Technical Field
[0001]
The present invention relates to a resin-impregnated
decorative paper and a resin-impregnated decorative plate.
10
Background Art
[0002]
Conventionally, a method for manufacturing a
resin-impregnated decorative plate has been proposed that
15 causes a metal plate to abut on a multi-layer composite of
a resin-impregnated decorative paper impregnated with a
thermosetting resin and a base member and performs heat
pressure molding, thereby obtaining a resin-impregnated
decorative plate in which the resin-impregnated decorative
20 paper and the base member are integrated together (e.g., see
PTL 1). In the manufacturing method of the resin-impregnated
decorative plate described in PTL 1, an embossed shape is
formed on a metal plate to give uneven patterns to a surface
of the resin-impregnated decorative plate, thereby giving a
25 touch feeling. Further, by adjusting the degree of
coarseness and fineness of the embossed shape, it is also
possible to give a gloss matte expression.
However, in the manufacturing method of the
3
resin-impregnated decorative plate described in PTL 1, it is
necessary to prepare the metal plate for each uneven pattern
to be given, and therefore there is a possibility that the
cost increases. Accordingly, it is conceivable to give
5 uneven patterns by providing foamed resin layers. However,
since a foamed resin having affinity with an impregnating
resin such as a melamine resin easily soaks into a base paper,
there is a possibility that a touch feeling or a gloss matte
feeling decreases.
10
Citation List
Patent Literature
[0003]
PTL 1: JP H09-262956 A
15
Summary of Invention
Technical Problem
[0004]
The present invention has been made focusing on the
20 problems described above and has an object to provide a
resin-impregnated decorative paper and a resin-impregnated
decorative plate that are excellent in gloss matte expression
and touch feeling while suppressing the cost.
25 Solution to Problem
[0005]
A resin-impregnated decorative paper according to one
aspect of the present invention is a resin-impregnated
4
decorative paper formed by impregnating a decorative paper
with an impregnating resin, the decorative paper including:
a base paper; a picture pattern layer provided on a surface
side of the base paper; a filling layer provided on a surface
5 of the picture pattern layer; and a foamed resin layer
provided on a surface of the filling layer, the foamed resin
layer formed by a foaming agent, wherein the filling layer
contains at least one of an epoxy-based resin, an
acrylic-based resin, a urethane-based resin, and a
10 casein-based resin.
A resin-impregnated decorative plate according to
another aspect of the present invention includes: the
resin-impregnated decorative paper; and a base member
integrated with the resin-impregnated decorative paper.
15
Advantageous Effects of Invention
[0006]
According to the present invention, it is possible to
foam a foaming agent by heat pressure molding to properly form
20 an uneven pattern on a surface of a 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 that are excellent in gloss matte expression
25 and touch feeling while suppressing the cost. Further, since
a filling layer containing at least one of an epoxy-based
resin, an acrylic-based resin, a urethane-based resin, and
a casein-based resin is provided, it is possible to restrain
5
a foamed resin forming a foamed resin layer from soaking into
a picture pattern layer or a base paper. Therefore, it is
possible to provide a resin-impregnated decorative paper and
a resin-impregnated decorative plate that are further
5 excellent in gloss matte expression and touch feeling.
Brief Description of Drawings
[0007]
FIG. 1 is a sectional view illustrating a
10 resin-impregnated decorative plate after heat pressure
molding; and
FIG. 2 is a sectional view illustrating a
resin-impregnated decorative plate before heat pressure
molding.
15
Description of Embodiments
[0008]
Hereinafter, a decorative paper, a resin-impregnated
decorative paper, and a resin-impregnated decorative plate
20 according to an embodiment of the present invention will be
described with reference to the drawings. The present
invention is not limited to the embodiment described below
and can also be added with a modification such as a change
in design based on knowledge of those skilled in the art. An
25 embodiment added with such a modification is also included
in the scope of the present invention. Each of the drawings
is illustrated in an exaggerated manner as appropriate to
facilitate the understanding.
