JPH04187429A - Thermosetting resin decorative panel - Google Patents

Abstract

PURPOSE:To obtain a decorative panel having heat generating action and having the same shape, appearance and physical properties as a usual decorative panel according to a usual manufacturing method by arranging a fiber base material containing a specific amount of a carbon fiber under a surface decorative layer to laminate and mold both of them. CONSTITUTION:A carbon fiber-containing fiber base material is obtained by adding 10-100g/m<2> of carbon fiber to a fiber base material such as paper, cloth or a nonwoven fabric. Since the carbon fiber generates heat, the carbon fiber is pref. provided to the part as close as possible to a surface decorative layer but, with due regard to the design effect of a decorative panel, it is proper to provide the same directly under the surface decorative layer or under the surface decorative layer and a thin core material layer. In order to clear the pattern of the decorative panel, as the surface decorative layer, melamine resin impregnated paper is most pref. but phenol resin impregnated paper can be also pref. used. As the core material layer, usual phenol resin impregnated paper is pref. used. For example, the melamine resin impregnated paper 1 being the decorative material layer wherein a melamine resin is infiltrated in white pigment mixed paper, carbon fiber mixed paper 3 being the core material layer and five phenol impregnated papers 4 are superposed one upon another in this order and molded to obtain the decorative panel. By this method, heat is generated without damaging the design effect as the decorative panel.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a decorative board that generates heat when energized and has a heating effect without impairing the design and physical properties of the decorative board.

[Conventional technology]

BACKGROUND ART Conventionally, various types of planar heating elements that generate heat from interior materials such as flooring and wall materials have been studied for heating floors and walls.

Planar heating elements that have been developed so far include (1) composites of metal foil and electrically insulating synthetic resin, (ii) synthetic resin films coated with or printed with a heating resistive ink film, (i) ) There are metal materials with high resistance such as nichrome alloy.

However, materials (1) and (fi) have difficulties in adhering metal foil and synthetic resin, or resistive ink and synthetic resin film, and in the case of (i), the cost of the resistive ink is extremely high. , it was difficult to put it into practical use. Also, (i
), it is difficult to control the heat generation temperature,
There are limitations on the insulating material that can be used to cover the heating element, and the thickness of the planar heating element itself becomes large.

[Problem to be solved by the invention]

The inventor of the present invention has conducted various studies with the aim of producing a decorative board that has a heat-generating effect, having the same shape, appearance, and physical properties as a normal decorative board, and using normal manufacturing methods. discovered that the desired purpose could be achieved by using fiber base materials such as paper, cloth, and non-woven fabric,
This has led to the completion of the present invention.

[Means to solve the problem]

The present invention provides a thermosetting resin decorative board formed by laminating and molding fiber base materials such as paper, cloth, and nonwoven fabric coated with or impregnated with a thermosetting resin, in which 10 to 10 carbon fibers are added under the surface decorative layer.
This is a thermosetting resin decorative board formed by laminating and molding a fiber base material containing 100 g/m2.

In the present invention, thermosetting resins include melamine resins, phenol resins, epoxy resins, etc., and are not particularly limited to melamine resins. Resins and phenolic resins are preferred, with melamine resins being most preferred. These resins may be partially modified with other resins, or may be mixed with other resins.

The fiber base material impregnated or coated with these thermosetting resins is paper, woven fabric made of natural fibers or synthetic fibers, or nonwoven fabric made of these fibers.

Furthermore, woven fabrics and nonwoven fabrics made of inorganic fibers can also be used. A thermosetting resin-impregnated fiber base material is obtained by impregnating or coating such a fiber base material with the above-mentioned thermosetting resin by a conventional method. The content of thermosetting resin in this resin-impregnated fiber base material is usually 25 to 55% by weight.

The carbon fiber-containing fiber base material, which is a feature of the present invention, contains carbon fibers in an amount of 10 to 100 g/m2 in a fiber base material such as the above-mentioned paper, cloth, or nonwoven fabric. Carbon fiber is used to make the decorative board conductive, but
If it is 10 g/m2 or less, the conductivity is low (and sufficient heat generation does not occur).

On the other hand, if it is 100 g/m2 or more, the conductivity becomes high and heat generation tends to be too large, which is not preferable. This carbon fiber-containing fiber base material may be impregnated with a thermosetting resin, but usually does not need to be impregnated with it. When not impregnated with resin, during lamination, the resin of the resin-impregnated fiber base material laminated on both sides flows, impregnates the carbon fiber-containing fiber base material, and hardens to form a strong bond.

