JPH0796592A - Manufacturing method of thermosetting resin decorative board - Google Patents

Abstract

(57) [Summary] [Purpose] There is a fine and clear printed pattern so that there is no flow or distortion of the design. A non-woven fabric 7 is formed on a fibrous base material 6 coated or impregnated with a thermosetting resin, and a transfer sheet 5 is formed by forming a transfer layer including at least a pattern layer on a peelable support sheet. After stacking in this order and so that the transfer layer is on the side of the nonwoven fabric 7 and pressurizing or heating and pressing to cure the thermosetting resin liquid and adhesively integrate the laminate,
The peelable support sheet is peeled off. The fine pattern layer printed on the support sheet is transferred as a part of the transfer layer during molding, and the nonwoven fabric prevents the transfer layer from flowing during molding.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a thermosetting resin decorative board, which is preferably used as a surface material for furniture, kitchen appliances, interior materials for construction, cabinets for low-power appliances and the like.

[0002]

2. Description of the Related Art Conventionally, as a method for producing a thermosetting resin decorative board with a make-up on its surface, a printed non-woven fabric or the like is superposed on a fibrous base material sheet impregnated with a thermosetting resin, Those which are laminated at the same time as thermocompression molding (for example, JP-A-57-191018 and JP-A-62-1).
No. 52733) or a fibrous base material sheet / transfer film impregnated with a thermosetting resin, which is pressed or heated under pressure (for example, JP-B-38-
No. 22732) is known.

[0003]

In the former case described in the prior art, when a fibrous base material sheet such as a non-woven fabric or titanium paper is printed, thread scraps or the like are generated and a problem of dust clogging occurs. There is a problem in that clear printing cannot be performed and a clear picture cannot be provided because the ink is easily removed.

In the latter case, although there is no problem as described above, since the fibrous material containing the thermosetting resin is dissolved and diffused by the pressure and heat in the mold at the time of molding, a thin transfer film. However, there is a problem in that the liquid flows at the same time and the pattern flows and is distorted or the pattern is cracked.

The present invention has been made in view of the above problems, and an object thereof is a thermosetting resin makeup which has a fine and clear printed pattern and has no flow or distortion of the pattern. It is intended to provide a method for producing a thermosetting resin decorative board capable of obtaining a board.

[0006]

In order to achieve the above-mentioned object, a method for producing a thermosetting resin decorative board according to the present invention comprises a nonwoven fabric on a fibrous base material coated or impregnated with a thermosetting resin. And a transfer sheet in which a transfer layer including at least a pattern layer is formed on a releasable support sheet are laminated in this order so that the transfer layer is on the non-woven fabric side, and pressed or heated and pressed. After the thermoplastic resin liquid is cured and the laminate is adhered and integrated, the peelable support sheet is peeled off.

Further, after peeling the peelable support sheet, a transparent coating film may be formed by coating on the surface having the transfer layer.

As the fibrous base material, paper, non-woven fabric, woven fabric,
Felt, mat, etc. are used. Among these, titanium paper, high-quality paper, kraft paper, Japanese paper, etc. can be used as paper, and as non-woven fabric, woven fabric, felt or mat, glass fiber, asbestos, potassium titanate fiber, alumina fiber, silica fiber, carbon fiber It is possible to use those made of inorganic fibers such as, and organic resins such as polyester and vinylon.

As the thermosetting resin, a melamine resin, a diallyl phthalate resin, a guanamine resin, an unsaturated polyester resin, an epoxy resin, a polyurethane resin, etc. are added with a polymerization initiator, a cross-linking agent, an extender pigment, etc., if necessary. Stuff used.

Impregnation of a state in which the resin is filled in the fibrous base material layer by penetrating into the fibrous base material layer, and it does not penetrate into the fibrous base material layer at all or reaches the back surface even if it penetrates. In the present invention, either coating or impregnation may be defined as the state where the coating is not applied. Then, as specific means for applying or impregnating, roll coating, flow coating,
Comma coat, dipping, brushing, pouring etc.

An example of a fibrous base material coated or impregnated with a thermosetting resin is SMC (sheet molding compound), which is manufactured by, for example, one side of a first separator film such as a polyethylene film.
Resin prepolymer, curing catalyst, accelerator, curing retarder,
A chopped strand obtained by cutting a glass roving made by bundling glass fibers after applying a resin compound prepared by kneading an air drying agent and a filler such as calcium carbonate, talc, clay, etc. by a knife coating method etc. After spraying, a separate resin compound similar to that applied to one surface of the first separator film is applied to one surface of the second separator film by the same application method, and then the first separator film and the second separator film are applied. The separator films are stacked so that the resin compound-coated surfaces of both separator films face each other via the spread chop strands, and pressure is applied by roll pressure to impregnate / remove the resin compound spread chop strands. A method of foaming, humidifying and curing is adopted. The resin for producing the SMC is not particularly limited, but usually unsaturated polyester or epoxy is often used.

Next, an outline of an SMC molding method for producing an FRP article using the above SMC will be described. An equipment capable of applying heat and pressure to a pair of opposing molds,
Usually, a large heat press with a mold installed is used.
Cut the SMC to the required size in the mold, peel off the front and back films, and place it. Also, after stacking several sheets if necessary, set the temperature to 1
It is heated and pressed under the conditions of 00 to 180 ° C. and a pressure of 30 to 200 kg / cm ² for 1 to 8 minutes to be cured by a reaction such as cross-linking polymerization and addition polymerization, and then molded.

As another example of the fibrous base material coated or impregnated with the thermosetting resin, titanium paper (titanium oxide powder mixed paper) having a weight of about 50 to 150 g / m ² per square meter of melamine resin or diallyl phthalate is used. Examples thereof include those obtained by impregnating a resin prepolymer solution and drying the solvent.

The transfer sheet transfers a transfer layer composed of a pattern layer or the like once formed on the releasable support sheet to another transfer target, and the releasable support sheet may be released as necessary. A layer may be provided, and the transfer layer includes a decorative layer such as a metal vapor deposition layer, a peeling layer, an adhesive layer, etc. in addition to the pattern layer,
One or more of these layers are selected as required. In addition,
Here, the release layer is a layer that remains on the support sheet side after transfer and facilitates peeling from the transfer layer, and the release layer transfers to the transfer target side after transfer to protect the surface of the transfer layer. Say a layer that will be a layer. The peeling is performed between the release layer and the peeling layer. The pattern layer and the decorative layer may be provided on the front surface or partially, and the pattern may be a design of natural products such as wood grain, stone grain, cloth grain, letters, figures, symbols, or various abstract patterns. .

As the releasable support sheet used for the transfer sheet, a film having a releasability of 5 to 200 μm from the transfer layer is used. Examples of the material include polyester resins such as polyethylene terephthalate, polybutylene terephthalate and polyethylene terephthalate / isophthalate copolymers, polyolefin resins such as polyethylene, polypropylene and polymethylpentene, or polypropylene on the surface of paper such as fine paper and thin paper. Those coated with a polyolefin resin such as polymethylpentene are used.

As the release layer, a coating film of a paint in which a release agent such as a fluororesin, various waxes and silicones is added to a known vehicle such as an acrylic resin, a fibrin resin or a vinyl resin is formed. Or a releasable resin such as a fluorine-based resin, silicone, melamine-based resin, polyolefin resin, ionizing radiation cross-linkable polyfunctional acrylate, polyester, or epoxy resin is applied, and a film is formed by extrusion coating or the like. Use the one that you made.

As the release layer, a resin composition having a release property with respect to the release support sheet and having desired physical properties as the surface protective layer of the transfer layer after completion of transfer is selected. In particular, when surface scratch resistance, chemical resistance, and stain resistance are required, a thermosetting resin or an ionizing radiation curable resin is usually used. The film thickness is also selected depending on the desired physical properties and the like, but is usually 0.1 to 10 μm. Examples of the thermoplastic resin used include ethyl cellulose, cellulose nitrate, cellulose acetate, ethyl hydroxyethyl cellulose, cellulose derivatives such as cellulose acetate propionate,
Styrene resin or styrene copolymer such as polystyrene and poly α-methylstyrene, acrylic resin such as polymethyl methacrylate, polyethyl methacrylate, polyethyl acrylate and polybutyl acrylate, polyvinyl chloride, polyvinyl acetate, chloride There are vinyl copolymers such as vinyl / vinyl acetate copolymer and polyvinyl butyral.

The adhesive layer is a layer for transferring and adhering the transfer layer to the transferred material, and is a heat-sensitive adhesive, a solvent activated adhesive,
Select from ionizing radiation curable adhesives etc. according to the application. The adhesive layer may be omitted when the transfer layer other than the adhesive layer such as the pattern layer and the release layer has sufficient adhesiveness. The heat-sensitive adhesive exhibits adhesiveness by heating, and the resin used is polystyrene, a styrene resin such as poly α-methylstyrene or a styrene copolymer, polymethyl methacrylate, polyethyl methacrylate, polyacrylic. Acrylic resin such as ethyl acetate and polybutyl acrylate, polyvinyl chloride, polyvinyl acetate, vinyl chloride / vinyl acetate copolymer, vinyl copolymer such as polyvinyl butyral, polyisoprene rubber, polyisobutylene rubber, styrene butadiene rubber There are rubber-based resins such as butadiene acrylonitrile rubber.

As the transparent coating film provided as necessary, a thermosetting resin such as unsaturated polyester, polyurethane or epoxy, or an ionizing radiation curable resin is preferably used. In addition to being colorless and transparent, various dyes and pigments are added to make it transparent.
It may be matt transparent. That is, the transfer layer should not be hidden. Here, as the ionizing radiation, visible rays, ultraviolet rays, electron beams and the like are used.

As a specific means for applying pressure or heat to cure the thermosetting resin layer and bond and integrate the laminate, a fibrous base material layer between two flat plates and an uncured thermosetting resin are used. A laminate of resin and decorative sheet is sandwiched and press-formed by pressurizing or heating both flat plates, and biaxially stretched in a square-shaped form as is conventionally done in the manufacture of unsaturated polyester decorative plates. A method in which a polyethylene terephthalate film is tensioned and attached, and the four corners are fixed to a mold, and the film surface is placed on the surface of the uncured resin and pressed, in the cavity between the male and female molds The so-called stamping molding in which the laminated body is inserted and pressure or heat and pressure is applied by both molds is used. The heating is performed to start or accelerate the crosslinking of the thermosetting resin or the polymerization reaction itself, and may be omitted if heating is not required. In addition, the temperature for heating depends on the type of resin,
Although it is determined by the composition, it is usually about 40 to 150 ° C.

The shape of the thermosetting resin decorative plate may be a flat plate, a curved plate or the like. Further, if necessary, various base materials may be lined and laminated on the back surface (opposite surface of the decorative sheet) of the decorative plate of the present invention. As the backing base material, a plate or sheet made of synthetic resin, metal, wood or the like is appropriately used.

[0022]

In the method for producing a thermosetting resin decorative board of the present invention having the above-mentioned structure, a fine pattern layer is printed on a support sheet having a flat surface and having printability, which is used as a transfer layer during molding. Since it is transferred as a part, a clear pattern is provided, and at the same time, the non-woven fabric plays a role of preventing the flow of the transfer layer at the time of molding, thereby preventing the flow and distortion of the pattern. Further, if the support sheet is left attached, it is left until the time of use or a post-process such as coating and is peeled off when necessary, the support sheet directly serves as a protective film.

[0023]

Embodiments of the present invention will be described below with reference to the drawings.

A biaxially stretched polyethylene terephthalate film (Toray: F65) having a thickness of 26 μm was prepared, and as shown in FIG.
On the support sheet 1, as shown in FIG. 1, an acrylic resin (Showa Ink Mfg. Co., Ltd .: Haku 46-7) release layer 2, an ink containing a mixture of acrylic and vinyl chloride / vinyl acetate copolymer as a binder. (Showa Ink Mfg. Co., Ltd .: B
A transfer sheet 5 was prepared by sequentially forming a pattern layer 3 of C heat resistance) and an adhesive layer 4 made of a mixture of acrylic and vinyl chloride / vinyl acetate copolymer by a gravure printing method. The design was a marble stone pattern.

Next, two sheets of SMC6 having an unsaturated polyester prepolymer and glass fiber as components and a thickness of 2 mm were prepared, the separator films on the front and back sides thereof were peeled off and stacked, and then the transfer sheet 5 and the polyester resin were laminated. Non-woven fabric 7
(Made by DuPont Japan: Sontara 8000, weight 41
g) are superposed and laminated so that the transfer layer of the transfer sheet 5 is on the nonwoven fabric 7 side, and this is set in the mold 8 as shown in FIG. 2 at a temperature of 130 to 150 ° C. and a pressure of 20 to 100.
Molding was performed by heating and pressurizing at kg / cm ^{2 for} about 6 minutes.
Thus, a vanity panel having a protective film (support sheet) on the surface was obtained. Then, the support sheet on the surface was peeled off before use.

[0026]

As described above, according to the method for producing a thermosetting resin decorative board of the present invention, the fine pattern layer printed on the support sheet is transferred as a part of the transfer layer during molding, Furthermore, since the nonwoven fabric prevents the transfer layer from flowing at the time of molding, it is possible to manufacture a decorative board having a fine and clear printed pattern and having no pattern flow or distortion.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of a transfer sheet.

FIG. 2 is a schematic cross-sectional view showing a state in which a laminated body is bonded and integrated in a mold.

[Explanation of symbols]

 1 Support Sheet 2 Release Layer 3 Picture Layer 4 Adhesive Layer 5 Transfer Sheet 6 SMC 7 Nonwoven Fabric 8 Mold

Claims (2)

[Claims] 1. A non-woven fabric on a fibrous base material coated or impregnated with a thermosetting resin, and a transfer sheet comprising a releasable support sheet on which a transfer layer containing at least a pattern layer is formed. Sequentially and stacking them so that the transfer layer is on the non-woven fabric side, pressurizing or heating and pressing to cure the thermoplastic resin liquid and adhesively integrate the laminated body, and then peel the peelable support sheet. A method for producing a thermosetting resin decorative board, which comprises: 2. A non-woven fabric on a fibrous base material coated or impregnated with a thermosetting resin, and a transfer sheet formed by forming a transfer layer containing at least a pattern layer on a peelable support sheet. After stacking them in order, and stacking them so that the transfer layer is on the nonwoven fabric side, pressurizing or heating and pressurizing to cure the thermoplastic resin liquid and adhesively integrating the laminate, and peeling the peelable support sheet. 2. A method for producing a thermosetting resin decorative board, which comprises forming a transparent coating film on the surface having a transfer layer.