JPH0453744A - Manufacture of mildewproof pattern decorative panel - Google Patents

Abstract

PURPOSE:To obtain a decorative panel generating no mildew even during long- term use at a high humidity place by superposing a nonwoven fabric printed with pattern becoming a surface layer and a material for a base layer consisting of a liquid thermosetting resin, a filler and a fiber material one upon another to cure and mold both of them under pressure. CONSTITUTION:A nonwoven fabric printed with a pattern becoming a surface layer and a material for a base layer containing at least a thermosetting resin, a filler and a fiber material are superposed one upon another in such a state that a decorative base panel is used or not used to be cured and molded under pressure. For example, a resin alone selected from a group consisting of an unsaturated polyester resin and an acrylic resin or a molding material containing the resin and a fiber material such as a glass fiber is arranged on a molding material and both of them are simultaneously molded under pressure. Or, a transparent molding sheet based on the pattern printed nonwoven fabric is prepared using the resin same to the thermosetting resin used in the material for the base layer and superposed on the material for the base layer as the surface layer and both of them are cured and molded under pressure.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Application of the Invention) The present invention relates to a method for producing a mold-resistant patterned decorative board. More specifically, the present invention relates to a method for producing a mold-free decorative board made of a patterned nonwoven fabric resin composite layer.

(Prior art) Conventionally, a patterned decorative board was manufactured by bonding a decorative paper with a pattern printed on the substrate side, and flowing a liquid thermosetting resin, such as an unsaturated polyester resin, onto the decorative paper surface. After coating with a coater etc., the resin is cured, or a film such as a vinylon or polyester film is placed on the coated resin, defoamed with a roller, and then cured. Either a dry method is used in which a patterned printing paper is impregnated with a curable resin, such as a diallyl phthalate composite resin, a dried resin-impregnated decorative paper is placed, and the paper is cured by heating and pressing.

(Problems to be Solved by the Invention) However, all of these methods require time and effort to adhere the printed paper to the substrate, or impregnate and dry the printed paper with a resin liquid, resulting in a large number of steps and cost. It becomes expensive. In addition, decorative boards using printed decorative paper,
If these are used on the walls or ceilings of rooms with high humidity such as bathrooms or kitchens in houses and ships, mold will inevitably form, causing problems in terms of appearance and hygiene. It was hoped that the problem would be resolved.

The present inventors first investigated and researched the current situation in order to develop a decorative board that does not generate mold. That is, using decorative paper printed with a pattern, a test piece (with a bubble rate of 0.02% or less) was prepared by impregnating a thermosetting resin with S, and its water absorption rate (at 40°C) was prepared. For example, in the case of unsaturated polyester resin, a value of 2.6% by weight was measured. On the other hand, the water absorption rate of the unsaturated polyester resin alone measured at the same time was 0. It was found that the resin was not completely immersed into the decorative paper and water was absorbed into the non-3-soaked decorative paper.

Next, the decorative paper was pretreated with an aqueous solution of melamine resin, which is thought to be most commonly impregnated into decorative paper, and then dried, and then diallylphthale-1 resin was impregnated and dried, followed by curing under heat and pressure. The water absorption rate of the sample was measured in the same manner, and it was assumed that an unsoaked layer remained on the decorative paper. From these experimental results, thermosetting resin decorative laminates using patterned decorative paper have a thermosetting resin S
A layer of decorative paper that does not soak remains, and this layer absorbs water, which causes mold to develop during long-term use of decorative laminates in humid areas. It is judged that

(Means for Solving the Problem) As a result of intensive research in order to develop a patterned decorative board that does not generate mold, the present inventor has discovered that the present inventor has developed a decorative paper with a non-S soaked paper layer remaining even after thorough resin soaking as described above. It has been found that the problem can be solved by using an E1 degree fabric or an inorganic nonwoven fabric, which has a clear pattern and has extremely low water absorption. That is, the present invention uses a decorative substrate,
Or, without using it, a nonwoven fabric with a pattern printed on the surface layer and the base layer material containing at least a liquid thermosetting resin, a filler, and a fiber material are layered, and the JF Book 4 material is placed under pressure. The present invention provides a method for producing a mold-resistant patterned decorative board characterized by hardening and molding.

” In the production method described in 2, for example, unsaturated polyester resin,
A resin selected from the group consisting of allyl resins, acrylic resins, etc., or these resins and wNMf + A material,
For example, if a molding material containing glass fiber or the like is used, -1
- and pressure-molding at the same time, it is possible to easily obtain a decorative board with particularly good appearance smoothness and protection of the surface layer. In addition, using the same resin and thickener as the thermosetting resin that uses the pattern-printed nonwoven fabric as the material for the base layer, a transparent molded sheet using the nonwoven fabric as a material is made, and this is used as the surface layer for the base layer material. It is also possible to perform pressure curing molding in layers.

