JPS62142642A - Continuous long-sized decorative sheet and continuous manufacture of long-sized decorative sheet - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to a continuous long decorative sheet and a continuous manufacturing method thereof, and particularly to a continuous long decorative sheet that is thin and has excellent flexibility, stickiness, and strength. The present invention relates to a continuous manufacturing method for a long decorative sheet, characterized in that pre-coated thin decorative paper and thermosetting resin-impregnated core paper are laminated under heat and pressure using a continuous heating and pressure molding machine.

[Prior Art] Conventionally, this type of continuous long decorative sheet and its manufacturing method include the following.

(1) Pattern paper made of decorative paper with a basis weight of 55 to 1701/ld in which shielding titanium oxide is impregnated with melamine resin, and overlay impregnated paper also impregnated with melamine resin. A continuous long melamine/phenol resin decorative sheet made by laminating patterned paper impregnated with resin on the front side and core paper impregnated with phenol resin etc. on the back side in one heat-pressing layer using a continuous heating and pressure molding press. Since the surface resin of this decorative sheet is melamine resin, the surface hardness is particularly high, and other physical and chemical properties are also excellent, making it a high-quality decorative sheet with performance similar to that of high-pressure melamine decorative boards. However, it is expensive (and has the disadvantage of being somewhat inflexible).

(2) Pattern paper and/or overlay paper impregnated with diallyl phthalate resin on the decorative paper made with titanium oxide, and core paper also impregnated with diallyl phthalate resin are laminated together under heat and pressure using a continuous heating and pressure forming press. A continuous long decorative sheet made of diallyl phthalate resin. Although this decorative sheet is slightly inferior to the melamine/phenol resin continuous long decorative sheet described in (1) above in terms of surface hardness and surface physical and chemical properties, it is highly flexible and can be bent, and is similar to high-pressure dauph decorative sheets. This is a vertical decorative board. However, this decorative sheet is also expensive (it is difficult to achieve a glossy surface finish, and it is difficult to emboss the uneven wood grain).

(8) A patterned paper made by impregnating the above-mentioned titanium oxide decorative paper with a solvent-free polyester resin that has not gone through the B stage, and a core paper also impregnated with polyester resin are continuously heated and pressed while wet. A continuous long decorative sheet made of polyester resin that is laminated and molded using a press. This decorative sheet has surface properties that are between those of the melamine/phenol resin continuous long decorative sheet described in (1) above and the diallyl phthalate resin described in (2) above, and has an amount of resin on the surface. Since it is rich in , the surface hardness, especially wear resistance, is good. However, there is a drawback to the manufacturing method because solvent-free polyester resin-impregnated paper is laminated and molded in a wet state.

(4) A decorative sheet in which patterned paper pre-coated with urethane resin and a core made of reinforced paper are bonded and laminated using a roll press molding machine using an adhesive such as vinyl acetate resin or urea resin. Since this decorative sheet is simply bonded and laminated using a roll press, it has the disadvantage of easily causing paper separation, and other quality is also extremely poor, and the surface is easily dented and scratched, but on the other hand, it is the cheapest. It is something.

[Problem that the invention seeks to solve]

The present invention solves all of the drawbacks of the conventional decorative sheet and its manufacturing method, and provides a decorative sheet that is highly flexible, tenacious, firm, and extremely strong, and has a surface performance that is superior to that of conventional melamine. A continuous long decorative sheet that is approximately equivalent to a resin decorative sheet or a diallyl phthalate resin decorative sheet, has a sheet thickness of 0.2 to 0.511 rM·, and is relatively thin and has a price commensurate with the thickness, and a method for producing the same. The purpose is to provide the following.

In other words, since pre-coated tissue paper is used for the surface decorative paper, it is advantageous in terms of price, and since the pre-coated resin on the surface is integrally molded with the phenolic resin on the core, the surface hardness is particularly high, with no dents and no scratches. It has an excellent quality that is hard to resist, and has excellent other physical and chemical properties, and the back side of the pre-coated decorative paper on the surface is fully soaked with resin components by heat-pressing, so there is no peeling or delamination at all. The present invention is characterized by providing a continuous and long decorative sheet that does not cause folding and a method for manufacturing the same.

[Means for solving problems]

In order to achieve the above object, the present invention employs the following means.