6
[0009]
(Configuration)
As illustrated in FIGS. 1 and 2, a resin-impregnated
decorative plate 1 according to an embodiment of the present
5 invention is a decorative plate obtained by applying heat
pressure molding to a multi-layer composite of a
resin-impregnated decorative paper 2 and a base member 3 to
integrate the resin-impregnated decorative paper 2 and the
base member 3 with each other. Specifically, the
10 resin-impregnated decorative plate 1 includes the base member
3 and the resin-impregnated decorative paper 2 provided on
the surface 3a side of the base member 3. The
resin-impregnated decorative plate 1 according to the
embodiment of the present invention is a resin-impregnated
15 decorative plate used for, for example, interior decoration
of floor surfaces, wall surfaces, ceilings, and the like of
buildings, surface decoration materials of furniture,
various cabinets, and the like, surface decoration of
furnishings, vehicle interior decoration, and the like. FIG.
20 1 illustrates the resin-impregnated decorative plate 1 after
the heat pressure molding, and FIG. 2 illustrates the
resin-impregnated decorative plate 1 before the heat pressure
molding.
[0010]
25 (Base member)
The kind of the base member 3 is not particularly limited.
It is possible to use an arbitrary base member according to
a use of the resin-impregnated decorative plate 1 to be
7
targeted. For example, a woody base member such as a wood
veneer, a plywood, a laminated wood, a particle board, a
medium density fiberboard, or a hard fiberboard, a fibrous
base member such as a paper board, a woven fabric, a nonwoven
5 fabric, a resin-impregnated paper, or a resin-impregnated
fabric, an inorganic base member such as a gypsum board, a
slate board, a calcium silicate board, a slag gypsum board,
a wood wool cement board, a slag cement board, an autoclaved
lightweight concrete board, or a glass fiber-reinforced
10 concrete board, a metal base member such as a steel plate,
a brass plate, an aluminum plate, a duralumin plate, or a
stainless steel plate, a synthetic resin base member such as
an acrylic resin plate, a styrene resin plate, an ABS
(Acrylonitrile butadiene styrene) resin plate, a
15 polycarbonate resin plate, a nylon resin plate, a polystyrene
resin plate, a polypropylene resin plate, a polyester resin
plate, or a glass fiber-reinforced plastic plate, or the like,
or a composite or a multi-layer composite of two or more kinds
selected from these base members or the like can be adopted.
20 [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 an
25 impregnating resin 5 and then drying the decorative paper 4.
The decorative paper 4 includes a base paper 6, a picture
pattern layer 7, filling layers 8, and foamed resin layers
9. The picture pattern layer 7 is provided on a surface 6a
8
of the base paper 6. The filling layers 8 are provided on
a surface 7a of the picture pattern layer 7. The foamed resin
layers 9 are provided on surfaces 8a of the filling layers
8.
5 [0012]
(Base paper)
As the base paper 6, it is possible to use a fibrous
sheet-like object, such as paper with high water absorbency,
that allows impregnation of the impregnating resin 5. For
10 example, a thin paper, a titanium paper, a high-quality paper,
a bleached or unbleached kraft paper, or the like can be
adopted. In particular, considering both the suitability
for printing and the suitability for resin impregnation, the
titanium paper is the most suitable. When taking advantage
15 of the texture of the surface 3a of the base member 3, it is
preferable to use a so-called transparent paper having a
property of becoming transparent by the impregnation of the
impregnating resin 5. The thickness of the base paper 6 is
not particularly limited, but the basis weight is preferably
20 in a range of 20 gm2 or more and 200 gm2 or less.
