.
- the foamed resin layer 8 When the foamed resin layer 8 is arranged in the pattern pattern layer 7, the foamed resin layer 8 is relatively brighter than other parts of the pattern in the pattern formed by the pattern pattern layer 7. It is mixed in the low dark color portion and arranged in the pattern pattern layer 7.
- the ratio of the volume of the foamed resin layer 8 to the total value of the volume of the dark-colored portion and the volume of the foamed resin layer 8 is preferably 70% or more. In particular, 90% or more is most preferable.
- the method of arranging the foamed resin layer 8 is not particularly limited.
- a method of printing a printing ink obtained by dispersing the foamed resin layer 8 in a diluting solvent together with an appropriate binder resin on the pattern layer 7. can be adopted.
- the binder resin for example, a thermosetting resin having a urethane bond such as a two-component curable urethane resin, a curable resin such as an ionizing radiation curable resin, casein, and an emulsion resin as main components can be used. ..
- thermosetting resin examples include melamine-based resin, epoxy-based resin, urea-based resin, phenol-based resin, unsaturated polyester-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, aminoalkyd-based resin, and silicone.
- a system resin or the like can be used.
- the ionizing radiation curable resin for example, a (meth) acrylate-based resin, an unsaturated polyester-based resin, or the like can be adopted.
- the printing method of the printing ink of the foamed resin layer 8 is not particularly limited as in the pattern layer 7, and for example, a gravure printing method, an offset printing method, a screen printing method, a flexo printing method, and a letterpress printing method. Any printing method such as a method or an inkjet printing method can be used.
- thermosetting resin layer 9 As the thermosetting resin layer 9, a thermosetting resin used in the production of a known resin-impregnated decorative board can be used.
- a thermosetting resin used in the production of a known resin-impregnated decorative board can be used.
- epoxy resin, casein resin, acrylic resin, urethane resin, melamine resin, diallyl phthalate resin, benzoguanamine resin, alkyd resin, unsaturated polyester resin, phenol resin, urea resin, etc. Can be adopted.
- the printing method of the thermosetting resin layer 9 is not particularly limited as in the pattern layer 7, and is, for example, a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a letterpress printing method, and an inkjet. Any printing method such as a printing method can be used.
- the thermosetting resin layer 9 preferably has a thickness of 1 ⁇ m or more and 15 ⁇ m or less. If the thickness of the thermosetting resin layer 9 is less than 1 ⁇ m, the scratch resistance and stain resistance of the resin-impregnated decorative paper 2 may decrease.
- the thickness of the thermosetting resin layer 9 exceeds 15 ⁇ m, the design property of the resin-impregnated decorative paper 2 and the design stability after long-term storage may deteriorate. More preferable is 5 ⁇ m or more and 10 ⁇ m or less.
- the thermosetting resin layer 9 is provided in a range of 30% or more of the surface area of the foamed resin layer 8. If the thermosetting resin layer 9 is in the range of less than 30% of the surface area of the foamed resin layer 8, the scratch resistance of the resin-impregnated decorative paper 2 may be lowered. More preferred is 50% or more.
- the thermosetting resin layer 9 contains colored ink.
- Vehicles for coloring ink include chlorinated polyethylene such as chlorinated polyethylene and chlorinated polypropylene, polyester, polyurethane composed of isocyanate and polyol, polyacrylic, polyvinyl acetate, polyvinyl chloride, vinyl chloride-vinyl acetate copolymer, and cellulose.
- One type or a mixture of two or more types of a system resin, a polyamide resin, or the like is used, and a pigment, a solvent, various auxiliary agents, or the like is added thereto to form an ink.
- the pattern layer 7 is provided on the surface 6a of the base paper 6, the foamed resin layer 8 is provided on the surface 7a of the pattern layer 7, and the thermosetting resin layer 9 is provided on the surface 8a of the foamed resin layer 8.
- the decorative paper 4 is immersed in a water-based impregnating liquid in which the impregnated resin 5 is dissolved or dispersed in water, and the decorative paper 4 is impregnated with the impregnated resin 5.
- thermosetting resin used in the production of a known resin-impregnated decorative board can be used.
- melamine-based resin, epoxy-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, alkyd-based resin, unsaturated polyester-based resin, phenol-based resin, urea-based resin and the like can be adopted.
- the impregnation of the impregnating resin 5 may be performed from the front side of the decorative paper 4 on which the pattern layer 7 is formed, or from the opposite side. Further, one side may be impregnated twice, or both sides may be impregnated at the same time.
