JPH06126766A - Production equipment of endless melamine resin decorative sheet - Google Patents

Abstract

PURPOSE:To realize smooth continuous forming by preventing a sander from clogging at after-working by a method wherein laminate is cooled with a cooling device provided just after a continuous pressing machine, with which impregnated papers are successively laminated so as to be turned into the laminate. CONSTITUTION:Impregnated overlay paper 1, impregnated pattern paper 2, impregnated core paper 3 and impregnated backing paper 5, respective rolls of which are mounted on an impregnated paper unwinding device A so as to be successively laminated in the order named and then inserted in a continuous pressing machine B in order to be fed by heating drums 5, carried under heat by being pinched with an upper and a lower endless steel belts 6 and 7 and formed under pressure at a pressurizing part 8. The formed laminate is cooled with cooling rolls 9, which are provided just after the continuous pressing machine B so as to harden the pregnated resins and, after being sanded with the belt sender 10 in a sanding device D on after-process and after-sized, taken up. Thus, since sanding is performed after the hardening of the resins, the clogging of the belt sander 10 is prevented from occurring, resulting in realizing continuous forming.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is an endless melamine which is long in the longitudinal direction among thermosetting resin decorative plates mainly used for interior layers of buildings, vehicles, ships and the like and for makeup or base of furniture. The present invention relates to a decorative plate manufacturing apparatus.

[0002]

2. Description of the Related Art Conventionally, as a method for producing a long endless decorative board, for example, there is a method described in JP-A-56-144151. This method relates to a method for continuously producing a laminated sheet or a metal foil-clad laminated sheet, and when a thermosetting resin such as an unsaturated polyester resin or a diallyl phthalate resin is cured, condensed water or carbon dioxide is added. A method of continuously conveying a plurality of long impregnated papers impregnated with a thermosetting resin liquid that does not substantially generate a reaction by-product such as gas, and curing with a continuous molding press having an endless steel belt. Is. In this method, as described in the specification of the publication, the melamine resin and the phenol resin of the present invention are excluded.

Further, the specification of JP-B-51-15875 describes a method for producing a cosmetic sheet using a continuous molding machine having a steel belt. The purpose of this method is
As described in the specification, a flexible cosmetic sheet made of a synthetic rubber or a thermoplastic synthetic resin system, and in particular, is a permanent processing method due to its flexibility. Thus, a method for obtaining an endless melamine resin decorative board has not yet been established industrially.

[0004]

Therefore, in view of the above-mentioned prior art, the present inventor has conducted diligent research to make the curing speed of the melamine-based resin and the phenol-based resin fast, and as a result, in several tens of seconds. The melamine-based resin and the phenol-based resin that have been impregnated into the paper can be cured, significantly improving the productivity of the conventional melamine decorative board by the batch method and having the same quality as the batch method. The present invention has been newly discovered that endless can be continuously produced.

[0005]

SUMMARY OF THE INVENTION The gist of the present invention is to provide an impregnated paper unwinding device for impregnated paper impregnated with a fast-curing phenol resin composition or a fast-curing melamine resin composition. A continuous molding press machine that sequentially stacks and integrates into a laminated body, a processing unit for making the obtained laminated body into a product, and an endless melamine resin decorative board including a product winding device that winds up the obtained product In the manufacturing apparatus, a cooling device for cooling the laminated body is provided immediately after the continuous molding press machine, which is an apparatus for manufacturing an endless melamine resin decorative board. In this manufacturing apparatus, in the continuous molding press, all four drums, or the upper and lower two drums are heating drums, and a pair of endless steel belts driven by the drums and the endless steel belts. It consists of a pressurizing unit that pressurizes through the belt,
Further, it is preferable that the cooling device comprises a plurality of cooling rolls.

The present invention uses the conventional production method of a batch type melamine resin decorative board by a multi-stage press, and has the same resin constitution as this melamine resin decorative board, that is, the melamine resin is the surface layer and the phenol resin is the core layer. With the constitution described above, a melamine resin decorative board having the same quality, that is, a quality that passes JIS K6903 (thermosetting resin decorative board), has been improved in the curing speed of the melamine resin and the phenol resin to a rapid curing property and continuous molding. The use of a press machine made it possible to industrially manufacture an endless melamine decorative board.

