JP4417752B2 - Post foam decorative board and manufacturing method thereof - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a post-form decorative board having a curved surface used for interiors of buildings and vehicles, and a method for manufacturing the same.

  A melamine decorative board is usually manufactured by using melamine resin-impregnated paper on the surface and phenol resin-impregnated paper on the core part, and laminating them and heating and pressing at high temperature and high pressure. Both the surface layer melamine resin and the core layer phenolic resin are thermosetting resins, but the surface layer melamine resin has high hardness, heat resistance, rigidity and durability as a decorative board, etc. Therefore, it is used for applications that require mechanical strength and durability, such as desk tops and counters. Figured.

  Since the melamine decorative board has such a high rigidity, it is necessary to heat it up to a high temperature in order to develop plasticization of the decorative board and to perform post-form molding. Heating conditions such as heating temperature and heating time must be set according to the softening temperature, which is a characteristic of the melamine decorative board, or the type of post-form processing equipment, and are found from long-term experience and intuition. ing.

For example, in post-form processing, it is necessary to process the base substrate in accordance with the specified shape. Immediately before the processing, an adhesive is applied to the adhesive surface between the melamine decorative board and the processed base substrate. Affixing is performed along the shape of the base substrate while pressure-bonding the melamine decorative board plasticized by heating. Japanese Patent Application Laid-Open No. 8-1850 describes the use of a synthetic rubber adhesive in which an isocyanate curing agent is added to a chloroprene rubber adhesive for such adhesion.
JP-A-8-1850 (Claim 1)

  In post-form processing, it is necessary to heat the decorative plate at a high temperature as described above. Therefore, it is necessary to use a processing device having a function capable of heating to a high temperature, and the operation procedure is inevitably complicated. A processing apparatus having such a high-temperature heating function is special, and its use is limited to the post-form processing operation of the melamine decorative board. Therefore, factories having such special processing devices and craftsmen who are skilled in operation are limited, leading to an increase in the cost of post-form processed products.

  Furthermore, in the final processing step of post-form processed products, it is necessary to finish processed products having a three-dimensional solid shape, but woodworking such as commonly used panel saws, NC control routers, multi-axis drilling machines, etc. Since the equipment for processing is for flat plate processing and is not suitable for the final processing work of post-form processed products, a dedicated processing device is used. However, since there are generally few processing factories with such dedicated equipment, most of the processing is often done manually using tools such as circular saws, hand routers, and trimmers. It will require careful work. As a result, there has been a problem that the productivity of the post-form processed product cannot be improved and the manufacturing cost increases.

  In addition, since melamine resin and phenol resin, which are constituent resins of melamine decorative boards used for post-form processing, are both thermosetting resins, the condensation reaction further proceeds by heating during processing, and curing and shrinkage accompanying this. Therefore, there has been a problem that shrinkage of the entire decorative surface due to heating during post-form processing is unavoidable. For this reason, warpage is likely to occur in the processed product, and the dimensional accuracy and bending angle accuracy are likely to be distorted, making high-precision processing difficult.

  For this reason, if a post-form decorative board that can be easily bent at room temperature and can maintain high shape accuracy and dimensional accuracy after processing is obtained, the base substrate layer is bent in advance, or a high-temperature heating step Etc. can be omitted, and a significant cost reduction can be achieved, which is extremely convenient.

  On the other hand, melamine decorative boards have been used for a long time as interior materials for railway vehicles because of their excellent properties as flame retardant materials. However, inferior processability has been a drawback, and in recent years, the parts to be used have been limited.

  Therefore, the object of the present invention is that bending can be easily performed at room temperature, high shape accuracy and dimensional accuracy can be maintained after processing, and further, it is in compliance with the incombustible non-combustibility standard of railway vehicle materials that are the standard for flame retardant materials. An object of the present invention is to provide a post-form decorative board that passes and a method for manufacturing the same.