[0013]
(Picture pattern layer)
The picture pattern layer 7 is a layer for giving a design
property by a picture pattern to the resin-impregnated
25 decorative paper 2. The picture pattern layer 7 is formed
by using a printing ink or the like in which a coloring agent
such as a dye or a pigment is dissolved or dispersed in a
diluent solvent along with an appropriate binder resin. The
9
kind of the printing ink is not particularly limited and may
be an oil-based ink or a water-based ink. Specifically, as
the printing ink, it is possible to use a usual printing ink
having no liquid repellency.
5 In particular, considering the suitability for the
impregnation of the impregnating resin 5, the water-based ink
is the most suitable. The water-based ink has good affinity
with an aqueous solution of an impregnating resin as compared
to the oil-based ink. Therefore, when the water-based ink
10 is used, the decorative paper 4 can be quickly and uniformly
impregnated with the impregnating resin 5 in an impregnation
process in the manufacture of the resin-impregnated
decorative plate 1, and further, the strength can be exhibited
in the excellent picture pattern layer 7 by integration with
15 the impregnating resin 5. The kind of the water-based ink
is not particularly limited, but it is preferable that the
water-based ink contain a binder resin mainly composed of
casein and an emulsion resin.
[0014]
20 Such a binder resin has a property of becoming
water-insoluble through a drying process after printing of
ink. Therefore, when a binder resin containing such a binder
resin is used, the picture pattern layer 7 is difficult to
redissolve in an aqueous solution of the impregnating resin
25 5 in a resin impregnation process in the manufacture of the
resin-impregnated decorative plate 1, so that it is possible
to hold the picture pattern and further it is possible to
prevent contamination of the impregnating resin 5.
10
As the emulsion resin, it is possible to adopt, for
example, an acrylic-based emulsion resin, a vinyl
acetate-based emulsion resin, a styrene-based emulsion resin,
a urethane-based emulsion resin, or the like. In the binder
5 resin, for example, a water-soluble resin such as polyvinyl
alcohol or polyacrylamide, a water-soluble polymer such as
polysaccharide or cellulose derivative, or the like may be
used in addition to the casein and the emulsion resin to
improve the stability of ink.
10 [0015]
A method for forming the picture pattern layer 7 is not
particularly limited. It is possible to use an arbitrary
printing method such as, for example, a gravure printing
method, an offset printing method, a screen printing method,
15 a flexographic printing method, a relief printing method, or
an ink jet printing method. Between layers of the picture
pattern layer 7 and the base paper 6, a solid ink layer intended
for base coloring may be provided. When the solid ink layer
is provided, an arbitrary coating method such as a roll
20 coating method, a gravure coating method, a rod coating method,
a knife coating method, an air knife coating method, a spray
coating method, a lip coating method, or a die coating method,
for example, can also be used as a method for forming the solid
ink layer other than various printing methods described
25 above.
The kind of a picture formed by the picture pattern layer
7 is not particularly limited. It is possible to use an
arbitrary picture according to a use of the resin-impregnated
11
decorative plate 1 to be targeted. For example, a wood grain
pattern, a stone grain pattern, a fabric grain pattern, an
abstract pattern, a geometric figure, a character, a sign,
a monochromatic plain pattern, or the like or a combination
5 of two or more kinds selected from these patterns or the like
can be adopted.
[0016]
(Filling layer)
The filling layers 8 are coating layers partially formed
10 on the picture pattern layer 7 for preventing penetration of
a foamed resin into the base paper 6. As a resin forming the
filling layers 8, it is possible to use, for example, a curable
resin such as a thermosetting resin having a urethane bond,
such as a two-component curable urethane resin, or an ionizing
15 radiation curable resin. As the curable resin, it is possible
to use, for example, a thermosetting resin such as an
epoxy-based resin, an acrylic-based resin, a urethane-based
resin, a casein-based resin, a melamine-based resin, a
urea-based resin, a phenol-based resin, an unsaturated
20 polyester-based resin, a diallyl phthalate-based resin, a
benzoguanamine-based resin, an aminoalkyd-based resin, or a
silicone-based resin, an ionizing radiation curable resin
such as a (meth)acrylate-based resin or an unsaturated
polyester-based resin, or the like.