That is, according to the present invention, there is a step of applying a surface coating resin such as urethane resin or amino alkyd resin to the surface of thin decorative paper and drying it, and a step of applying a flexible resin such as phenol resin, polyester resin, and/or diallyl phthalate resin to the core paper. a step of impregnating a thermosetting resin with a thermosetting resin, and further applying a thermosetting resin for replenishing at least adhesive strength as necessary on one side of the thermosetting resin-impregnated core paper, and applying the surface coating resin. A long process comprising the steps of continuously laminating the back side of the thin decorative paper and the resin-rich side of the thermosetting resin-impregnated core paper and integrally molding them with heat and pressure using a continuous heating and pressure forming press. By employing the continuous production method for long decorative sheets, it is possible to obtain excellent continuous long decorative sheets as described below.

That is, according to the present invention, by taking the above means,
The decorative surface is coated with a surface coating resin such as urethane resin or amino alkyd resin in advance and dried, and then the pre-coated thin decorative paper and the core paper impregnated with a flexible thermosetting resin such as phenol or polyester resin are continuously heated and pressed. A continuous long decorative sheet formed by laminating one layer under heat and pressure using a molding press can be obtained.

The decorative sheet has a thickness of 0.2 after laminating under heat and pressure.
~0.5% and is a highly flexible laminate, and the surface of the decorative sheet has J.
The number of wear times in the taper type abrasion test using IS-NI-6902 is 200 times or more, and the pencil hardness is 2H.
It is characterized by the above.

Note that the thermosetting resin adhesive is applied to the back side of the pre-coated thin paper, applied to the surface of the core paper, or supplemented by inserting a sheet-like material coated or impregnated with the adhesive in advance. This is a decorative sheet that is characterized by:

In addition, the pre-coated thin decorative paper may be embossed with a concave-convex pattern or the like, or the embossed pattern may be formed on the decorative surface by applying embossing during hot-press single lamination using a continuous heating and pressure molding press. This is a special decorative sheet.

The surface of the decorative sheet is characterized in that it is a decorative surface having a hardness of at least H to 2H in terms of pencil hardness, and further, the characteristic property of the decorative sheet of the present invention is that the decorative sheet is elastic. It is highly flexible and has a radius of curvature (R) of 5 or more under normal temperature and pressure at 5° to 30°C or under heat and pressure at 100° to 170°C. It is characterized by having bending workability.

In the method for continuously manufacturing a long decorative sheet of the present invention, the basis weight of the thin decorative paper is 23 to ff 5 f/1.
F? It is desirable that the surface coating resin be applied to the decorative surface in an amount of 20 to 601/Wt in terms of solid content.

On the other hand, the basis weight of the core paper is 100N250g/m2
, and the flexible thermosetting resin has a solid content of 5
It is desirable that the impregnation is 0 to 120%.

Furthermore, it is advantageous that a thermosetting resin adhesive is interposed between the precoated thin paper and the thermosetting resin-impregnated core paper to supplement the adhesive resin component.

That is, on the back side of the pre-coated thin decorative paper or at least one side of the thermosetting resin-impregnated core paper, on the side that will be bonded to the thin decorative paper pre-coated with the surface coating resin, epoxy resin, phenolic resin, melamine, etc. It is advantageous that the material is coated with a thermosetting resin selected from resin, urea resin, polyester resin, and diallyl phthalate resin, which has an adhesive strength of one or more than two bars.

Further, a sheet-like material such as an overlay paper coated with or impregnated with the thermosetting resin adhesive is continuously supplied and inserted between the precoated thin decorative paper and the thermosetting resin-impregnated core paper. You can also do it.

Further, the thin decorative paper whose surface is pre-coated with a thermosetting resin may be pre-embossed with an uneven pattern or the like.

On the other hand, during the continuous heating and pressure forming press, an embossed pattern-formed sheet material inserted so as to be in continuous contact with the surface of the precoated thin decorative paper is pressed to form an embossed pattern on the decorative surface. I can do it.

In addition, the molding pressure of the continuous heating pressure molding press is 10~
It is preferable that the heating temperature is 25 kq/d and the heating temperature is 120 to 160°C.

Next, the most typical embodiment of the present invention and various performances of the decorative sheet obtained by this embodiment will be explained.

(Example) Example 1 A continuous long patterned paper whose surface was pre-coated with 80 g β of urethane resin paint on the surface of thin decorative paper with a basis weight of 80 g or more,
On the other hand, kraft paper having a basis weight of 190 f/F& was impregnated with a phenol resin to an impregnation rate of 9596, and dried to obtain a continuous long core paper. These wound rolls were placed on the unwinding roll installation part of a continuous heating and pressure press machine, and gradually and continuously fed into a stainless steel dull belt press so that they were integrated. The heating temperature at this time is 150
℃, the press molding pressure was 15 kg/d,
The time required for molding was 90 seconds. Table 1 shows the main performances of the continuous and long decorative sheet thus obtained.