  In such a situation, the present inventors have intensively studied. As a result, if the pressure-sensitive adhesive is used to bond the decorative layer constituting the post-form decorative board and the base substrate layer, the heating step is not performed. It is found that a post-form decorative board that can be easily bent at room temperature, can maintain high shape accuracy and dimensional accuracy after processing, and that passes the flammability and non-combustibility standards of railway vehicle materials. The invention has been completed.

That is, the present invention has a decorative layer, a base substrate layer, and an adhesive layer formed by bonding the decorative layer and the base substrate layer, and the decorative layer contains a melamine resin and an aqueous thermoplastic resin. And the adhesive layer contains one or two pressure-sensitive adhesives selected from a synthetic rubber pressure-sensitive adhesive and an acrylic pressure-sensitive adhesive, and the base substrate layer is made of an aluminum plate. A featured post-form decorative panel is provided.

The present invention is also a method for producing the post-form decorative board, comprising a decorative layer material containing a melamine resin and an aqueous thermoplastic resin , a synthetic rubber-based pressure-sensitive adhesive, and an acrylic-based pressure-sensitive adhesive. It is characterized by laminating an adhesive layer material containing one or two selected pressure-sensitive adhesives and a base substrate layer material made of an aluminum plate in this order, and pressurizing and adhering the laminate. A method for manufacturing a post-form decorative board is provided.

  The post-form decorative board of the present invention can be easily obtained by bending at room temperature. In addition, high shape accuracy and dimensional accuracy can be maintained after bending. The manufacturing method of the post-form decorative board of this invention can reduce a process man-hour significantly compared with the conventional manufacturing method. Also, in post-form processing, special features related to the decorative plate manufacturing apparatus and its technology are removed, and general-purpose devices and general-purpose techniques used in general decorative plate processing are sufficient, which can contribute to cost reduction and productivity improvement. . Furthermore, by passing the flammable incombustibility standard for railway vehicle materials, it can be used in various parts because of the ease of bending in interior applications such as railway vehicles.

  A post-form decorative board (hereinafter, also referred to as “PF decorative board”) in an embodiment of the present invention has a decorative layer, a base substrate layer, and an adhesive layer formed by bonding the decorative layer and the base substrate layer. The adhesive used in the adhesive layer is a pressure sensitive adhesive.

  The decorative layer in the PF decorative board of the present invention is not particularly limited. For example, a resin-carrying decorative substrate obtained by supporting a resin or a resin composition on a decorative substrate such as decorative paper, alone or together with other constituent materials The one formed by pressure molding may be mentioned.

The decorative paper is not particularly limited. For example, a paper made by mixing a pigment in cellulose such as pulp, or a printed decorative paper obtained by printing a pattern or color on cellulose such as pulp by a gravure printing method or an ink jet printing method. Can be mentioned. When such papermaking paper or printing decorative paper is used, the weighing is not particularly limited, but usually 50 to 150 g / m ² can be used.

  The resin or resin composition is not particularly limited, and examples thereof include a thermosetting resin, a thermoplastic resin, or a mixture thereof. In addition, inorganic fillers such as alumina and silica, and organic fillers such as pulp and pulp floc can be blended as necessary.

  The thermosetting resin is not particularly limited, and examples thereof include novolac type phenol resins such as phenol nopolac resin, cresol novolac resin, bisphenol A novolak resin, unmodified resole phenol resin, tung oil, linseed oil, walnut oil, and the like. Modified phenolic resin such as resol type phenolic resin such as oil-modified resol phenolic resin, bisphenol type epoxy resin such as bisphenol A epoxy resin and bisphenol F epoxy resin, novolak type epoxy resin such as novolac epoxy resin, cresol novolac epoxy resin, biphenyl Type epoxy resin, epoxy resin, urea (urea) resin, resin having triazine ring such as melamine resin, unsaturated polyester resin, bismaleimide resin, polyurethane resin, diallyl phthalate DOO resins, silicone resins, resins having a benzoxazine ring, cyanate ester resins. One or more of these can be used in combination.