25 [0017]
A method for printing the filling layers 8 is not
particularly limited like the picture pattern layer 7. It
is possible to use an arbitrary printing method such as, for
12
example, a gravure printing method, an offset printing method,
a screen printing method, a flexographic printing method, a
relief printing method, or an ink jet printing method.
As the forming positions of the filling layers 8, those
5 aligned in terms of design with a pattern (picture pattern)
formed by the picture pattern layer 7 can be used. For example,
the filling layers 8 are formed at portions where a matte or
glossy texture is to be expressed in the pattern (picture
pattern) formed by the picture pattern layer 7. This makes
10 it possible to further improve the design property of the
resin-impregnated decorative plate 1. The resin for forming
the filling layers 8 may be colorless or colored.
[0018]
The film thickness of the filling layer 8 is
15 satisfactorily 0.5 μm or more and 15 μm or less and, in
particular, more preferably 1 μm or more and 10 μm or less.
When the film thickness is less than 0.5 μm, the foamed resin
(thermoplastic resin) may soak into the base paper 6. When
the film thickness is greater than 15 μm, the design property
20 decreases.
It is satisfactory for the filling layer 8 to be provided
in a range of 100% or more of the surface area (coating area)
of the foamed resin layer 9 and, in particular, it is more
preferable for the filling layer 8 to be provided in a range
25 of 150% or less of the surface area of the foamed resin layer
9. When less than 100% of the surface area of the foamed resin
layer 9, the foamed resin forming the foamed resin layer 9
may soak into the picture pattern layer or the base paper.
13
When greater than 150% of the surface area of the foamed resin
layer 9, the design property decreases. In the case where
the arrangement position of the foamed resin layer 9 is
aligned with a picture formed by the picture pattern layer
5 7, it can be rephrased as follows. It is satisfactory for
the filling layer 8 to be provided in a range of 100% or more
of the area of the picture formed by the picture pattern layer
7, and it is more preferable for the filling layer 8 to be
provided in a range of 150% or less of the area of the picture
10 formed by the picture pattern layer 7.
[0019]
(Foamed resin layer)
The foamed resin layers 9 are layers for giving a gloss
matte expression and a touch feeling by uneven patterns 10
15 on a surface of the resin-impregnated decorative paper 2. The
kind of a foaming agent is not particularly limited, and an
arbitrary foaming agent can be used. For example, it is
possible to adopt a pyrolytic chemical foaming agent such as
an azo-based foaming agent such as azodicarbonamide or
20 azobisformamide, or a hydrazide-based foaming agent such as
oxybenzenesulfonyl hydrazide or paratoluenesulfonyl
hydrazide, a microcapsule foaming agent, or the like.
In particular, the microcapsule foaming agent is the most
suitable. The microcapsule foaming agent has a capsule and
25 a volatile substance enclosed in the capsule. The
microcapsule foaming agent enters a foamed state when the
volatile substance is volatilized to expand the capsule. As
a material of the capsule, it is possible to use, for example,
14
a vinylidene chloride-acrylonitrile copolymer or the like.
As a material of the volatile substance, it is possible to
use, for example, aliphatic hydrocarbon or the like.
[0020]
5 As the foaming agent, it is preferable that the average
particle diameter before foaming be 2/3 times or more and 50
times or less the layer thickness of the picture pattern layer
7. When the average particle diameter is less than 2/3 times
the layer thickness of the picture pattern layer 7, there is
10 a possibility that the gloss matte feeling and the touch
feeling may become poor. On the other hand, when the average
particle diameter is greater than 50 times the layer thickness
of the picture pattern layer 7, there is a possibility that
the foamed resin layers 9 after foaming may drop off the
15 decorative paper 4, or the like, so that the scratch
resistance decreases. Herein, the average particle diameter
is an average particle diameter by microscopic observation.