Since the laminated body heated and pressed between the endless steel belts is not completely cooled, sanding with a sand paper or the like as it is tends to cause clogging of the sander. Further, when the edges of the continuous laminate are cut off, if they are not completely cooled, the surface of the laminate is apt to be scratched by the pressing roll of the edge cutter, etc. By installing a cooling device immediately after the press machine, the laminate is cooled before processing to make products such as sanding or edge cutting, so clogging of the sander is prevented and scratches at the time of edge cutting are prevented. Can also be prevented. Further, since the product obtained by the present invention is a laminate of foreign substances, warping occurs only by natural cooling, but the laminate is cooled after being heated and pressed by a cooling device to eliminate warpage.

Detailed contents and embodiments of the present invention will be specifically described below with reference to the drawings. FIG. 1 is a vertical cross-sectional view of an endless melamine resin decorative board obtained by the present invention. In this drawing, an endless melamine resin decorative board 11 has a surface layer of an overlay 1 and a pattern 2 which is a fast-setting melamine resin. And the core 3 in the layer below is a long-cure resin composition in which a fast-curing phenolic resin and the bucca-4 are fast-curing phenolic resin or a fast-curing melamine resin. It refers to a decorative sheet in the shape of a roll, the thickness of which varies depending on the number of cores 3 or the basis weight of the base papers that make up all of them and their resin impregnation amounts.
The thickness is preferably 0.2 mm to 0.8 mm, but is not particularly limited. Further, these decorative plates are roughly classified according to their use into a general plate which is used as a flat plate, a vertical plate, a vehicle plate and a post-forming plate which is used as a curved surface portion.
In the case of vertical use, the overlay 1 may or may not be provided. In other words, the overlay plays a role of protecting the surface pattern when it is used for work tops such as desks, dining tables, and sinks, and is an indispensable layer for horizontal applications,
This is because abrasion resistance is not required for vertical applications.

The above melamine resin contains melamine and formaldehyde as main components, and the fast-curing melamine-based resin used in the present invention is a temperature which is matched to the lamination curing with the phenol-based resin used for the core. 6 hours at 140 ° C
It is a resin adjusted to the condition of being hardened in 0 seconds or less. In general, melamine resins have fast curing properties among condensed resins, but under the above curing conditions, a satisfactory surface condition cannot be obtained due to insufficient resin flow and gas generated by condensation.

In the present invention, the above-mentioned drawbacks are improved, and it is a melamine resin containing melamine and formaldehyde as main components and partially alkyl etherified by alcohols, glycols, or oxides. Depending on the conditions, urea, benzoguanamine, acetoguanamine, paratoluenesulfonic acid amide and the like modifiers are included.

Next, the fast-curing phenolic resin is
Similar to the melamine-based resin, it satisfies the curing conditions of a temperature of 140 ° C. and a time of 60 seconds or less, and is obtained by a limited compounding ratio of phenol, alkylphenol and formaldehyde as main components and a limited reaction method. It is a thing. The curing conditions of the phenol resin used in the conventional batch-type melamine resin decorative board are temperature 14
When the temperature is 0 ° C., it takes 3 minutes or more and usually 4 to 5 minutes. The surface finish of the endless melamine resin decorative plate 11 differs depending on the application and is not limited to a smooth one or an embossed one.

As described above, the endless melamine resin decorative board obtained by the apparatus of the present invention is batch type 909 × 1818 mm by a conventional multi-stage press machine.
(3 x 6) or 1212 x 2424 (4 x 8)
While it is obtained by manufacturing a melamine resin decorative plate of the same size, since it is a long endless scroll, the size in the length direction is free and there are many advantages in terms of application. That is, when used for a long counter, desk, etc., the melamine resin decorative board of the conventional size has a seam because the length is limited, but the endless melamine resin decorative board obtained by the device of the present invention has a seam. It is a single piece that does not have, and is excellent in design. And 0.6
When a thin melamine resin decorative sheet having a thickness of less than or equal to mm is manufactured by a conventional multi-stage press, the thin melamine resin decorative sheet is not commercially available because it is often damaged due to its thinness and the yield is lowered.