  The thermoplastic resin is not particularly limited. For example, polyolefins such as polyethylene, polypropylene, and ethylene-vinyl acetate copolymer, cyclic polyolefins and modified polyolefins, polystyrene such as nylon 6, nylon 46, nylon 66, nylon 610, nylon 612, nylon 11, nylon 12, nylon 6-12, nylon 6-66 and other polyamides, polyimide, polyamideimide, polycarbonate, poly- (4-methylpentene-1), ionomer, polymethyl methacrylate, and other acrylic resins, Acrylonitrile-butadiene-styrene copolymer (ABS resin), acrylonitrile-styrene copolymer (AS resin), styrene copolymers such as butadiene-styrene copolymer, polyoxymethylene, poly Polyester resins such as ethylene terephthalate, polyphenylene oxide, polyphenylene sulfide, polycarbonate, polyether, polyether ether ketone, polyether imide, polyacetal and other heat resistant resins, aromatic polyester and other liquid crystal resins, styrene, polyolefin, poly Various thermoplastic elastomers such as vinyl chloride, polyurethane, polyester, polyamide, polybutadiene, trans polyisobrene, fluoro rubber, and chlorinated polyethylene, or copolymers and blends mainly composed of these. And polymer alloys. One of these can be used alone, or two or more can be mixed and used. Among these, a melamine resin, which is a thermosetting resin, is preferable in that heat resistance, stain resistance, hardness, and transparency can be imparted to the surface of the decorative layer.

  Moreover, in addition to the above-mentioned characteristics, the resin composition used in combination with the melamine resin and the aqueous thermoplastic resin can impart flexibility and make the decorative board suitable for bending. It is preferable in that it can be performed. The aqueous thermoplastic resin is a thermoplastic resin that can be dissolved in water or easily dispersed in water, and is not particularly limited, and examples thereof include an aqueous acrylic resin, an aqueous urethane resin, a vinyl acetate resin, and polyvinyl alcohol. One of these may be used alone, or two or more may be used in combination. Among these water-based thermoplastic resins, water-based acrylic resins are particularly preferable in that they can impart dimensional stability and light discoloration resistance to the decorative layer.

  When the melamine resin and the aqueous thermoplastic resin are used in combination, the blending ratio is not particularly limited, but the aqueous thermoplastic resin is preferably 5 to 60 parts by weight, more preferably 15 to 25 parts per 100 parts by weight of the melamine resin. Parts by weight. Thereby, the characteristic which a melamine resin and an aqueous thermoplastic resin have can be expressed with sufficient balance. When the blending amount of the aqueous thermoplastic resin is less than the above lower limit, the effect of blending the aqueous thermoplastic resin may not be sufficient. Moreover, when the said upper limit is exceeded, the surface hardness and heat resistance which a melamine resin has may fall.

  The method for supporting the resin or resin composition on the decorative substrate is not particularly limited. For example, the method of immersing the cosmetic substrate in a resin varnish obtained by diluting the resin or resin composition with water or an organic solvent, the resin Alternatively, a method of preparing a dispersion in which a resin composition prepared in a solid powder form is dispersed in a poor solvent such as water, and supporting the adjusted solution on a decorative base material, and solidifying the resin or resin composition Examples include a method in which a powdery base material is directly supported on a decorative base material. Among these, the method of immersing the decorative base material in the resin varnish is preferable in that the resin base material can be uniformly and easily impregnated in the decorative base material.

  In the resin-supported decorative base material, the amount of the resin or resin composition to be supported on the decorative base material is not particularly limited, but may be 40 to 60% by weight in terms of solid content with respect to the entire resin-supported decorative base material. preferable.

  After the resin or resin composition is supported on the decorative base material as described above, it is preferably heated to remove most of this when water or an organic solvent is used, and to the thermosetting resin. Then, it can be in a semi-cured state, and a resin-carrying decorative base material excellent in handleability can be produced.