- the impregnation rate of the impregnated resin 5 (the ratio of the mass of the impregnated resin to the mass of the decorative paper 4 after impregnation) is preferably 20% or more and 80% or less. In particular, 40% or more and 70% or less is most preferable. Further, in order to obtain the resin-impregnated decorative board 1 having excellent physical properties, it is important to uniformly impregnate the entire base paper 6 with the impregnated resin 5.
- the resin-impregnated decorative paper 2 is obtained by drying the decorative paper 4 impregnated with the impregnated resin 5. Subsequently, the resin-impregnated decorative paper 2 is placed on the base material 3 (FIG. 2), and a metal plate (mirror surface plate) is placed on the surface of the resin-impregnated decorative paper 2 on which the foamed resin layer 8 and the thermosetting resin layer 9 are formed. ), And heat and pressure molding is performed on the laminate of the resin-impregnated decorative paper 2 and the base material 3, and the resin-impregnated decorative paper 2 and the base material 3 are integrated to obtain the resin-impregnated decorative plate 1. Be done.
- the foaming agent is foamed by the heat during heat and pressure molding, and the position where the foamed resin layer 8 is arranged rises to form the uneven pattern 10 (FIG. 1). Then, the formed uneven pattern 10 gives the resin-impregnated decorative board 1 a gloss matte feeling and a touch feeling.
- An adhesive or the like may or may not be interposed between the base material 3 and the resin-impregnated decorative paper 2.
- a core paper may be interposed in the same manner as in the method adopted for the known melamine resin decorative board.
- a suitable base paper such as titanium paper, bleached or unbleached kraft paper, and glass fiber non-woven fabric, which is impregnated with an uncured thermosetting resin can be used.
- thermosetting resin any thermosetting resin can be used depending on the physical characteristics required for the target resin-impregnated decorative board 1.
- melamine-based resin epoxy-based resin, diallyl phthalate-based resin, benzoguanamine-based resin, urethane-based resin, alkyd-based resin, unsaturated polyester-based resin, phenol-based resin, urea-based resin and the like
- the core paper include phenol resin impregnated kraft paper, which has been widely used as a core paper for melamine resin decorative boards.
- a heat and pressure molding method for adhering the resin-impregnated decorative paper 2 in a laminated state on the base material 3 for example, a method of abutting a metal plate and pressing it under flat pressure, a circular pressure type continuous laminating method, or the like is used. be able to.
- a continuous laminating method using a metal endless belt is preferable. According to the continuous laminating method, it is possible to continuously manufacture a high-quality resin-impregnated decorative plate 1 that has no surface warpage or waviness, has good interlayer adhesion, and is densely cured and integrated.
- the surface shape of the resin-impregnated decorative plate 1 is the same as the surface shape of the metal plate used in the continuous laminating method, the metal endless belt, the embossed sheet made of the curable resin, or the like. It will be the one that was done. Therefore, as an embossed sheet made of a metal plate, a metal endless belt, a curable resin, etc., a resin having an excellent surface glossiness and smoothness can be used by using a mirror-like or smooth polished surface. An impregnated decorative plate 1 can be obtained.
- the target resin-impregnated decorative plate 1 can be used. It is also possible to obtain a resin-impregnated decorative plate 1 having an arbitrary surface finish depending on the application.
- the resin-impregnated decorative board 1 of the present invention is not limited to the embodiment described in detail above, and can be implemented with various modifications as long as the gist of the present invention is not deviated.
- the resin-impregnated decorative paper 2 is obtained by impregnating the decorative paper 4 with the impregnated resin 5, and the decorative paper 4 includes the base paper 6 and the pattern layer 7.
- a foamed resin layer 8 and a thermosetting resin layer 9 are provided.
- the pattern pattern layer 7 is provided on the surface 6a side of the base paper 6.
- the foamed resin layer 8 was formed by a foaming agent arranged on the surface 7a of the pattern layer 7 or in the pattern layer 7.
- the thermosetting resin layer 9 contains at least one of an epoxy resin, a casein resin, an acrylic resin, and a urethane resin, and the thermosetting resin layer 9 is provided on the surface 8a of the foamed resin layer 8. It was.
- the foaming agent can be foamed by heat and pressure molding, and an uneven pattern can be appropriately formed on the surface of the resin-impregnated decorative paper. Further, since it is not necessary to prepare a metal plate for each uneven pattern 10, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative plate 1 having excellent gloss matte expression and touch feeling while suppressing the cost. Further, the resin-impregnated decorative paper 2 and the resin-impregnated decorative plate 1 are provided, in which the raised portion of the uneven pattern 10 can be protected by the thermosetting resin layer 9, and the stain resistance and the design stability after long-term storage are improved. can do.