(Function) It is important to select a nonwoven fabric that can be printed with a clear pattern by any existing technique such as gravure printing or screen printing as the nonwoven 4+ used in the present invention. Suitable nonwoven fabrics for this purpose include inorganic or 6-organic fibers and mixed fibers thereof, and commercially available glass paper or polyester fiber nonwoven fabrics are particularly advantageously used. The thickness of these nonwoven fabrics is 0.
It is necessary that the pattern is clearly printed using any existing technology, and that the printing ink used is evenly applied and fixed in the thickness direction of the nonwoven fabric. must have been done. Therefore, in practical terms, the thickness of the nonwoven fabric is preferably 0.05 to 2.0+ms.
＋Later is better.

On the other hand, the nonwoven fabric used in the present invention not only satisfies the condition of good printability in two series, but also includes a nonwoven fabric 41 with a pattern printed on it, at least a thermosetting resin, a filler and Sen! (When the base layer material containing the IjtA material, that is, the so-called root molding compound (hereinafter abbreviated as SMC) is stacked and pressurized, the material for the base layer needs to be minutely packed into the gaps between the nonwoven fabrics). Needless to say, SMC1: Fillers and fibers contained in 1) do not flow out through the mesh of the nonwoven fabric, and the nonwoven fabric acts as a filter paper, and only the resin passes through the mesh of the nonwoven fabric. It is a necessary condition that the resin oozes out to the surface layer and forms a smooth resin surface layer. When the mesh of the nonwoven fabric is uneven, the filler oozes out together with the resin in the SMC, and the clearly printed pattern becomes unclear and indistinct, resulting in a decorative board with no commercial value. Therefore, a nonwoven fabric that does not meet these conditions is a nonwoven fabric in which organic or inorganic weave is densely arranged, and in the case of glass paper, it is 100 to 1000 g/rri', preferably 2
50-400y:/rr? , 20-200g/ry for polyester fiber non-woven fabric? , preferably 60-150
Non-woven fabrics of g/ba are used to advantage.

Thermosetting resins used in the SMC of the base layer material used in the present invention include unsaturated polyester resins, allyl resins such as diallyl phthalate polymers, acrylic resins, and epoxy resins. , used in combination with polymerization accelerators and additional small association compounds. Also,
As a filler, calcium carbonate, talc, etc., which are generally commercially available, are used, and they have a
It is used in a range of 0 to 140% by weight, preferably 80 to 120% by weight. Furthermore, it is also possible to use titanium white in combination to make the printed pattern clearer.

The fiber materials used in the present invention include inorganic or fi
Machine-based fibers are used.The shape of the fiber material can be short fibers, matte fibers, woven fabrics, etc. alone or in combination, but in general, inexpensive short glass fibers are used. or glass pine) is used for f>−. These fibers (the amount of dye used is 5 to 80% of the thermosetting resin)
Commercial weight% preferably 10 to 50% by weight in the case of short glass fibers
used within the range. In addition, when the decorative board is not used, these fibers 1F and +4 serve as reinforcement for the decorative board.
” will be fulfilled.

The base layer material used in the present invention includes a thermosetting resin as described above, a filler and a small amount of a thickener such as magnesium oxide or isocyanate, and a mixture thereof is impregnated into the fiber material to thicken it. It is preferable to use a SMC with a The thickness of these materials for the base layer is arbitrary and there is no limit, but it is preferable that the material be pressure molded to a decorative board thickness of 0.2 to 3 mm.

Although a decorative substrate may or may not be used, substrates commonly used as decorative substrates, such as veneer plywood, calcium silicate plates, or steel plates, are used.

Among the molding conditions for the molding material in carrying out the present invention,
The molding temperature is 15 to 200°C, preferably 80 to 1
The molding time can be shortened by heat molding at 60° C., and the fluidity of the molding material is improved by lowering the viscosity of the resin, so that the nonwoven fabric can be densely filled into the gaps. In addition, it is desirable to heat-form the resin because it has the effect of facilitating exudation of the resin through the mesh of the nonwoven fabric. On the other hand, the molding pressure during molding must be at least 10 kgf/c-1-, which is necessary for the thermosetting resin in the molding charge to pass through the network of the printed nonwoven fabric and form the surface layer. pressure is required. Preferably, 40 to 100 kg f /cj is desirable under heating at 80° C. or higher. Also,
The pressure molding time requires sufficient time for the blended SMC to harden, and is generally about 3 to 20 minutes.

The mold used in the present invention may be either a resin mold or a metal mold.The surface layer of the mold may be any desired surface layer such as smooth, matte, or embossed so as to obtain the desired decorative laminate surface layer. things are used.

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

Example 1 A 3mm veneer plywood was used as a decorative substrate, and S was used as a base layer material.
0 parts of unsaturated polyester resin 11) as MC, 80 parts of calcium carbonate, 2.5 cm long glass ml ([4
S consisting of 0 parts, 1.1° 2 parts of t-butyl perbenzoe and 1.5 parts of magnesium oxide as a thickener.
MC was prepared. On the other hand, the prefecture 0.000cm is silk-printed in a predetermined pattern. 2+agi.

80 g/rrr polyester fiber 11: nonwoven fabric was prepared.

Place a stainless steel mirror plate with frame spacers of 61Il on the four corners on the lower plate of the Uita molding press, place the nonwoven A II on the bottom), then place the plywood on the SMC and L sides, and immediately The press was clamped with a pressure of 30 kg f /cJ, and molding was carried out at 135° C. for 7 minutes.

The obtained decorative plywood had a smooth appearance and a clear pattern in relief, and had good commercial value. In addition, I used this decorative board on the ceiling of my bathroom for 6 months, and no mold was observed at all.

Example 2 In addition to not using plywood as a decorative board, Example 1
Using exactly the same SMC and nonwoven fabric as in Example 1, a patterned nonwoven fabric decorative board was molded under the same conditions as in Example 1 using a molding press equipped with a 3-frame spacer. The water absorption rate (soaked at 40° C. for 2 weeks) of the obtained decorative board was measured and a value of 0.26% was obtained. On the other hand, the water absorption rate of the SMC single cured board excluding the nonwoven fabric is 0.
．． The figure was about the same as 24%.

Also, after using this decorative board on the ceiling of the bathroom for 6 months, there was no sign of mold growth at all.

Example 3 A 10-1 ■↓ acid calcium board was used as the decorative substrate, the SMC of Example 1 was used as the base layer l1, and as a nonwoven fabric,
300g/rr with printed pattern? A transparent molded sheet obtained by impregnating the glass paper of Example 1 with a resin consisting of 100 parts of the unsaturated polyester resin of Example 1 and 3 parts of magnesium oxide as a thickener was used.

A frame spacer of 12+++m was placed, and heat and pressure molding was performed under the same conditions as in Example 1. The obtained decorative board was a patterned decorative board with a smooth surface.

Also, I used this decorative board on the ceiling of the kitchen for a year, but
No outbreak of heat mold was found.

Example 4 A 4IIIm veneer plywood was used as the substrate, and the SMC of Example 1 was used as the base layer material. Using a pattern-printed polyester fiber nonwoven fabric of 80g/rrr, this nonwoven fabric was pre-impregnated with a diallyl phthalate resin and dried at 80°C.
and veneer plywood are stacked and inserted into a flat plate forming press,
A diallylphthalate polymer resin decorative board was obtained by hot pressing at 140° C. and 40 kgf/cj for 10 minutes.

This diallylphthale!・Polymer resin decorative board is a highly commercially available decorative board with good smoothness, and when it was used on the walls of a commercial kitchen, no mold developed even after 6 months.

Comparative Example 1 A flat plate of 80 g/rf patterned decorative paper bonded to a 10 am calcium silicate plate with urea-vinyl acetate resin was used as a substrate.After coating unsaturated polyester resin on this, it was covered with vinylon film and rolled with a rubber roller. It was degassed and cured by passing it through a curing oven to obtain a normal polyester decorative board.

When this decorative board was attached to the walls and ceiling of a bathroom for practical use, mold was observed to grow within three months.

Comparative Example 2 A diallyl phthalate composite resin decorative board was obtained in the same manner as in Example 4, except that the base layer material SMC was not used. Although the decorative board had a good appearance, when it was used on the walls of a commercial kitchen, mold growth was observed after four months.

(Effects of the Invention) Since the present invention has the above-described configuration, there is no fear that mold will develop even if the obtained decorative board is used in a humid place for a long period of time. be.

Claims (2)

[Claims] (1) Layer a nonwoven fabric with a pattern printed on it to serve as the surface layer and a base layer material consisting of at least a liquid thermosetting resin, a filler, and a fiber material, and then harden and mold the layered product under pressure. A method for manufacturing a mold-resistant patterned decorative board characterized by: (2) The manufacturing method according to claim 1, further comprising using a decorative substrate.