  As the decorative layer in the PF decorative board of the present invention, the above-mentioned resin-supported decorative base material can be used either alone or with other constituent materials. Although it does not specifically limit as another structural material, For example, the material for protective layers used for the design surface side of a resin carrying decorative base material is mentioned, for example. Moreover, the metal foil used on the opposite side (adhesion layer side) of the design surface of the resin-carrying decorative base material or a thermoplastic resin sheet having non-hygroscopic permeability can be used. In the case of using a metal foil or a non-moisture permeable thermoplastic resin sheet on the opposite side of the design surface of the resin-carrying decorative substrate, an adhesive or thermosetting is used for adhesion to the resin-carrying decorative substrate. A functional resin-supporting substrate can be used in combination.

Although it does not specifically limit as said protective layer material, Usually, what carried the thermosetting resin on the base material for protective layers is mentioned. Although it does not specifically limit as a base material for protective layers, It is preferable that it is a highly transparent paper base material which has little ash content or does not contain ash content at all, Specifically, (alpha) -cellulose component is contained abundantly. Wood pulp fiber paper or linter cotton fiber paper can be used. The weight of the protective layer base material is not particularly limited, but for example, about 10 to 50 g / m ² can be used.

The protective layer material can be obtained by, for example, supporting the resin or resin composition used for the resin-supported decorative base material on the protective layer base material, and the same method can be applied as a method for supporting the material. Can do. The weight of the obtained protective layer material is not particularly limited, but for example, a material of about 35 to 80 g / m ² can be used. Such a protective layer imparts mechanical strength, heat resistance, and chemical resistance to the surface of the decorative board, and improves the durability of the pattern and color printed on the decorative layer.

  As the metal foil, an aluminum foil is preferable from the viewpoints of workability, price, and the like. Although it does not specifically limit as metal foil thickness, 0.01-0.30 mm is preferable, More preferably, it is 0.02-0.20 mm. By using such a metal foil, a dimensional change due to moisture absorption from the lower layer surface can be suppressed, and heat dissipation can be improved, so that heat resistance can be improved. Moreover, the mechanical strength excellent in handling can be provided to the decorative layer.

  The thermoplastic resin sheet having non-hygroscopic permeability is not particularly limited. For example, polyethylene, vinyl acetate, polypropylene, ABS resin, polyvinyl chloride, polyamide, polyethylene terephthalate, ethylene-α olefin copolymer, vinylidene chloride, In addition to polybutadiene, polyether sulfone, polyether ether ketone and the like, or a copolymer mainly composed of these, a sheet obtained by molding these blends, polymer alloys and the like can be used. Among these, a sheet obtained by molding a blend of polyethylene and vinyl acetate is preferable in terms of adhesion to other materials, high non-hygroscopic permeability, and low cost.

  Although it does not specifically limit as a thickness of the thermoplastic resin sheet which has non-hygroscopic permeability, it is 0.01-0.30 mm. More preferably, it is 0.08-0.20 mm. By using such a non-hygroscopic permeability thermoplastic resin sheet, dimensional change due to moisture absorption from the base substrate layer can be suppressed. Moreover, mechanical strength and flexibility excellent in handling can be imparted to the decorative layer.

An adhesive or a thermosetting resin-carrying substrate can be used for adhesion between the resin-carrying decorative substrate and the metal foil or the thermoplastic resin sheet having non-hygroscopic permeability. Although it does not specifically limit as an adhesive agent, For example, ethylene-vinyl acetate resin, aqueous acrylic resin, an epoxy resin, rosin modified phenol resin, rosin modified alkyd resin etc. are mentioned. Among these, ethylene-vinyl acetate resin and epoxy resin are preferable from the viewpoint of workability during adhesive coating and practical characteristics of the decorative board. When an adhesive is used, as its coating amount is not particularly limited, 5 to 30 g / ^{m 2} in solids, preferably 5 to 20 g / ^{m 2.} If the coating amount of the adhesive is less than the above lower limit value, the interlayer adhesive strength may not be sufficient, and if it exceeds the above upper limit value, it may not be economical.