- the thickness of the thermosetting resin layer 9 was set to 1 ⁇ m or more and 15 ⁇ m or less. Thereby, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative board 1 in which the deterioration of the design property is suppressed and the durability and the design stability after long-term storage are improved. Further, the thickness of the thermosetting resin layer 9 was set to 5 ⁇ m or more and 10 ⁇ m or less. Thereby, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative board 1 in which the deterioration of the design property is suppressed and the durability and the design stability after long-term storage are further improved.
- thermosetting resin layer 9 is provided in a range of 30% or more of the surface area of the foamed resin layer 8. Thereby, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative board 1 in which the scratch resistance and the design property are suppressed from being lowered.
- thermosetting resin layer 9 was provided in a range of 50% or more of the surface area of the foamed resin layer 8. As a result, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative board 1 in which the deterioration of scratch resistance and design is suppressed more effectively. In addition, the thermosetting resin layer 9 contained colored ink. As a result, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative board 1 in which whitening due to the foamed resin layer 8 is suppressed and the design is improved.
- the foamed resin layer 8 had an average particle size of 15 ⁇ m or more and 250 ⁇ m or less after foaming, and a foaming start temperature of 100 ° C. or more and 220 ° C. or less. Therefore, since the average particle size of the foamed resin layer 8 after foaming and the foaming start temperature are set to appropriate values, the foamed resin layer 8 can be foamed during heat-pressurization molding by the conventional method for manufacturing a resin-impregnated decorative board, and the resin.
- the uneven pattern 10 can be appropriately formed on the surface of the impregnated decorative plate 1. As a result, the resin-impregnated decorative board 1 can be made to have a gloss matte feeling and a touch feeling.
- an arbitrary uneven pattern 10 can be imparted to the surface of the resin-impregnated decorative plate 1, and it is not necessary to prepare a metal plate for each uneven pattern 10. Therefore, it is possible to provide the decorative paper 4 capable of forming the resin-impregnated decorative board 1 having excellent gloss matte expression and touch feeling while suppressing the cost.
- the average particle size of the foamed resin layer 8 after foaming is 15 ⁇ m or more and 250 ⁇ m or less and the foaming start temperature of the foamed resin layer 8 is 100 ° C. or more and 220 ° C. or less, an appropriate uneven pattern 10 can be formed and gloss is obtained. It is possible to provide a decorative paper 4 having excellent matte feeling, touch feeling, and scratch resistance. Further, in the decorative paper 4 according to the embodiment of the present invention, since the pattern formed by the pattern layer 7 and the arrangement position of the foamed resin layer 8 are synchronized, the pattern formed by the pattern layer 7 and the resin-impregnated makeup It is possible to form the resin-impregnated decorative plate 1 in which the uneven pattern 10 on the surface of the plate 1 is tuned in design.
- the average particle size of the foamed resin layer 8 before foaming is 2/3 times or more and 50 times or less the layer thickness of the pattern pattern layer 7. Therefore, it is possible to provide the resin-impregnated decorative board 1 which can form an appropriate uneven pattern 10 and has excellent gloss matte feeling, touch feeling, and scratch resistance.
- the resin-impregnated decorative board 1 according to the embodiment of the present invention includes a resin-impregnated decorative paper 2 and a base material 3 integrated with the resin-impregnated decorative paper 2. Therefore, it is possible to provide the resin-impregnated decorative board 1 having excellent gloss matte expression and touch feeling while suppressing the cost.
- Example 1 First, as the base paper 6, a titanium paper for decorative paper having good water absorption was prepared. Subsequently, a wood grain pattern was printed on the surface 6a of the base paper 6 with a water-based ink containing casein as a main component to form a pattern layer 7 having a layer thickness of 10 ⁇ m. As a printing method, a gravure printing method was used.
- a conduit pattern that is design-synchronized with the wood grain pattern of the pattern layer 7 is printed on the surface 7a of the pattern layer 7 with a water-based ink containing an epoxy containing a foaming agent as a main component.
- the foamed resin layer 8 was arranged in a conduit pattern.
- a printing method a direct gravure printing method was used.
- the foamed resin layer 8 a layer having an average particle size of 100 ⁇ m before foaming (10 times the layer thickness of the pattern layer 7), an average particle size after foaming of 120 ⁇ m, and a foaming start temperature of 180 ° C. was used.
- thermosetting resin layer 9 to be the overcoat layer was printed on the surface 8a of the foamed resin layer 8 to form the decorative paper 4.
- a gravure printing method was used as the printing method, and an epoxy resin was used for the thermosetting resin layer 9.