Among the carbon fiber-containing fiber base materials, paper containing carbon fiber is a mixed paper made by mixing a predetermined amount of pulp and carbon fiber, and the basis weight of this paper is usually 50 to 150 g/m
It is 2. Carbon fiber-containing cloth is made by twisting carbon fibers and natural fibers or synthetic fibers at a predetermined ratio and then weaving them together. Further, the carbon-containing nonwoven fabric is made by combining carbon fibers and the above-mentioned fibers in a predetermined composition. These carbon fiber-containing fiber base materials have an electrical conductivity of approximately 20 to 80 Ω/cm. Among these, carbon fiber-containing fiber base materials are preferred in the present invention from the viewpoint of uniformity of heat generation, ease of handling, etc. This is carbon fiber mixed paper.

Since this carbon fiber-containing fiber base material generates heat, the closer it is to the surface decorative layer, the better; however, when considering the design of the decorative board, it should be placed immediately below the surface decorative layer or between the surface decorative layer and the thin core material layer. The bottom is appropriate.

A core material layer for reinforcement is provided under the carbon fiber-containing fiber base material.

The surface decorative layer is most preferably melamine resin-impregnated paper in order to make the design of the decorative board clear, but phenol resin-impregnated paper can also be preferably used. Generally, phenol resin-impregnated paper is preferably used for the core material layer. It is better for the core material layer laminated on the carbon fiber-containing fiber base material to be thinner, so usually -
A sheet of impregnated paper is sufficient. In order to obtain the decorative laminate of the present invention, the resin-impregnated fiber base materials and the carbon fiber-containing fiber base materials described above are stacked in a predetermined order and heated and press-molded by a conventional method.

In the decorative board of the present invention, if electrodes for energization are provided in advance at a pair of opposing ends of the carbon fiber-containing fiber base material, electrical connection between the power source and the decorative board is easy. This electrode can be a copper foil of a suitable thickness, for example 60 microns, and is adhered to the carbon fiber-containing fibrous substrate with a conductive adhesive.

〔Example〕

The present invention will be explained below with reference to Examples.

Example 1 As shown in FIG. 1, impregnated paper 1, which is white pigmented paper impregnated with melamine resin, was used as the surface decorative layer, and carbon fiber mixed paper 3 with a carbon content of 60 g/m2 was used as the core material. Five sheets of phenolic resin-impregnated paper 4 were layered in this order and molded at 150° C. and 100 kg/cm 2 for 60 minutes to obtain a decorative board.

Example 2 As shown in FIG. 2, impregnated paper 11 made by impregnating melamine resin on paper with wood grain printing was used as the surface decorative layer, one sheet of phenol resin impregnated paper 12 was used as the core material layer, and carbon fiber mixed paper 13 was used as the carbon fiber mixed paper 13. Five sheets of phenolic resin-impregnated paper 14 having a content of 60 g/m 2 were stacked in this order as a core layer, and molded at 150° C. and 100 kg/cm 2 for 60 minutes to obtain a decorative board.

Note that the carbon fiber mixed paper 3.13 used was one in which copper foil with a width of 15+ nm and a thickness of 60 μm was adhered in advance to two opposing sides using a conductive adhesive.

These decorative laminates generated heat uniformly over the entire surface of the laminate by applying electricity to the carphone fiber mixed paper layer. When we glued a 10mm thick plywood board to the back of the decorative board and measured the heat generation temperature on the surface of the decorative board, we found that in the case of a size of 30 x 30cm, the heat generation temperature fluctuates somewhat depending on the outside temperature, but at a voltage of 100V it was approximately 70 degrees Celsius. , 50V and about 40° C., and these temperatures were reached in about 10 seconds after electricity was applied.

[Effects of the Invention] In the thermosetting resin decorative board of the present invention, the carbon fiber-containing fiber base material serves as a heat generating body and is placed under the surface decorative layer, so that the decorative board does not lose its design (it does not generate heat). do.

This heat generation is uniform over the entire surface of the decorative board. Also, it generates heat at low voltage, and the heat buildup is fast.

On the other hand, like ordinary thermosetting resin decorative boards, it also has excellent surface properties such as hardness, abrasion resistance, and heat resistance.

Therefore, it can be used for floor heating, wall heating, in kitchens, toilets, etc., and is also effective in preventing dew condensation when used as a ceiling material for bay windows.

[Brief explanation of drawings]

FIGS. 1 and 2 are cross-sectional views of examples of thermosetting resin decorative boards of the present invention, respectively.

Claims (1)

[Claims] (1) In a thermosetting resin decorative board formed by laminating and molding a fiber base material such as paper, cloth, or nonwoven fabric coated or impregnated with a thermosetting resin, 10 to 10 carbon fibers are added under the surface decorative layer.
A thermosetting resin decorative board formed by laminating and molding a fiber base material containing 0g/m^2.