Table 1 Performance table of decorative sheet Example 2 Patterned paper and core paper similar to those in Example 1 were obtained, and during continuous molding press, the embossed paper was brought into contact with the steel belt side on the patterned paper side that forms the surface. However, it was continuously molded under the same molding conditions as in Example 1 to obtain a continuous long rolled decorative sheet having a matte embossed pattern on the surface.

A comparison of various performances of the decorative sheet of the present invention having the embossed pattern thus obtained and a conventional decorative sheet is as shown in Table 2.

Table 2 Performance comparison table of decorative sheets (summary) ◎・・・・・・・・・・・・−・−＆Very excellent 0・・・・・・・・・・・・・・・・ Excellent Δ・・・・・・・・・・・・ Slightly inferior X・
・・・・・・・・・・・・・・・ As is clear from Table 2, the overall quality of the decorative sheet of the present invention is equal to or higher than that of conventional decorative sheets 2 and 8. In particular, because the back of the decorative sheet uses thermosetting resin-impregnated core paper, there are no defects such as paper peeling. It has excellent strength and flexibility, and is excellent in bending workability at room temperature or under heated conditions.

On the other hand, the appearance has the same surface finish as the conventional decorative sheet 1 that uses overlay paper, and the price is because it uses pre-coated paper with thin paper as the base material.
It is much cheaper and economically advantageous than the conventional decorative sheets 2 and 8.

Therefore, the quality corresponding to the cost and thickness of the sheet, especially the surface hardness and flexibility, is extremely good, and it can be used as a vertical wall decoration or edging material, especially in the corners of rooms with curved surfaces. It can be advantageously used as a decorative wall surface that requires curved surface workability such as corners). Further, since the decorative sheet of the present invention uses thin decorative paper, the printing is clearer than that of conventional decorative sheets due to the nature of this paper, and it has a beautiful decorative surface.

〔Effect of the invention〕

As described above, the decorative sheet of the present invention consists of a pre-coated thin decorative paper whose decorative surface is coated with a surface coating resin such as urethane resin or amino alkyd resin and dried, and a flexible thermal paper made of phenol or polyester resin. Since it is a continuous long decorative sheet made by laminating a core paper impregnated with a curable resin in one layer under heat and pressure using a continuous heating and pressure forming press, it has the following excellent effects.

(υ Although the thickness of the sheet is relatively thin at 0.2 to 0.5 ff, it is firm, sticky, extremely flexible, and has great strength.

(2) Although the cost is lower than that of conventional decorative sheets, there is no inferiority in terms of quality; in fact, it is superior in flexibility and especially surface hardness, and there are no significant shortcomings in overall performance. do not have.

(8) Since the base material is a thin decorative sheet, Jf je
t. The decorative printing surface is clearer and more beautiful than conventional decorative sheets.

The method for producing a decorative sheet of the present invention includes the steps of applying a surface coating resin such as urethane resin or amino alkyd resin to the surface of thin decorative paper and drying it, and applying phenol resin or polyester resin and/or diallyl phthalate to the core paper. A step of impregnating a flexible thermosetting resin such as a resin, and further applying a thermosetting resin for replenishing at least adhesive strength as necessary on one side of the thermosetting resin-impregnated core paper, and the surface coating. A process of continuously laminating and integrally molding with heat and pressure in a continuous heating and pressure forming press so that the back side of the thin decorative paper coated with the resin and the resin-rich side of the thermosetting resin-impregnated core paper are bonded to each other. The continuous manufacturing method of a long decorative sheet consisting of the following is characterized by the following excellent effects.

(1) Since the surface of thin decorative paper is pre-coated with urethane resin or alkyd resin, it has better workability and is cost-effective compared to the conventional manufacturing method of impregnating thermosetting resin. It is.

(This is a simpler method than the conventional method because it uses a method such as thermosetting resin coating for adhesion to the core paper.)