- the thickness of the thermosetting resin layer 9 was 0.5 ⁇ m, and the range in which the thermosetting resin layer 9 was provided was 25% of the surface area of the foamed resin layer 8. That is, although there are a plurality of foamed resin layers 8, each of them covers a range of 25% of the surface area with the thermosetting resin layer 9.
- the decorative paper 4 was impregnated with the impregnated resin 5, and then dried in an oven to form the resin-impregnated decorative paper 2.
- an aqueous melamine-based resin liquid was used as the impregnating resin 5.
- the resin-impregnated decorative paper 2 was placed on the base material 3.
- a particle board base material was used as the base material 3.
- the surface of the resin-impregnated decorative paper 2 on which the foamed resin layer 8 and the thermosetting resin layer 9 are formed is hot-pressed at about 160 ° C. to heat the laminate of the resin-impregnated decorative paper 2 and the base material 3.
- the resin-impregnated decorative paper 2 and the base material 3 were integrated by pressure molding to form the resin-impregnated decorative plate 1 of Example 1.
- a flat plate was used for hot pressing.
- the region of the pattern layer 7 without the foamed resin layer 8 and the thermosetting resin layer 9 has a gloss finish
- the region with the foamed resin layer 8 and the thermosetting resin layer 9 has a matte finish. It becomes.
- Example 2 In Example 2, a casein-based resin was used as the thermosetting resin layer 9. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 3) In Example 3, an acrylic resin was used as the thermosetting resin layer 9. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 4) In Example 4, a urethane-based resin was used as the thermosetting resin layer 9. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Example 5 In Example 5, the thickness of the thermosetting resin layer 9 was set to 1 ⁇ m. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 6) In Example 6, the thickness of the thermosetting resin layer 9 was set to 5 ⁇ m. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 7) In Example 7, the thickness of the thermosetting resin layer 9 was set to 7 ⁇ m. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Example 8 In Example 8, the thickness of the thermosetting resin layer 9 was set to 10 ⁇ m. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 9) In Example 9, the thickness of the thermosetting resin layer 9 was set to 15 ⁇ m. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 10) In Example 10, the range of the thermosetting resin layer 9 was increased by 5% to 30% of the surface area of the foamed resin layer 8. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Example 11 In Example 11, the range of the thermosetting resin layer 9 was increased by 25% to 50% of the surface area of the foamed resin layer 8. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Example 12 In Example 12, the range of the thermosetting resin layer 9 was increased by 35% to 60% of the surface area of the foamed resin layer 8. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Example 13 In Example 13, the range of the thermosetting resin layer 9 was increased by 55% to 80% of the surface area of the foamed resin layer 8. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Example 14) In Example 14, the range of the thermosetting resin layer 9 was increased by 75% to 100% of the surface area of the foamed resin layer 8. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Example 15 In Example 15, a colored ink was added to the thermosetting resin layer 9. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above. (Comparative Example 1) In Comparative Example 1, the thermosetting resin layer 9 was omitted. A resin-impregnated decorative board 1 was produced using the same materials and procedures as in Example 1 except for the above.
- Design evaluation In the design evaluation, 10 examiners evaluated the sensory test. If there are 7 to 10 people who have a good evaluation, it will be marked as " ⁇ ", if there are 1 to 6 people who have a good evaluation, it will be marked as " ⁇ ", and 0 people will have a good evaluation. In some cases, it was marked as "x”.
- Long-term environmental test In the long-term environmental test, the resin-impregnated decorative board 1 was left to stand in an environment of a temperature of 40 ° C. and a humidity of 90% for 2 months, and then evaluated by 10 examiners as a sensory test on changes in the design.
- thermosetting resin layer 9 As shown in Table 1, in the cross-cut test, no peeling was observed in all of Examples 1 to 15 and Comparative Example 1, and there was no problem in adhesion. However, as compared with Comparative Example 1 in which the thermosetting resin layer 9 was omitted, in Examples 1 to 15 in which the thermosetting resin layer 9 was provided, stain resistance and design stability after long-term storage were improved. In particular, as shown by the evaluation results of Examples 1 to 4, those using an epoxy resin, a casein resin, an acrylic resin, or a urethane resin as the thermosetting resin layer 9 have stain resistance and after long-term storage. There was no problem or excellent design stability.
- thermosetting resin layer 9 the thicker the thermosetting resin layer 9 is, the more the scratch resistance is improved, but the designability tends to be lowered.
- evaluation results of Examples 10 to 14 show, as the coating area of the thermosetting resin layer 9 is increased, the stain resistance is improved, but the design property tends to be lowered.