  In addition, when using a thermosetting resin-supported substrate, for example, use a material in which a thermosetting resin such as phenol resin or epoxy resin is supported on a substrate such as kraft paper together with a curing agent if necessary. Can do. The same method as in the case of the resin-supported decorative base material can be applied as the method of supporting.

  The molding conditions for pressure molding the resin-supporting substrate alone or with other constituent materials are not particularly limited, but the temperature is usually 110 to 160 ° C, preferably 120 to 150 ° C, and the pressure is 1 to 12 MPa, preferably 6 to 11 MPa.

  In the PF decorative board of the present invention, the thickness of the decorative layer obtained as described above is not particularly limited, but is preferably 0.15 to 0.8 mm. More preferably, it is 0.3-0.5 mm. Thereby, it can make it easy to process at normal temperature, maintaining the characteristic as a surface layer of a decorative board.

  Next, the adhesive layer in the PF decorative board of the present invention will be described. The adhesive layer has a function of adhering the decorative layer and the base substrate layer, and the adhesive used in the adhesive layer is a pressure-sensitive adhesive.

  The pressure sensitive adhesive used in the present invention is not particularly limited, and examples thereof include rubber pressure sensitive adhesives and acrylic pressure sensitive adhesives. Pressure sensitive adhesives apply a slight pressure at room temperature for a short time without using water, solvent, heat, etc., using the adhesive force of the pressure sensitive adhesive itself (spontaneous adhesion ability) It is an adhesive that adheres to the surface of a substance alone, and is also called an adhesive. Therefore, the pressure-sensitive adhesive used in the present invention is clearly different from a conventional synthetic rubber adhesive such as a chloroprene rubber adhesive that is bonded by heating.

  As the rubber-based pressure-sensitive adhesive, either a natural rubber-based or synthetic rubber-based pressure-sensitive adhesive may be used. Synthetic rubber pressure sensitive adhesives include butyl rubber (IIR), butadiene rubber (BR), styrene-butadiene rubber (SBR), isoprene rubber (IR), neoprene, polyisobutylene (PIB), acrylonitrile-butadiene rubber (NBR) Styrene-isoprene block copolymer (SIS), styrene-butadiene block copolymer (SBR), styrene-ethylene-butadiene block copolymer (SEBS), and the like.

  Examples of the acrylic pressure-sensitive adhesive include homopolymers or copolymers of acrylic monomers such as ethyl acrylate, methyl methacrylate, 2-hydroxyethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, and acrylic acid. Furthermore, the monomer etc. which can be copolymerized with the said acryl-type monomer are mentioned. The polymerization is not particularly limited, and examples thereof include solution polymerization and emulsion polymerization. Among these, acrylic pressure-sensitive adhesives are excellent in terms of heat resistance and light resistance.

  In the pressure-sensitive adhesive layer, known additives such as a release agent, a tackifier, a plasticizer, an anti-aging agent, a stabilizer, a filler, a pigment, and an antioxidant are blended as necessary. Also good.

  The adhesive layer may be only the pressure-sensitive adhesive layer, or may have a support layer for reinforcing the pressure-sensitive adhesive between the pressure-sensitive adhesive layers. There is no restriction | limiting in particular in the material of a support body layer, For example, a nonwoven fabric, a synthetic rubber sheet, a resin film, a foam etc. are mentioned.

