Title of the invention: Resin-impregnated decorative paper and resin-impregnated decorative board
Technical field
[0001]
The present invention relates to a resin-impregnated decorative paper and a resin-impregnated decorative board.
Background technology
[0002]
Conventionally, 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). In the method for manufacturing a resin-impregnated decorative plate described in 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 plate 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.
However, in the method for manufacturing a resin-impregnated decorative plate described in Patent Document 1, it is necessary to prepare a metal plate for each uneven pattern to be applied, which may increase the cost. Therefore, it is conceivable to provide an uneven pattern by providing a foamed resin layer. However, if the raised portion of the uneven pattern is not protected, the stain resistance and the design stability after long-term storage may decrease.
Prior art literature
Patent documents
[0003]
Patent Document 1: Japanese Patent Application Laid-Open No. 09-262965
Outline of the invention
Problems to be solved by the invention
[0004]
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 texture while suppressing cost, and has improved stain resistance and design stability after long-term storage. And to provide a resin impregnated decorative board.
Means to solve problems
[0005]
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. The heat-curable resin layer comprises a foamed resin layer formed by a foaming agent arranged on the surface of the pattern layer or in the pattern layer, and a heat-curable resin layer provided on the surface of the foamed resin layer. Includes at least one of an epoxy-based resin, a casein-based resin, an acrylic-based resin, and a urethane-based 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.
Effect of the invention
[0006]
According to the present invention, 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. This makes it 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.
A brief description of the drawing
[0007]
FIG. 1 is a cross-sectional view showing a resin-impregnated decorative board after heat-pressurization molding.
FIG. 2 is a cross-sectional view showing a resin-impregnated decorative board before heat-pressurization molding.
Embodiment for carrying out the invention
[0008]
Hereinafter, the decorative paper, the resin-impregnated decorative paper, and the resin-impregnated decorative board according to the embodiment of the present invention will be described with reference to the drawings. The present invention is not limited to the embodiments described below, and modifications such as design changes can be made based on the knowledge of those skilled in the art, and embodiments to which such modifications are added are also possible. , Is included in the scope of the present invention. In addition, each drawing is exaggerated as appropriate to facilitate understanding.
[0009]
(Constitution)
As shown in FIGS. 1 and 2, the resin-impregnated decorative board 1 according to the embodiment of the present invention 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. of buildings, surface decorative materials for furniture, various cabinets, surface decoration of fittings, vehicle interiors, and the like. It is a resin-impregnated decorative board. FIG. 1 shows a resin-impregnated decorative plate 1 after heat-pressurization molding, and FIG. 2 shows a resin-impregnated decorative plate 1 before heat-pressurization molding.
[0010]
(Base material)
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. For example, 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.
[0011]
(Resin impregnated decorative paper)
The resin-impregnated decorative paper 2 according to the embodiment of the present invention 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.
[0012]
(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 impregnated 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 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 a basis weight of 20 g / m 2 or more and 200 g / m 2 or less.
[0013]
(Pattern pattern layer)
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 oil-based ink or 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 the pattern is excellent due to the integration with the impregnated resin 5. Strength can be developed 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.
[0014]
Such a binder resin has a property of becoming poorly water-soluble by undergoing a drying process 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 at the time of manufacturing the resin-impregnated decorative plate 1, and the pattern is retained. It is possible to prevent the impregnated resin 5 from being contaminated.
As the emulsion resin, for example, acrylic type, vinyl acetate type, styrene type, urethane type and the like can be adopted. In addition to casein and emulsion resins, the binder resin includes, 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.
[0015]
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. Further, 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, as a method for forming the solid ink layer, for example, in addition to the above-mentioned various printing methods, 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 layer 7 is not particularly limited, and any pattern can be used depending on the intended use of the resin-impregnated decorative board 1. For example, 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.
[0016]
(Foam resin layer)
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. For example, azo-based chemical foaming agents such as azodicarbonamide and azobisformamide, hydrazide-based chemical foaming agents such as oxybenzenesulfonyl hydrazide and paratoluenesulfonyl hydrazide, and microcapsule foaming agents can be adopted.