- Example 15 by adding the colored ink to the thermosetting resin layer 9, not only the degree of freedom of design expression is improved, but also the whitening of the foamed resin layer 8 can be suppressed, and the design can be suppressed. The sex has improved.
- the resin-impregnated decorative board 1 of Examples 6, 7, 12, and 15 was particularly excellent.
- thermosetting resin layer 9 an epoxy resin is used as the thermosetting resin layer 9, but even if a casein resin, an acrylic resin, a urethane resin, or the like is used instead of the epoxy resin, it is basic. There is no big difference in physical properties, and almost the same results can be obtained.
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Abstract
Description
しかしながら、特許文献1に記載の樹脂含浸化粧板の製造方法では、付与しようとする凹凸模様毎に金属板を用意する必要があり、コストが増大する可能性がある。そのため、発泡樹脂層を設けることで凹凸模様を付与することが考えられる。しかしながら、凹凸模様の盛り上げ部が保護されていないと、耐汚染性及び長期保管後の意匠安定性が低下する可能性がある。
本発明の他の態様に係る樹脂含浸化粧板は、樹脂含浸化粧紙と、樹脂含浸化粧紙に一体化された基材と、を備える。
図1及び図2に示すように、本発明の実施形態に係る樹脂含浸化粧板1は、樹脂含浸化粧紙2と基材3との積層体に加熱加圧成型を行い、樹脂含浸化粧紙2と基材3とを一体化させてなる化粧板である。すなわち、樹脂含浸化粧板1は、基材3と、基材3の表面3a側に設けられた樹脂含浸化粧紙2と、を備えている。本発明の実施形態に係る樹脂含浸化粧板1は、例えば、建築物の床面、壁面、天井等の内装、家具、各種キャビネット等の表面装飾材料、建具の表面化粧、車両内装等に用いられる樹脂含浸化粧板である。図1は、加熱加圧成型後の樹脂含浸化粧板1を示し、図2は、加熱加圧成型前の樹脂含浸化粧板1を示す。
基材3の種類は、特に制限されるものではなく、目的とする樹脂含浸化粧板1の用途に応じて、任意の基材を用いることができる。例えば、木材単板、合板、集成材、パーティクルボード、中密度繊維板、硬質繊維板等の木質基材や、板紙、織布、不織布、樹脂含浸紙、樹脂含浸布等の繊維質基材、石膏ボード、スレート板、珪酸カルシウム板、スラグ石膏板、木毛セメント板、スラグセメント板、軽量気泡コンクリート板、ガラス繊維強化コンクリート板等の無機質基材、鋼板、真鍮板、アルミニウム板、ジュラルミン板、ステンレス板等の金属基材、アクリル樹脂板、スチロール樹脂板、ABS(Acrylonitrile butadiene styrene)樹脂板、ポリカーボネート樹脂板、ナイロン樹脂板、ポリスチレン樹脂板、ポリプロピレン樹脂板、ポリエステル樹脂板、ガラス繊維強化プラスチック板等の合成樹脂基材等或いはこれらから選ばれる2種以上の複合体又は積層体等を採用できる。
本発明の実施形態に係る樹脂含浸化粧紙2は、化粧紙4の全体に含浸樹脂5を含浸させた後、乾燥させて形成されている。化粧紙4は、原紙6と、絵柄模様層7と、発泡樹脂層8と、熱硬化性樹脂層9と、を備える。絵柄模様層7は、原紙6の表面6a上に設けられている。発泡樹脂層8は、絵柄模様層7の表面7a上、又は絵柄模様層7中に配置された発泡剤によって形成されている。図1では、絵柄模様層7の表面7a上に配置された発泡剤によって発泡樹脂層8を形成した例を示している。熱硬化性樹脂層9は、発泡樹脂層8の表面8a上に設けられている。
原紙6としては、含浸樹脂5の含浸が可能な吸水性のよい紙等の繊維質シート状体を用いることができる。例えば、薄葉紙、チタン紙、上質紙、晒又は未晒クラフト紙等を採用できる。特に、印刷適性と樹脂含浸適性との両面を考慮すると、チタン紙が最も好適である。また、基材3の表面3aの質感を活かす場合には、含浸樹脂5の含浸により透明化する性質を有する、所謂透明紙を用いることが好ましい。原紙6の厚さは、特に制限されるものではないが、坪量20g/m2以上200g/m2以下の範囲が好ましい。