However, since the endless melamine resin decorative board obtained by the device of the present invention is a rolled material, it is advantageous in the manufacturing method, and it is industrially possible to be thin, and the material cost is low. There is no difference with the board. That is, it has many excellent features such as physical properties that sufficiently pass JIS K6903 (thermosetting resin decorative board).

Next, an apparatus for producing the endless melamine resin decorative board of the present invention will be described with reference to the drawings. FIG. 2 is an explanatory view showing the main part of the manufacturing process of the endless melamine resin decorative board of the present invention. In this drawing, the overlaid impregnated paper 1 impregnated with the fast-curing melamine resin and the fast-curing melamine are shown. A pattern-impregnated paper 2 impregnated with a system resin, a core-impregnated paper 3 impregnated with a fast-curing phenolic resin, and a packer-impregnated paper 4 impregnated with a fast-curing phenolic resin or a fast-curing melamine resin. Each roll is attached to the impregnated paper unwinding device A so that it can be sequentially laminated from above, and is inserted into the continuous molding press B. The continuous molding press B is composed of a heating drum 5, endless steel belts 6 and 7, and a pressurizing unit 8, and the endless steel belt is driven by the heating drum. Then, the impregnated paper which is inserted into the continuous molding press is integrated with the mirror-finished steel belt 6 which comes into contact with the front side.
It is sandwiched between the steel belts 7 that are in contact with the back side. The upper and lower endless steel belts receive heat from the heating drum.

The four heating drums may be all four heating drums or two heating drums above and below. The heat is conducted by the upper and lower steel belts by driving the heating drum. The surface temperature of these steel belts is 140 to 1
The temperature is preferably 60 ° C., and this temperature depends on the grade of the obtained endless melamine resin decorative board. That is, in the case of producing an endless melamine resin decorative board for post forming, 140 to 150 ° C. is particularly preferable, and in the case of producing an endless melamine decorative board for general or vertical use, vehicle is 150 to 160 ° C. preferable. Next, the applied pressure is the tension applied to the endless steel belt and the pressing portion 8
It is advisable to pressurize with a fluid of 10 to 30 kg / cm ² .

The material of the endless steel belt is made of hard stainless steel (SUS304) and has a thickness of 1.2 mm. The surface condition of the mirror-finished steel belt 6 depends on the surface finish of the endless melamine resin decorative plate to be obtained.
That is, a mirror-finished steel belt 6 for obtaining a matte product
The surface condition of is a matte, and in the case of a glossy product, the surface condition of the mirror-finished steel belt is glossy. The surface finish of the steel belt on the back side is not particularly limited.

The laminate obtained by heating and pressurizing the impregnated paper with the continuous molding press B is not completely cooled. Therefore, this laminated body is cooled by the cooling device C. The cooling device C is preferably a cooling device including a plurality of cooling rolls 9, and the cooling roll 9 is preferably cooled by cooling water.

Thereafter, the back surface is continuously sanded by the sander device D using the belt sander 10 and the endless melamine resin decorative plate 11 is wound by the product winding device E. It should be noted that it is preferable that the edges are cut by edge cutting before being wound by the winding device E. Here, a cutting machine such as a guillotine cutter, a rotary knife, or a tip saw may be inserted in the preceding step of the product winding device E to cut it to an arbitrary length. That is, when the thickness of the decorative plate is 1.0 mm or more, it becomes difficult to wind it, and therefore the product is cut into a length according to the order of the market, loaded, packed and shipped. In the case of a scroll, the product is packed and shipped in a length that meets the market order.

As described above, in the apparatus for producing the endless melamine resin decorative board of the present invention, the melamine resin and the phenol resin are cured in several tens of seconds, and immediately after the continuous molding press machine. By using the cooling device, the productivity is significantly improved compared to the conventional method for producing a melamine resin decorative board, and a thin melamine resin decorative board can be produced with high yield. Therefore, it is an article that has extremely excellent effects such as being arbitrary.