The average particle diameter by microscopic observation can
be obtained by, for example, microscopically observing the
20 foaming agent, measuring the particle diameter of 100
particles of the microscopically observed foaming agent by
image processing software or the like, and then
number-averaging the measurement results. As the particle
diameter of the foaming agent, it is possible to adopt an
25 average value of the major axis diameter and the minor axis
diameter of the particle of the foaming agent.
[0021]
As the foaming agent, it is preferable that the average
15
particle diameter after foaming be 15 μm or more and 250 μm
or less. When the average particle diameter is less than 15
μm, there is a possibility that the gloss matte feeling and
the touch feeling may become poor. On the other hand, when
5 the average particle diameter is greater than 250 μm, there
is a possibility that the foamed resin layers 9 after foaming
may drop off the decorative paper 4, or the like, so that the
scratch resistance decreases. The average particle diameter
after foaming is more preferably 30 μm or more and 200 μm or
10 less. Herein, the average particle diameter of the foaming
agent after foaming is an average particle diameter by
microscopic observation like the average particle diameter
of the foaming agent before foaming. As the particle diameter
of the foaming agent after foaming used for the acquisition
15 of the average particle diameter, it is possible to adopt an
average value of the major axis diameter and the minor axis
diameter of a void formed by the foaming of the foaming agent.
The foaming start temperature of the foaming agent is
preferably 100°C or more and 220°C or less. When the foaming
20 start temperature is less than 100°C, the foaming start timing
is early, and therefore the time during which the foamed resin
layers 9 after foaming are heated and pressed is prolonged
so that the foamed resin layers 9 after foaming are crushed,
leading to a possibility that the gloss matte feeling and the
25 touch feeling may become poor. On the other hand, when the
foaming start temperature is higher than 220°C, the foamed
resin layers 9 are not sufficiently foamed by the heat
pressure molding performed by abutting a metal plate (mirror
16
plate) in the manufacture of the resin-impregnated decorative
plate 1, so that there is a possibility that the gloss matte
feeling and the touch feeling may become poor. The foaming
start temperature is more preferably 120°C or more and 200°C
5 or less.

CLAIMS
1. A resin-impregnated decorative paper formed by
impregnating a decorative paper with an impregnating resin,
5 the decorative paper comprising:
a base paper;
a picture pattern layer provided on a surface side of
the base paper;
a filling layer provided on a surface of the picture
10 pattern layer; and
a foamed resin layer provided on a surface of the filling
layer, the foamed resin layer formed by a foaming agent,
wherein the filling layer contains at least one of an
epoxy-based resin, an acrylic-based resin, a urethane-based
15 resin, and a casein-based resin.
2. The resin-impregnated decorative paper
according to claim 1, wherein the filling layer has a
thickness of 0.5 μm or more and 15 μm or less.
20
3. The resin-impregnated decorative paper
according to claim 2, wherein the filling layer has a
thickness of 1 μm or more and 10 μm or less.
25 4. The resin-impregnated decorative paper
according to any one of claims 1 to 3, wherein the filling
layer is provided in a range of 100% or more of a surface area
of the foamed resin layer.
37
5. The resin-impregnated decorative paper
according to claim 4, wherein the filling layer is provided
in a range of 150% or less of the surface area of the foamed
5 resin layer.
6. The resin-impregnated decorative paper
according to any one of claims 1 to 5, wherein the foamed resin
layer contains a colored ink.
10
7. The resin-impregnated decorative paper
according to any one of claims 1 to 6, wherein a picture formed
by the picture pattern layer and an arrangement position of
the foamed resin layer are aligned with each other.
15
8. A resin-impregnated decorative plate
comprising:
the resin-impregnated decorative paper according to
any one of claims 1 to 7; and
20 a base member integrated with the resin-impregnated
decorative paper.