JPH022698B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an endless melamine laminate that is elongated in the longitudinal direction among thermosetting resin decorative laminates used mainly for decorative purposes or base materials for interiors and furniture of buildings, vehicles, ships, etc. This invention relates to a decorative board and its manufacturing method.

Conventionally, as a continuous manufacturing method for obtaining a long endless decorative board, for example, there is a method described in Japanese Patent Application Laid-open No. 144151/1983. This method is related to the continuous production of laminates and metal foil-clad laminates, and when thermosetting resins such as unsaturated polyester resins and diallyl phthalate resins are cured, they are exposed to condensed water and carbon dioxide gas. This is a method in which multiple long sheets of impregnated paper impregnated with a thermosetting resin liquid that does not substantially generate reaction by-products such as . As described in the patent specification, this method excludes the melamine resin and phenolic resin of the present invention. Also, Tokko Akira
The specification of Japanese Patent No. 51-15875 describes a method for manufacturing a decorative sheet using a continuous molding machine having a steel belt. The purpose of this method is to produce a flexible decorative sheet made of synthetic rubber or thermoplastic synthetic resin system, as described in the specification, which is particularly flexible due to the permanent shaping process. . As described above, a method for obtaining an endless melamine resin decorative board has not yet been established in the industrial field.

Therefore, in view of the above-mentioned conventional technology, the present inventors conducted intensive research and made the curing speed of melamine resin and phenol resin faster. As a result, the melamine resin and phenol resin were impregnated into paper in several tens of seconds. This makes it possible to significantly improve the productivity of melamine resin decorative laminates produced by the conventional batch method, and at the same time, it is a new technology that allows melamine resin decorative laminates with the same quality as the batch method to be produced endlessly and continuously. Based on these findings, we have arrived at the present invention.

The present invention is equivalent to the conventional batch-type melamine resin decorative board production method using a multistage press machine, with the same resin composition as this melamine resin decorative board, that is, a structure in which melamine resin is used as the surface layer and phenolic resin is used as the core layer. The quality of the melamine resin decorative laminate, which meets JISK6903 (thermosetting resin decorative laminates), was developed for the first time in the industry by improving the curing speed of melamine resin and phenolic resin to be faster and using a continuous molding press. It has now become possible to provide endless melamine decorative boards.

Hereinafter, detailed contents and embodiments of the present invention will be specifically explained based on the drawings.

FIG. 1 is a longitudinal cross-sectional view of an endless melamine resin decorative board according to the present invention, and in this drawing,
In the endless melamine resin decorative board 11, the overlay 1 and pattern 2 on the surface layer are made of fast-curing melamine resin, the core 3 of the layer below is made of fast-curing phenol resin, and the backer 4 is made of fast-curing phenol. This refers to a long scroll-shaped decorative board made of resin or fast-curing melamine-based resin, and its thickness is determined by the number of cores 3 or the basis weight of the base paper that makes up all of them. It varies depending on the amount of resin impregnated, and is preferably from 0.2 mm to 0.8 mm, but is not particularly limited. These decorative laminates are broadly classified by purpose into general laminates used as flat laminates, vertical laminates, vehicular laminates, and post-forming laminates used as curved surfaces. In the case of vertical use, overlay 1 may or may not be present. In other words, the overlay serves to protect the surface pattern when used on worktops such as desks, dining tables, sinks, etc., and is an essential layer for horizontal applications, but for vertical applications, it is a wear-resistant layer. This is because there is no need for sex.

The above-mentioned melamine resin has melamine and formaldehyde as its main components, and the fast-curing melamine resin used in the present invention is a melamine resin that is cured at a temperature of 140°C in accordance with the lamination curing with the phenolic resin used for the core.
This resin has been adjusted to cure in 60 seconds or less at ℃. Generally, melamine resin has a fast curing property among condensation resins, but under the above curing conditions, a satisfactory surface condition cannot be obtained due to insufficient flow of the resin and gas generated by condensation. The present invention has improved the above-mentioned drawbacks, and is a partially alkyl etherified melamine resin whose main components are melamine and formaldehyde, limited to alcohols, glycols, and oxides. It contains a modifier such as guanamine and para-toluenesulfonic acid amide.