Next, examples of the present invention will be described.

【Example】

Example 1 0.2 mol of aliphatic alcohol to 1 mol of melamine,
Overlay paper and pattern paper were impregnated with a resin solution prepared by adding 0.3% of KATANIT A (manufactured by Nitto Kagaku Co., Ltd.), which is a latent curing catalyst, to a melamine resin condensate synthesized with 1.3 mol of formaldehyde and dried. After that, the roll was wound to obtain a roll of Overlay impregnated paper and pattern impregnated paper. At this time, the resin impregnation rate for each base paper was 20% for the overlay.
It was 0% and the pattern was 120%. Next, a core resin made of kraft paper and a backer paper were impregnated with a phenol resin condensate synthesized by 0.7 mol of phenol and 0.3 mol of alkylphenol with 1.5 mol of formaldehyde, respectively. Then, it was dried and wound to obtain a roll of core-impregnated paper and bucker-impregnated paper. At this time, the impregnation rate of each base paper was 60% for the core and 70% for the backer.

The rolls of impregnated paper thus obtained were attached to an impregnated paper unwinding device in the form of an overlay, a pattern, a core and a backer. Then, they were inserted so as to be sequentially stacked between the steel belts of the continuous molding press. At this time, the temperature of the upper and lower endless steel belts is 160 ° C. and the applied pressure is 20 kg / cm ² . Then, after heating and pressurizing for 20 seconds, cool with a cooling roll #
The back surface was sanded with a sandpaper of 60 and wound up to obtain a 0.6 mm endless melamine resin decorative board.
At this time, the impregnated paper feed speed and the speed of the steel belt were synchronized, and the production speed was 10 m / min.

[0022]

As described above, an endless melamine resin decorative board obtained by laminating the impregnated paper impregnated with the fast-curing phenol resin composition or the fast-curing melamine resin composition by the device of the present invention is provided. It can be manufactured continuously, and in particular, by providing a cooling device immediately after the continuous molding press, the laminate is cooled before being processed into a product such as sanding or edge cutting, so that the eyes of the sander can be manufactured. Prevents clogging and also prevents scratches at the time of edge cutting, so that continuous molding proceeds smoothly. The obtained product has no warp, and a good endless melamine resin decorative board can be manufactured.

[0023]

[Brief description of drawings]

FIG. 1 is a vertical sectional view of an endless melamine resin decorative board obtained by the present invention.

FIG. 2 is a schematic explanatory view of an endless melamine resin decorative board manufacturing apparatus of the present invention.

[Explanation of symbols]

 1 Overlay impregnated paper consisting of melamine resin 2 Pattern impregnated paper consisting of melamine resin 3 Core impregnated paper consisting of phenolic impregnated paper 4 Bucker impregnated paper consisting of phenolic impregnated paper 5 Heating drum 6 Surface Side mirror belt 7 Belt on the back side 8 Belt 8 Pressurizing part 9 Cooling roll 10 Belt sander 11 Endless melamine resin decorative board A Impregnated paper unwinding device B Continuous molding press C Cooling device D Sanding device E Product Winding device

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Claims (3)

[Claims] 1. An impregnated paper unwinding device for impregnated paper impregnated with a fast-curable phenol resin composition or a fast-curable melamine resin composition, and these impregnated papers are sequentially laminated and integrated to form a laminate. In a continuous molding press machine, a processing unit for converting the obtained laminate into a product, and an apparatus for manufacturing an endless melamine resin decorative board, which comprises a product winding device that winds the obtained product, immediately after the continuous molding press machine. An apparatus for manufacturing an endless melamine resin decorative board, comprising a cooling device for cooling the laminate. 2. The continuous molding press machine comprises all four drums, or the upper and lower two drums of which are heating drums, and a pair of endless steel belts driven by the drums and the endless steel belts are provided. The manufacturing device for an endless melamine resin decorative board according to claim 1, which comprises a pressurizing section for pressurizing through. 3. The apparatus for manufacturing an endless melamine resin decorative board according to claim 1, wherein the cooling device comprises a plurality of cooling rolls.