絵柄模様層7は、樹脂含浸化粧紙2に絵柄模様による意匠性を付与するための層である。絵柄模様層7は、染料又は顔料等の着色剤を適当なバインダー樹脂とともに希釈溶媒中に溶解又は分散してなる印刷インキ等を用いて形成される。印刷インキの種類は、特に制限されるものではなく、油性インキでもよいし、水性インキであってもよい。すなわち、印刷インキとしては、撥液性を有しない、通常の印刷インキを用いることができる。
特に、含浸樹脂5の含浸適性を考慮すると、水性インキが最も好適である。水性インキは、油性インキと比較して、含浸樹脂の水溶液との馴染みがよい。それゆえ、水性インキを用いた場合、樹脂含浸化粧板1製造時の含浸工程において、化粧紙4に含浸樹脂5を迅速且つ均一に含浸でき、さらに、含浸樹脂5との一体化によって優れた絵柄模様層7に強度を発現できる。また、水性インキの種類は、特に制限されるものではないが、カゼイン、エマルジョン樹脂を主成分とするバインダー樹脂を含むものが好ましい。
エマルジョン樹脂としては、例えば、アクリル系、酢酸ビニル系、スチレン系、ウレタン系等を採用できる。また、バインダー樹脂には、カゼイン、エマルジョン樹脂の他に、インキの安定性を向上させるために、例えば、ポリビニルアルコール、ポリアクリルアミド等の水溶性樹脂や多糖類、セルロース誘導体等の水溶性高分子等を併用してもよい。
絵柄模様層7が形成する絵柄の種類は、特に制限されるものではなく、目的とする樹脂含浸化粧板1の用途に応じて、任意の絵柄を用いることができる。例えば、木目柄、石目柄、布目柄、抽象柄、幾何学図形、文字、記号、単色無地等、或いはこれらから選ばれる2種以上の組み合わせ等を採用できる。
発泡樹脂層8は、樹脂含浸化粧紙2の表面の凹凸模様10によるグロスマット表現及び手触り感を付与するための層である。発泡剤の種類は、特に制限されるものではなく、任意の発泡剤を用いることができる。例えば、アゾジカルボンアミド、アゾビスホルムアミド等のアゾ系、オキシベンゼンスルホニルヒドラジド、パラトルエンスルホニルヒドラジド等のヒドラジド系等の熱分解型の化学発泡剤、マイクロカプセル発泡剤等を採用できる。
特に、マイクロカプセル発泡剤が最も好適である。マイクロカプセル発泡剤は、カプセルと、カプセルに封入された揮発物質とを有している。そして、マイクロカプセル発泡剤は、揮発物質が揮発してカプセルを膨張させることで、発泡状態となる。カプセルの材料としては、例えば、塩化ビニリデンーアクリルニトリル共重合体等を用いることができる。また、揮発物質の材料としては、例えば、脂肪族炭化水素等を用いることができる。
熱硬化性樹脂層9としては、公知の樹脂含浸化粧板の製造時に使用される熱硬化性樹脂を用いることができる。例えば、エポキシ系樹脂、カゼイン系樹脂、アクリル系樹脂、ウレタン系樹脂、メラミン系樹脂、ジアリルフタレート系樹脂、ベンゾグアナミン系樹脂、アルキド系樹脂、不飽和ポリエステル系樹脂、フェノール系樹脂、尿素系樹脂等を採用できる。特に、エポキシ系樹脂、カゼイン系樹脂、アクリル系樹脂、ウレタン系樹脂の少なくとも一つを含むことが好ましい。
熱硬化性樹脂層9は、厚さが1μm以上15μm以下であることが好ましい。熱硬化性樹脂層9の厚さが1μm未満であると、樹脂含浸化粧紙2の耐傷付性及び耐汚染性が低下する可能性がある。一方、熱硬化性樹脂層9の厚さが15μmを超えると、樹脂含浸化粧紙2の意匠性及び長期保管後の意匠安定性が低下する可能性がある。より好適なのは、5μm以上10μm以下である。
熱硬化性樹脂層9は、着色インキを含有する。着色インキのビヒクルとしては、塩素化ポリエチレン、塩素化ポリプロピレン等の塩素化ポリオレフィン、ポリエステル、イソシアネートとポリオールからなるポリウレタン、ポリアクリル、ポリ酢酸ビニル、ポリ塩化ビニル、塩化ビニル-酢酸ビニル共重合体、セルロース系樹脂、ポリアミド系樹脂等を一種又は二種以上混合して用い、これに顔料、溶剤、各種補助剤等を加えてインキ化したものが使用できる。
次に、本発明の実施形態に係る樹脂含浸化粧板1の製造方法について説明する。
まず、原紙6の表面6a上に絵柄模様層7を設け、絵柄模様層7の表面7a上に発泡樹脂層8を設け、発泡樹脂層8の表面8a上に熱硬化性樹脂層9を設けることで化粧紙4を形成する。そして、含浸樹脂5を水に溶解又は分散させた水系含浸液に化粧紙4を浸漬し、化粧紙4に含浸樹脂5を含浸させる。