Next, a fast-curing phenolic resin is one that satisfies the curing conditions of 60 seconds or less at a temperature of 140°C, similar to the melamine-based resin, and includes phenol,
It contains alkylphenol and formaldehyde as main components and is obtained by a limited blending ratio and a limited reaction method. The curing conditions for phenolic resins used in conventional batch-based melamine resin decorative boards require at least 3 minutes, usually 4 to 5 minutes, at a temperature of 140°C.

Note that the surface finish of the endless melamine resin decorative board 11 varies depending on the application, and is not limited to smooth, embossed, etc.

As described above, the endless melamine resin decorative board of the present invention can be produced in batches using a conventional multi-stage press machine such as 909 x 1818 mm (3 shaku x 6 shaku) or 1212 x 2424 mm (4 shaku x 8 shaku). This size is obtained by manufacturing melamine resin decorative boards, but since it is a long endless roll, the lengthwise size can be freely adjusted, and it has many advantages in terms of usage. That is, when used for long counters, desks, etc., conventional sized melamine resin decorative boards have seams because of their limited length, but the endless melamine resin decorative board of the present invention is a single piece with no seams. , is excellent in design. When thin melamine resin decorative boards of 0.6 mm or less are manufactured using conventional multi-stage press machines, they are not often commercially available because they are often damaged during handling due to their thinness and the yield is reduced. However, since the endless melamine resin decorative board of the present invention is a roll, it is advantageous in terms of manufacturing process, and it can be made industrially thin, and material costs are low, and in terms of quality, it is no different from conventional melamine resin decorative boards. That is, it has many excellent characteristics, including physical properties that fully pass JISK6903 (thermosetting resin decorative board).

Next, a method for producing an endless melamine resin decorative board of the present invention will be explained based on the drawings.

FIG. 2 is an explanatory drawing showing the main parts of the manufacturing process of the endless melamine resin decorative board of the present invention. In this drawing, overlay impregnated paper 1 impregnated with melamine resin, pattern impregnated paper 2, Each roll of core-impregnated paper 3 and backer-impregnated paper 4 impregnated with phenolic resin or melamine resin is attached to an impregnated paper unwinding device A so that it can be laminated one after another from above, and is inserted into a continuous molding press B to continuously form the rolls. The forming press B is made up of a heating drum 5, endless steel belts 6 and 7, and a pressure section 8, and the endless steel belt is driven by the heating drum. The piece of impregnated paper inserted into the continuous molding press is sandwiched between a mirror-finished steel belt 6 in contact with the front side and a steel belt 7 in contact with the back side. Additionally, the upper and lower endless steel belts receive heat from the heating drum.

All four of the heating drums may be heating drums, or two heating drums may be used, an upper and a lower heating drum. In addition, heat is conducted by the upper and lower steel belts driven by the heating drum. The surface temperature of these steel belts is preferably 140 to 160°C, and this temperature depends on the grade of the endless melamine resin decorative board obtained. In other words, when manufacturing endless melamine resin decorative boards for post-forming, 140 to 150
℃ is particularly preferable, when producing endless melamine decorative boards for general use, vertical use, and vehicles.
150-160°C is preferred. Next, a pressing force of 10 to 30 kg/cm ² is applied by the tension applied to the endless steel belt and the pressing section 8. The preferred pressure for production is 20 to 30 Kg/cm ² . The material of the endless steel belt is hard stainless steel (SUS304) with a thickness of 1.2 mm.The surface condition of the mirror-finished steel belt 6 for surfaces varies depending on the surface finish of the endless melamine resin decorative board to be obtained. That is, in the case of obtaining a product with rips, the surface condition of the mirror-finished steel belt 6 is ripped, and in the case of a product with rips, the surface condition of the mirror-finished steel belt 6 is ``with rips''. Note that the surface finish of the steel belt on the back side is not particularly limited.

After the impregnated paper is heated and pressed by such a continuous molding press machine B, it is cooled by a cooling device C comprising a cooling roll 9 using cooling water. After that, belt sander 1
The endless melamine resin decorative board 11 is continuously sanded with a sander D using a sander D using a sander D, and the endless melamine resin decorative board 11 is wound up with a product winding device E.