In particular, the microcapsule foaming agent is the most suitable. The microcapsule foaming agent has a capsule and a volatile substance encapsulated in the capsule. Then, the microcapsule foaming agent is in a foamed state when the volatile substance volatilizes and expands the capsule. As the material of the capsule, for example, a vinylidene chloride-acrylonitrile copolymer or the like can be used. Further, as the material of the volatile substance, for example, an aliphatic hydrocarbon or the like can be used.
[0017]
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. Here, 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 measurement results. As the particle size of the foaming agent, the average value of the major axis diameter and the minor axis diameter of the particles of the foaming agent can be adopted.
[0018]
The foaming agent preferably has an average particle size of 15 μm or more and 250 μm or less after foaming. If it is less than 15 μm, the gloss matte feeling and the touch feeling may be weakened. On the other hand, if it is larger than 250 μm, 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 μm or more and 200 μm or less. Here, 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.
[0019]
Also, the foaming start temperature of the foaming agent is 1.It is preferably 00 ° C. or higher and 220 ° C. or lower. If the temperature is lower than 100 ° C., the timing of the start of 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. On the other hand, when the temperature is higher than 220 ° C., the foamed resin layer 8 is not sufficiently foamed by the heat-pressing molding performed by abutting the metal plate (mirror surface plate) at the time of manufacturing the resin-impregnated decorative plate 1, and the gloss matte feeling and the touch are obtained. The feeling may be weakened. More preferred is 120 ° C. or higher and 200 ° C. or lower.
[0020]
The type of the concavo-convex pattern 10 formed by the foamed resin layer 8 after foaming is not particularly limited, and may be structurally synchronized with or non-synchronized with the pattern formed by the pattern pattern layer 7. .. In particular, in consideration of obtaining a resin-impregnated decorative board 1 having excellent designability, the one that is design-synchronized with the pattern formed by the pattern pattern layer 7 is most suitable. When the pattern formed by the pattern layer 7 and the uneven pattern 10 are designedly synchronized, 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 layer 7. For example, the foamed resin layer 8 is arranged on the surface of the pattern layer 7 so as to cover a dark-colored portion having a relatively lower brightness than the other portions of the pattern in the pattern formed by the pattern layer 7. do. The ratio of the area covered with 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. When 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 designedly 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.
[0021]
When the foamed resin layer 8 is arranged in the pattern layer 7, the foamed resin layer 8 is relatively brighter than the other parts of the pattern in the pattern formed by the pattern layer 7. It is mixed in the low dark color portion and arranged in the 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.
[0022]
The method of arranging the foamed resin layer 8 is not particularly limited, and for example, 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. As 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. .. Examples of the thermosetting resin 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. Further, as the ionizing radiation curable resin, for example, a (meth) acrylate-based resin, an unsaturated polyester-based resin, or the like can be adopted.
[0023]
Further, 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 flexographic printing method, and a letterpress printing method are used. Any printing method such as a method or an inkjet printing method can be used.
[0024]
(Thermosetting resin layer)
As the thermosetting resin layer 9, a thermosetting resin used in the production of a known resin-impregnated decorative board can be used. For example, 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. In particular, it is preferable to contain at least one of an epoxy resin, a casein resin, an acrylic resin, and a urethane resin.
[0025]
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 μm or more and 15 μm or less. If the thickness of the thermosetting resin layer 9 is less than 1 μm, the scratch resistance and stain resistance of the resin-impregnated decorative paper 2 may decrease. On the other hand, if the thickness of the thermosetting resin layer 9 exceeds 15 μm, the design property of the resin-impregnated decorative paper 2 and the design stability after long-term storage may deteriorate. More preferable is 5 μm or more and 10 μm or less.
[0026]
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 decrease. 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, polyvinyl chloride, 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 to the mixture to make an ink.
[0027]
(Manufacturing method of resin-impregnated decorative board)
Next, a method for manufacturing the resin-impregnated decorative board 1 according to the embodiment of the present invention will be described.