連続ラミネート方式を用いた場合、樹脂含浸化粧板1の表面形状は、連続ラミネート方式で使用される金属板や金属製無端ベルト、硬化型樹脂等で作製されたエンボスシートの表面形状がそのまま賦形されたものとなる。それゆえ、金属板や金属製無端ベルト、硬化型樹脂等で作製されたエンボスシートとして、表面を鏡面状等の平滑に研磨したものを用いることで、表面の光沢度や平滑性に優れた樹脂含浸化粧板1を得ることができる。
本発明の樹脂含浸化粧板1は、以上に詳述した実施の形態に限定されるものではなく、本発明の趣旨を逸脱しない範囲において、種々の変形を加えて実施することができる。
また、熱硬化性樹脂層9の厚さを5μm以上10μm以下にした。これにより、意匠性が悪くなることを抑制し、耐久性及び長期保管後の意匠安定性をさらに向上させた樹脂含浸化粧紙2及び樹脂含浸化粧板1を提供することができる。
また、熱硬化性樹脂層9を発泡樹脂層8の表面積のうち30%以上の範囲に設けた。これにより、耐傷付性及び意匠性が低下することを抑制した樹脂含浸化粧紙2及び樹脂含浸化粧板1を提供することができる。
また、熱硬化性樹脂層9に着色インキを含有させた。これにより、発泡樹脂層8による白化を抑制し、意匠性を向上させた樹脂含浸化粧紙2及び樹脂含浸化粧板1を提供することができる。
さらに、本発明の実施形態に係る化粧紙4は、絵柄模様層7が形成する絵柄と発泡樹脂層8の配置位置とが同調しているため、絵柄模様層7が形成する絵柄と樹脂含浸化粧板1の表面の凹凸模様10とが意匠的に同調した樹脂含浸化粧板1を形成できる。
また、本発明の実施形態に係る樹脂含浸化粧板1は、樹脂含浸化粧紙2と、樹脂含浸化粧紙2に一体化された基材3とを備えるようにした。そのため、コストを抑えつつ、グロスマット表現及び手触り感に優れた樹脂含浸化粧板1を提供することができる。
(実施例1)
まず、原紙6として、吸水性のよい化粧紙用のチタン紙を用意した。続いて、原紙6の表面6aに、カゼインを主成分とした水性インキで木目模様を印刷し、層厚10μmの絵柄模様層7を形成した。印刷方法としては、グラビア印刷方式を用いた。続いて、インラインで、絵柄模様層7の表面7aに、発泡剤を含有したエポキシを主成分とした水性インキで、絵柄模様層7の木目模様と意匠的に同調した導管模様を印刷して、導管模様状に発泡樹脂層8を配置した。印刷方法としては、ダイレクトグラビア印刷方式を用いた。発泡樹脂層8としては、発泡前の平均粒径が100μm(絵柄模様層7の層厚の10倍)、発泡後の平均粒径が120μm、発泡開始温度が180℃となるものを用いた。
実施例2では、熱硬化性樹脂層9として、カゼイン系樹脂を用いた。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例3)
実施例3では、熱硬化性樹脂層9として、アクリル系樹脂を用いた。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例4)
実施例4では、熱硬化性樹脂層9として、ウレタン系樹脂を用いた。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
実施例5では、熱硬化性樹脂層9の厚さを1μmとした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例6)
実施例6では、熱硬化性樹脂層9の厚さを5μmとした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例7)
実施例7では、熱硬化性樹脂層9の厚さを7μmとした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
実施例8では、熱硬化性樹脂層9の厚さを10μmとした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例9)
実施例9では、熱硬化性樹脂層9の厚さを15μmとした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例10)
実施例10では、熱硬化性樹脂層9の範囲を5%増加させ、発泡樹脂層8の表面積の30%とした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
実施例11では、熱硬化性樹脂層9の範囲を25%増加させ、発泡樹脂層8の表面積の50%とした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例12)
実施例12では、熱硬化性樹脂層9の範囲を35%増加させ、発泡樹脂層8の表面積の60%とした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