Here, a cutting machine such as a guillotine cutter, a rotary knife, or a tip saw may be installed in the pre-process of the product winding device E to cut the product to an arbitrary length. That is, if the thickness of the decorative board is 1.0 mm or more, it will be difficult to roll it up, so it will have to be cut into lengths according to market orders, loaded, packed, and shipped. In the case of scrolls, they are packaged and shipped in lengths according to market orders.

As described above, the method for manufacturing the endless melamine resin decorative board of the present invention is such that the melamine resin and phenolic resin are cured in several tens of seconds, and the pressure of 20 Kg/cm ² to 30 Kg/cm ² is applied. By using a continuous molding press machine with a steel belt that adds Furthermore, thin melamine resin decorative boards can now be produced at high yields, and furthermore, the length direction is endless, making it optional.

Next, examples of the present invention will be described.

Example 1 0.2 aliphatic alcohol per mole of melamine
Overlay paper and pattern paper are impregnated with a resin liquid prepared by adding 0.3% of a latent curing catalyst, Catanitsu A (manufactured by Nitto Chemical Co., Ltd.) to a melamine resin condensate synthesized with 1.3 moles of formaldehyde, dried, and then rolled up. Rolls of overlay impregnated paper and pattern impregnated paper were obtained. At this time, the resin impregnation rate for each base paper was 200% for the overlay and 120% for the pattern. Next, a phenol resin condensate synthesized with 0.7 mol of phenol, 0.3 mol of alkylphenol, and 1.5 mol of formaldehyde is impregnated into a core paper made of kraft paper and backer paper, dried and rolled up, and the core impregnated paper and backer paper are impregnated. Obtained a paper scroll. At this time, the impregnation rate for each base paper is 60% for the core and 70% for the backer.
It was hot.

Each roll of impregnated paper thus obtained is placed on an impregnated paper unwinding device for overlay, pattern, core,
I installed it so that it would be a backer. Thereafter, they were inserted between the steel belts of a continuous molding press so that they were stacked one on top of the other. At this time, the temperature of the upper and lower endless steel belts was 160℃, and the pressing force was 20℃.
Kg/ ^cm2 . Then, after heating and pressurizing for 20 seconds,
After cooling with a cooling roll and sanding the back side with #60 sandpaper, a 0.6 mm endless melamine resin decorative board was obtained.

At this time, the impregnated paper feeding speed and the steel belt speed are synchronized, and the manufacturing speed is
It was 10m/min.

[Brief explanation of drawings]

FIG. 1 is a longitudinal sectional view of the endless melamine resin decorative board of the present invention. 1 is an overlay impregnated paper made of melamine resin, 2 is a pattern impregnated paper made of melamine resin,
3 is a core impregnated paper made of phenolic impregnated paper; 4
is a backer-impregnated paper made of phenol-based impregnated paper. FIG. 2 is an explanatory diagram of the schematic steps of the method for producing an endless melamine resin decorative board of the present invention. A
is an impregnated paper unwinding device, B is a continuous molding press machine, C is
is a cooling device, D is a sanding device, and E is a product winding device. 5 is a heating drum, 6 is a mirror-finished steel belt on the front side, 7 is a steel belt on the back side, 8 is a pressure section, 9 is a cooling roll, 10 is a belt sander, and 11 is an endless melamine resin decorative board.

[Claims]

1. In a method for manufacturing a polyvinyl chloride resin laminate, in which a layer of polycarbonate resin or fluororesin is laminated on at least one side of a polyvinyl chloride resin via an adhesive, a. The tackiness of the adhesive changes depending on the temperature. (b) bonding a polyvinyl chloride resin film and a polycarbonate resin or fluororesin film using the adhesive to obtain a pre-laminated film having a thickness that can be wound into a roll; c. The pre-laminated film is laminated with at least one second polyvinyl chloride resin sheet or film so that the polycarbonate resin or fluorine resin is on the surface, and is heated and pressurized to integrate, and cannot be rolled into a roll. A method for producing a polyvinyl chloride resin laminate, characterized by forming a laminate sheet or a molded plate. 2. The manufacturing method according to claim 1, wherein the pre-laminated film obtained in step 2b is a continuous strip wound into a roll. 3. A patent application characterized in that the adhesive is a saturated polyester hot melt adhesive containing a crosslinking agent.