First, 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. Form the decorative paper 4. Then, 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.
[0028]
As the impregnating resin 5, a thermosetting resin used in the production of a known resin-impregnated decorative board can be used. For example, 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 in two steps, 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 are 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.
[0029]
Subsequently, 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. ) Is abutted against the laminated body 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 paper 1. Be done. At that time, the foaming agent foams due to the heat during the heat-pressurization 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 glossy matte feeling and a feeling of touch.
[0030]
An adhesive or the like may or may not be interposed between the base material 3 and the resin-impregnated decorative paper 2. Further, if necessary, a core paper may be interposed in the same manner as in the method adopted for the known melamine resin decorative board. As the core paper, for example, a suitable base paper such as titanium paper, bleached or unbleached kraft paper, and glass fiber non-woven fabric, which is impregnated with a thermosetting resin in an uncured state can be used. Further, as the thermosetting resin, any thermosetting resin can be used depending on the physical characteristics required for the target resin-impregnated decorative board 1. For example, 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. Examples of the core paper include phenol resin impregnated kraft paper, which has been widely used as a core paper for melamine resin decorative boards.
[0031]
As a heat-pressurizing 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. In particular, a continuous laminating method using a metal endless belt is preferable. According to the continuous laminating method, it is possible to continuously produce a high-quality resin-impregnated decorative plate 1 which has no surface warpage or waviness, has good interlayer adhesion, and is densely cured and integrated.
When the continuous laminating method is used, 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 with excellent surface gloss and smoothness can be used by using a mirror-like smooth polished surface. The impregnated decorative plate 1 can be obtained.
[0032]
Of course, by using an embossed sheet made of any desired matte or textured metal plate, metal endless belt, curable resin, etc., if necessary, the target resin-impregnated decorative plate 1 can be obtained. It is also possible to obtain a resin-impregnated decorative plate 1 having an arbitrary surface finish depending on the intended use.
The resin-impregnated decorative board 1 of the present invention is not limited to the embodiment described in detail above, and can be implemented by adding various modifications without departing from the spirit of the present invention.
[0033]
As described above, the resin-impregnated decorative paper 2 according to the embodiment of the present invention 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. rice field. As a result, 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 present invention provides a resin-impregnated decorative paper 2 and a resin-impregnated decorative plate 1 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.
[0034]
Further, the thickness of the thermosetting resin layer 9 was set to 1 μm or more and 15 μm or less. Thereby, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative plate 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 μm or more and 10 μm or less. Thereby, it is possible to provide the resin-impregnated decorative paper 2 and the resin-impregnated decorative plate 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.
Further, the 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 deteriorated.
[0035]
Further, the thermosetting resin layer 9 is 50 out of the surface area of ​​the foamed resin layer 8.It was provided in the range of% or more. Thereby, 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 more effectively suppressed.
In addition, the thermosetting resin layer 9 contained colored ink. This makes it 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.
[0036]
The foamed resin layer 8 had an average particle size of 15 μm or more and 250 μm 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-pressing molding by the conventional method for manufacturing a resin-impregnated decorative board, and the resin can be foamed. 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 glossy matte feeling and a feel to the touch. Further, by adjusting the arrangement position of the foamed resin layer 8 on the decorative paper 4, 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.
[0037]
Further, since the average particle size of the foamed resin layer 8 after foaming is 15 μm or more and 250 μm 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 with each other, 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.
[0038]
Further, in the decorative paper 4 according to the embodiment of the present invention, 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 layer 7. Therefore, it is possible to provide a resin-impregnated decorative board 1 which can form an appropriate uneven pattern 10 and has excellent gloss matte feeling, touch feeling, and scratch resistance.
Further, 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
[0039]
Hereinafter, examples and comparative examples of the resin-impregnated decorative board 1 according to the present invention will be described. The present invention is not limited to the following examples.