Claims (1)

[Claims] 1. Pre-coated thin decorative paper whose decorative surface is coated with a surface coating resin such as urethane resin or aminoalkyd resin and dried, and impregnated with flexible thermosetting resin such as phenol or polyester resin. A continuous long decorative sheet made by laminating core paper and hot pressing in a continuous heating and pressing press. 2. The decorative sheet according to claim 1, wherein a thermosetting resin adhesive is interposed between the precoated thin decorative paper and the thermosetting resin-impregnated core paper to replenish the adhesive resin component. 3. The thermosetting resin adhesive is applied to the back side of the pre-coated thin paper, or applied to the surface of the core paper, or supplemented by inserting a sheet material coated or impregnated with the adhesive in advance. A decorative sheet according to claim 1 or 2, characterized in that: 4. The pre-coated thin decorative paper may be embossed with a concave-convex pattern or the like, or an embossed pattern may be formed on the decorative surface by applying embossing during hot-press single lamination using a continuous heating and pressure forming press. A decorative sheet according to claim 1. 5. The decorative sheet has a thickness of 0.2 after laminating under heat and pressure.
The decorative sheet according to claim 1, which is a laminate having a thickness of 0.5 m/m and high flexibility. 6. The surface of the decorative sheet has been worn 200 times by the tapered abrasion test according to JIS-K-6902.
2. The decorative sheet according to claim 1, wherein the decorative sheet has a decorative surface having a surface hardness of at least 100% hardness. 7. The decorative sheet according to claim 1, wherein the surface of the decorative sheet is a decorative surface having a pencil hardness of at least 2H to 3H or more. 8. The decorative sheet has elasticity or flexibility and is heated at room temperature and pressure of 5° to 30°C or 1.
The decorative sheet according to claim 1, characterized in that it has bendability with a radius of curvature (R) of 5 or more under any condition under heating and pressure of 00° to 170°C. 9. A step of applying a surface coating resin such as urethane resin or amino alkyd resin to the surface of the thin decorative paper and drying it, and applying a flexible thermosetting resin such as phenol resin, polyester resin and/or diallyl phthalate resin to the core paper. a step of applying a thermosetting resin to one side of the thermosetting resin-impregnated core paper to at least replenish adhesive strength as needed; and a back side of the thin decorative paper coated with the surface coating resin. Continuous production of a long decorative sheet comprising the steps of continuously laminating the side and the resin-rich side of the thermosetting resin-impregnated core paper and integrally molding the sheet with heat and pressure using a continuous heating and pressure forming press. Method. 10. The basis weight of the thin decorative paper is 23 to 55 g/m^2, and the surface coating resin on the decorative surface is 20 g/m2 in terms of solid content.
10. The method for continuously manufacturing a decorative sheet according to claim 9, wherein the decorative sheet is coated at a rate of 60 g/m^2. 6. The basis weight of the core paper is 100 to 250 g/m^2, and the flexible thermosetting resin is 50 g/m^2 in terms of solid content.
10. The method for continuously manufacturing a decorative sheet according to claim 9, wherein the decorative sheet is impregnated with a material of 120% to 120%. 11. Epoxy resin, phenol resin, melamine resin, urea resin, polyester resin on at least one side of the thermosetting resin-impregnated core paper, the side that will be bonded to the thin decorative paper pre-coated with surface coating resin. 10. The continuous production method of a decorative sheet according to claim 9, wherein the decorative sheet is coated with one or more thermosetting resins having adhesive strength selected from diallyl phthalate resins. 12. The molding pressure of the continuous heating pressure molding press is 10~
25kg/cm^2, heating temperature is 120-160
10. The method for continuously producing a decorative sheet according to claim 9, wherein the temperature is .degree. 13. The continuous decorative sheet according to claim 9, wherein the thin decorative paper is pre-coated with a thermosetting resin on the surface thereof and has been embossed with an uneven pattern or the like. Production method. 14. During the continuous heating and pressure forming press, press the embossed pattern-formed sheet material charged so as to be in continuous contact with the surface of the precoated thin decorative paper to form an embossed pattern on the decorative surface. A method for continuously producing a decorative sheet according to claim 9, characterized in that: 15. The cosmetic according to claim 9, wherein the decorative surface formed by pressing the embossed pattern-formed sheet material has a matte embossed pattern. Continuous sheet manufacturing method. 16. The hardness of the decorative surface is at least H~ in terms of pencil hardness.
The method for continuously producing a decorative sheet according to claim 9, which has a surface hardness of 2H and has a surface hardness that has been abraded 200 times or more in the tapered abrasion test according to JIS-K-6902. . 17. The thermosetting resin adhesive is applied to the back side of the pre-coated thin paper, or applied to the surface of the core paper, or supplemented by inserting a sheet material coated or impregnated with the adhesive in advance. A method for manufacturing a decorative sheet according to claims 9 to 16, characterized in that: