JPS58201645A - Manufacture of melamine resin decorative material - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a melamine resin decorative material.

Conventionally, melamine resin decorative boards have been produced by laminating six surface layer sheets made of decorative paper impregnated with melamine resin and a core layer sheet made of kraft paper or the like impregnated with phenol resin, and then hot-press molded. However, it took a long time to cure the phenol resin, resulting in a long molding cycle and poor productivity.

Naturally, therefore, continuous molding was completely impossible.

The present invention relates to a method for producing a melamine resin decorative material that solves the above-mentioned problems.More specifically, the present invention relates to a surface layer sheet in which overlay paper, decorative paper, etc. is impregnated with melamine resin, and a phenol resin in a base material such as kraft paper. Using a core layer sheet impregnated with phenol resin and an auxiliary sheet in which a porous base material is impregnated with a curing agent, curing accelerator, etc. that accelerates the curing reaction of phenolic resin, the auxiliary sheet is placed between the core layer sheets. The present invention relates to a method for producing a melamine resin decorative material, which is characterized by hot-press molding a laminate in which a sheet for a surface layer is superimposed on the laminate.

The curing agent and curing accelerator retained in the porous base material include:
Ingredients that increase the curing speed of phenolic resins, such as oxalic acid, sheselic acid, organic acids with 11% citric acid, latent acidic substances such as halatoluenesulfone I, or other polymerizable monomers such as acrylic acid and maleic anhydride. Prepolymers, polymers, and phosphorus I! copolymerized with monomers of Inorganic acids such as iI can be used to prepare paper, cloth, non-woven fabrics, etc. made from natural fibers such as cellulose fibers, kraft fibers, and linter fibers, or synthetic fibers such as vinylon, nylon, and acrylic. The auxiliary sheet is made by impregnating or coating a porous base material and holding it.

However, in a semi-heterogeneous system using ffm impregnated paper, the mixing rate of acidic substances is slower than in a simple mixing system, so it is necessary to adopt a method that allows the mixing to proceed as much as possible. . For example, these problems can be solved by interposing the auxiliary sheet between the sheets for the core layer, or by selecting a porous material with a small basis weight and good permeability as the base material. Further, the auxiliary sheet may be placed between the surface layer sheet and the core layer sheet.

The core layer sheet and the surface layer sheet can be made by impregnating the same porous base material as above with a resol type phenol resin and a melamine formaldehyde resin.

As mentioned above, the purpose of the present invention is to shorten the molding cycle of melamine resin decorative materials and to achieve continuous molding. Next, we will discuss a molding method for carrying out continuous molding. This is a schematic diagram of the molding equipment to be adopted, in which two endless belts (5) (5) I'IIJ'lK surface layer sheet <rzu, core layer sheet Korean, running in parallel in the same direction and at the same speed. , Q-ri and auxiliary sea)
(11) is continuously inserted, and is continuously heated and pressurized by heating means consisting of a heating plate attached to the molding device ffK and pressurizing means using compressed air. Heating oil or steam is circulated through the heating plate (72), and the heating can be adjusted to a predetermined temperature if it is below 250°C, and the pressure can be adjusted to 1 to 2 with a pressure regulator.
5■- The pressure can be adjusted to a predetermined level in the cabinet, and continuous molding can be performed under certain conditions.

Furthermore, by controlling the running speed of Endrespel (5) (5), it is possible to adapt to the molding conditions of the melamine resin and the core layer.

We also use etched steel endless belts, stainless steel endless belts, and use embossed paper, embossed resin sheet woven fabric, embossed metal sheets, etc. that can withstand multiple molding conditions between the endless belt and the surface J-sheet. By inserting the shaped sheet, it is embossed and finished, allowing the molding of decorative materials with excellent three-dimensionality and touch.

Furthermore, for continuous molding, in addition to the above molding method, as shown in Fig. 2, a molding material is inserted between a molding drum (7) with a heating mechanism and a steel belt O11, and a hydraulic cylinder Or) is used. In addition to a method in which molding pressure is applied by the tension of an applied steel belt and molding is performed by continuously applying pressure and heating, a molding method using continuous rolls can be adopted.

According to the method for manufacturing a melamine resin decorative material according to the present invention, the molding process has conventionally been carried out using a high-pressure press for a long time, but since the molding time can be significantly shortened, the molding efficiency can be significantly improved. In addition, energy saving is achieved because the heating time is shortened, and at the same time, impregnated paper, etc. is automatically inserted into the molding process, which eliminates the preparation (setting) process for laminating impregnated paper, etc., which was necessary in conventional batch presses. It is no longer necessary and labor savings have also been achieved.

Example, Comparative Example Basis weight 50f/W? α-cellulose paper was impregnated with melamine resin containing a hardening agent at a resin rate of 80 cm to form a sheet for the surface layer, and kraft paper with a basis weight of 120 f/ff/ was impregnated with a resol type phenol resin at a resin rate of 60 cm. Each sheet for the core layer was created. Also, the average weight is 301% α
Impregnation of cellulose paper in 50% methanol solution of para-toluene sulfonic acid.
I created auxiliary sheets for 01 and H150. As an example, the auxiliary sheet was laminated between each of the core sheets, and then the surface layer sheet was laminated, and the decorative material of the example was hot-press molded. Further, as a comparative example, a sheet for the surface layer was laminated on the two sheets for the core layer, and a composite material of the comparative example was molded.

The results were as shown in Table-1.

Table-1 *Note: Molding time at which a molded product without blistering or peeling was obtained after being left in boiling water for 30 minutes

[Brief explanation of the drawing]

Figure 1 is a schematic diagram of a molding device that inserts a molding material between two running endless belts and pressurizes and heats it from the back side of the endless belt to continuously mold the material. Figure 2 shows a heating molding drum (7 ) and a steel belt QG, a molding pressure is applied by the tension of the steel belt applied by a hydraulic cylinder 01), and the molding material is continuously heated and pressurized to form the molding device. be. 1.9... Tension 1 roll 2... Drive roll 3... Pressure palm 4...
··compressor

Claims (1)

[Claims] 1. Pattern paper in which a porous base material is impregnated with melamine resin;
A sheet for the surface layer such as overlay paper, a sheet for the core layer in which a porous base material is impregnated with a resol type phenol resin, and an auxiliary sheet in which the porous base material is impregnated with a phenol resin curing agent or curing accelerator are appropriately prepared. A method for manufacturing a melamine resin decorative material, which is characterized by laminating a laminated core layer and hot-pressing molding. 2. A method for manufacturing a melamine resin decorative material according to claim 1, which involves continuous molding.