(Example 1)
First, as the base paper 6, titanium paper for decorative paper with 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 μm. As a printing method, a gravure printing method was used. Subsequently, in-line, on the surface 7a of the pattern layer 7, a conduit pattern that is designed to be synchronized with the wood grain pattern of the pattern layer 7 is printed 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. As a printing method, a direct gravure printing method was used. As the foamed resin layer 8, a layer having an average particle size of 100 μm before foaming (10 times the layer thickness of the pattern layer 7), an average particle size of 120 μm after foaming, and a foaming start temperature of 180 ° C. was used.
[0040]
Subsequently, the 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 μm, 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, there are a plurality of foamed resin layers 8, and in all of them, the range of 25% of the surface area is covered with the thermosetting resin layer 9. Subsequently, 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. As the impregnating resin 5, an aqueous melamine-based resin liquid was used. Subsequently, the resin-impregnated decorative paper 2 was placed on the base material 3. As the base material 3, a particle board base material was used. Subsequently, 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. Pressure molding was performed to integrate the resin-impregnated decorative paper 2 and the base material 3 to form the resin-impregnated decorative plate 1 of Example 1. A flat plate was used for the hot pressing. In the resin-impregnated decorative plate 1, the region of the pattern layer 7 without the foamed resin layer 8 and the thermosetting resin layer 9 has a gloss finish, and the region with the foamed resin layer 8 and the thermosetting resin layer 9 has a matte finish. It becomes.
[0041]
(Example 2)
In Example 2, a casein-based resin was used as the thermosetting resin layer 9. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(Example 3)
In Example 3, an acrylic resin was used as the thermosetting resin layer 9. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(Example 4)
In Example 4, a urethane-based resin was used as the thermosetting resin layer 9. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
[0042]
(Example 5)
In Example 5, the thickness of the thermosetting resin layer 9 was set to 1 μm. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(Example 6)
In Example 6, the thickness of the thermosetting resin layer 9 was set to 5 μm. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(Example 7)
In Example 7, the thickness of the thermosetting resin layer 9 was set to 7 μm. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
[0043]
(Example 8)
In Example 8, the thickness of the thermosetting resin layer 9 was set to 10 μm. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(Example 9)
In Example 9, the thickness of the thermosetting resin layer 9 was set to 15 μm. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(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. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
[0044]
(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. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(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. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
[0045]
(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. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(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. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
[0046]
(Example 15)
In Example 15, colored ink was added to the thermosetting resin layer 9. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
(Comparative Example 1)
In Comparative Example 1, the thermosetting resin layer 9 was omitted. Other than that, the resin-impregnated decorative board 1 was produced by the same materials and procedures as in Example 1.
[0047]
(Performance evaluation)
The following performance evaluations were performed on the resin-impregnated decorative boards 1 of Examples 1 to 15 and Comparative Example 1.
(Cross cut test)
In the cross-cut test, a cross-cut is made in the resin-impregnated decorative plate 1 with a cutter, and whether or not peeling occurs is evaluated. When there is no significant peeling at the time of cross-cutting, it is marked with "○", and when there is significant peeling, it is marked with "x".
[0048]
(Pollution test)
In the contamination test, the resin-impregnated decorative plate 1 was coated with black crayon and red ink, and after 1 hour, it was wiped off with alcohol, and the degree of unwiped residue was evaluated. When the degree of unwiped residue is less than 30%, it is evaluated as "○", when the degree of unwiped residue is 30% or more and less than 70%, it is "△", and when the degree of unwiped residue is 70% or more, it is "×". did.
(Tactile evaluation)
In the tactile sensation evaluation, 10 examiners evaluated it as a 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 there will be 0 people who have a good evaluation. In some cases, it was marked as "x".
[0049]
(Design evaluation)
In the design evaluation, 10 examiners evaluated it as a 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 there will be 0 people who 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 for 2 months in an environment of a temperature of 40 ° C. and a humidity of 90%, and then evaluated by 10 examiners as a sensory test on changes in the design. 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 there will be 0 people who have a good evaluation. In some cases, it was marked as "x".
[0050]
(Comprehensive judgment)
Comprehensive evaluation was made by the above five items: cross-cut test, contamination test, tactile evaluation, design evaluation, and long-term environmental test. Particularly excellent ones were given as "◎", excellent ones were given as "○", those with almost no problems were given as "△", and those with problems were given as "×".
(Evaluation results)
Table 1 shows the results of these evaluations.
[0051]
[table 1]

[0052]
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 provided with the thermosetting resin layer 9, 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. The design stability of the above was excellent or there was almost no problem. Further, as shown by the evaluation results of Examples 5 to 9, the thicker the thermosetting resin layer 9 is, the better the scratch resistance is, but the more the designability tends to be lowered. Further, as shown by the evaluation results of Examples 10 to 14, as the coating area of ​​the thermosetting resin layer 9 is increased, the stain resistance is improved, but the designability tends to be lowered. Further, as shown by the evaluation results of 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. As a comprehensive judgment, the resin-impregnated decorative board 1 of Examples 6, 7, 12, and 15 was particularly excellent. In Examples 5 to 14, 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 the physical properties, and almost the same results can be obtained.
[0053]
Although the above description has been made with reference to a limited number of embodiments, the scope of rights is not limited to them, and modifications of the embodiments based on the above disclosure are obvious to those skilled in the art.
Code description
[0054]
1 ... Resin-impregnated decorative board, 2 ... Resin-impregnated decorative paper, 3 ... Base material, 3a ... Surface, 4 ... Cosmetic paper, 5 ... Impregnated resin, 6 ... Base paper, 6a ... Surface, 7 ... Pattern layer, 7a ... Surface , 8 ... foamed resin layer, 8a ... surface, 9 ... thermosetting resin layer, 10 ... uneven pattern
The scope of the claims
[Claim 1]
A resin-impregnated decorative paper made by impregnating decorative paper with impregnated resin.
The decorative paper is
With the base paper
The pattern layer provided on the surface side of the base paper and
Foam formed by a foaming agent placed on the surface of the pattern layer or in the pattern layer.With the resin layer,
A thermosetting resin layer provided on the surface of the foamed resin layer is provided.
The thermosetting resin layer is a resin-impregnated decorative paper containing at least one of an epoxy-based resin, a casein-based resin, an acrylic-based resin, and a urethane-based resin.
[Claim 2]
The resin-impregnated decorative paper according to claim 1, wherein the thermosetting resin layer has a thickness of 1 μm or more and 15 μm or less.
[Claim 3]
The resin-impregnated decorative paper according to claim 2, wherein the thermosetting resin layer has a thickness of 5 μm or more and 10 μm or less.
[Claim 4]
The resin-impregnated decorative paper according to any one of claims 1 to 3, wherein the thermosetting resin layer is provided in a range of 30% or more of the surface area of ​​the foamed resin layer.
[Claim 5]
The resin-impregnated decorative paper according to claim 4, wherein the thermosetting resin layer is provided in a range of 50% or more of the surface area of ​​the foamed resin layer.
[Claim 6]
The resin-impregnated decorative paper according to any one of claims 1 to 5, wherein the thermosetting resin layer contains colored ink.
[Claim 7]
The resin according to any one of claims 1 to 6, wherein the foaming agent has an average particle size of 15 μm or more and 250 μm or less after foaming, and a foaming start temperature of 100 ° C. or more and 220 ° C. or less. Impregnated decorative paper.
[Claim 8]
The resin-impregnated decorative paper according to any one of claims 1 to 7, wherein the pattern formed by the pattern layer and the arrangement position of the foamed resin layer are synchronized with each other.
[Claim 9]
The resin impregnation according to any one of claims 1 to 8, wherein the foaming agent has an average particle size before foaming of 2/3 times or more and 50 times or less the layer thickness of the pattern layer. Decorative paper.
[Claim 10]
The resin-impregnated decorative paper according to any one of claims 1 to 9 and
A resin-impregnated decorative board characterized by comprising a base material integrated with the resin-impregnated decorative paper.