実施例13では、熱硬化性樹脂層9の範囲を55%増加させ、発泡樹脂層8の表面積の80%とした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(実施例14)
実施例14では、熱硬化性樹脂層9の範囲を75%増加させ、発泡樹脂層8の表面積の100%とした。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
実施例15では、熱硬化性樹脂層9に着色インキを加えた。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
(比較例1)
比較例1では、熱硬化性樹脂層9を省略した。それ以外は、実施例1と同じ材料・手順で、樹脂含浸化粧板1を作製した。
実施例1~15、比較例1の樹脂含浸化粧板1に対し、以下に示す性能評価を行なった。
(クロスカット試験)
クロスカット試験では、樹脂含浸化粧板1にカッターにてクロスカットを入れ、剥離が起きるか否かを評価する。クロスカット時に著しい剥離がない場合を「○」とし、著しい剥離がある場合を「×」とする。
汚染試験では、樹脂含浸化粧板1に黒クレヨン及び赤インキを被覆させ、1時間後にアルコールで拭き取り、拭き取り残し度合を評価した。拭き取り残り度合が30%未満である場合を「○」とし、拭き取り残し度合が30%以上70%未満である場合を「△」とし、拭き取り残し度合が70%以上である場合を「×」とした。
(触感評価)
触感評価では、官能試験として10人の試験員で評価を行なった。評価が良いとした人が7~10名である場合に「○」とし、評価が良いとした人が1~6名である場合に「△」とし、評価が良いとした人が0人である場合に「×」とした。
意匠評価では、官能試験として10人の試験員で評価を行なった。評価が良いとした人が7~10名である場合に「○」とし、評価が良いとした人が1~6名である場合に「△」とし、評価が良いとした人が0人である場合に「×」とした。
(長期環境試験)
長期環境試験では、温度40℃、湿度90%の環境下に樹脂含浸化粧板1を2ヵ月間放置した後、意匠の変化に関する官能試験として10人の試験員で評価を行なった。評価が良いとした人が7~10名である場合に「○」とし、評価が良いとした人が1~6名である場合に「△」とし、評価が良いとした人が0人である場合に「×」とした。
上記のクロスカット試験、汚染試験、触感評価、意匠評価、長期環境試験による五項目によって総合的に評価した。特に優れているものを「◎」とし、優れているものを「○」とし、問題が殆どないものを「△」とし、問題があるものを「×」とした。
(評価結果)
これらの評価結果を表1に示す。
Claims (10)
- 化粧紙に含浸樹脂を含浸させた樹脂含浸化粧紙であって、
前記化粧紙は、
原紙と、
前記原紙の表面側に設けた絵柄模様層と、
前記絵柄模様層の表面上、又は前記絵柄模様層中に配置された発泡剤によって形成された発泡樹脂層と、
前記発泡樹脂層の表面上に設けた熱硬化性樹脂層と、を備え、
前記熱硬化性樹脂層は、エポキシ系樹脂、カゼイン系樹脂、アクリル系樹脂、ウレタン系樹脂の少なくとも一つを含むことを特徴とする樹脂含浸化粧紙。 - 前記熱硬化性樹脂層は、厚さが1μm以上15μm以下であることを特徴とする請求項1に記載の樹脂含浸化粧紙。
- 前記熱硬化性樹脂層は、厚さが5μm以上10μm以下であることを特徴とする請求項2に記載の樹脂含浸化粧紙。
- 前記熱硬化性樹脂層は、前記発泡樹脂層の表面積のうち30%以上の範囲に設けられることを特徴とする請求項1~3の何れか一項に記載の樹脂含浸化粧紙。
- 前記熱硬化性樹脂層は、前記発泡樹脂層の表面積のうち50%以上の範囲に設けられることを特徴とする請求項4に記載の樹脂含浸化粧紙。
- 前記熱硬化性樹脂層は、着色インキを含有することを特徴とする請求項1~5の何れか一項に記載の樹脂含浸化粧紙。
- 前記発泡剤は、発泡後の平均粒径が15μm以上250μm以下であり、発泡開始温度が100℃以上220℃以下であることを特徴とする請求項1~6の何れか一項に記載の樹脂含浸化粧紙。
- 前記絵柄模様層が形成する絵柄と前記発泡樹脂層の配置位置とが同調していることを特徴とする請求項1~7の何れか一項に記載の樹脂含浸化粧紙。
- 前記発泡剤は、発泡前の平均粒径が前記絵柄模様層の層厚の2/3倍以上50倍以下であることを特徴とする請求項1~8の何れか一項に記載の樹脂含浸化粧紙。
- 請求項1~9の何れか一項に記載の樹脂含浸化粧紙と、
前記樹脂含浸化粧紙に一体化された基材と、を備えることを特徴とする樹脂含浸化粧板。
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