  The adhesive layer preferably has a thickness of 30 μm or more and less than 250 μm, more preferably 30 μm or more and less than 200 μm. If the thickness is less than 30 μm, the pressure-sensitive adhesive layer cannot exhibit sufficient adhesive strength, and the end portion is lifted or peeled off during bending. On the other hand, if it is 250 μm or more, the pressure-sensitive adhesive layer functions as a heat insulation layer, and in the flammability test of the railway vehicle material, heat dissipation from the test surface is prevented and the temperature rise is accelerated, so that it is difficult to obtain nonflammability performance. That is, when the thickness of the adhesive layer is in the above range, sufficient adhesive strength and incombustible performance are simultaneously provided. The thickness of the adhesive layer is a value obtained by subtracting the measured thickness value of the decorative layer and the measured thickness value of the base material layer from the measured thickness value of the post-form decorative board. The thickness of these plate-like materials can be measured by a method based on JIS K6902. That is, hold the plate to be measured horizontally or vertically, measure the outer circumference of a total of 8 places with a micrometer, 2 places on each side along the inside which is 10 cm or more away from the periphery, and the average value thereof is the thickness .

  When a pressure-sensitive adhesive layer having a support layer is used as the adhesive layer, the thickness of the support layer is preferably 50 μm or less. Further, it is necessary that a pressure-sensitive adhesive layer is coated on each side of the support layer by 30 μm or more. This is because if the thickness of the support layer exceeds 50 μm, the shear shear force generated in the adhesive layer during bending cannot be sufficiently relaxed. Furthermore, if the surface of the support layer does not have a pressure-sensitive adhesive layer of 30 μm or more, sufficient adhesive strength cannot be expressed.

The tensile shear bond strength of the adhesive layer is preferably 50 N / 100 mm ² or more. If the tensile shear bond strength is equal to or greater than the above lower limit value, it can withstand shear shear force generated during bending or shear shear force generated by dimensional changes of the decorative layer due to changes in the humidity environment, generation of cracks, decorative layer It is possible to prevent peeling. The tensile shear adhesive strength of the adhesive layer is measured in accordance with the tensile shear adhesive strength test method defined in JIS Z1541 “Super-Strong Double-Sided Adhesive Tape”.

  In the PF decorative board of the present invention, examples of the base substrate include a metal plate, a plywood board, a fiber board, a foamed resin board, a resin board, a laminated board in which two or more of these boards are combined, and a composite board. However, a metal plate of 0.1 to 3 mm, particularly an aluminum plate, is preferable in consideration of heat dissipation in a flammability test for railway vehicle materials.

  If the PF decorative board of the present invention is a so-called intermediate product before bending, the PF decorative board is manufactured to produce the PF decorative board, and if it is subjected to bending, Used for applications that require mechanical strength and durability, such as top plates, counters, and vehicle interiors.

  The adhesive layer used in the PF decorative board of the present invention is manufactured in advance as a double-sided adhesive tape, laminated in the order of a decorative layer material, a double-sided adhesive tape and a base substrate layer material, and the laminate is pressure-bonded. Can be manufactured. When a support layer for reinforcement is not used for the adhesive layer, it is also possible to apply a pressure sensitive adhesive directly to the material for the decorative layer or the material for the base substrate layer instead of manufacturing the double-sided tape in advance. .

  The PF decorative board of the present invention can be manufactured by pressurizing and bonding the laminate, and further bending. Although it does not specifically limit as said bending process, For example, a normal woodworking apparatus, for example, a rollermatic apparatus, an iron bender apparatus, and a sheet metal processing apparatus include a roll bender apparatus, a brake press apparatus, etc., for example. In such a bending process, when performing a process (outside bending process) such that the decorative layer of the PF decorative board comes to the outer peripheral side, it is preferable to use a roll bender device, and the decorative layer comes to the inner peripheral side. When performing such processing (inward bending processing), it is preferable to use a brake press device. When the outer bending process is performed using the roll bender device, the minimum rollable diameter is determined by the top roll diameter of the roll bender device. For example, when the bending process is performed with R15, the top roll having a diameter of 30 mm or less is used. Is preferably used. The bending process can be performed at room temperature.

  In the manufacturing method of the PF decorative board of this invention, it is desirable to have the process of pressurizing and re-adhering the whole surface or a partial surface of the process PF decorative board after performing the said bending process. Thereby, even when the adhesive layer undergoes slip deformation during bending, the initial adhesive force can be restored.

  Although it does not specifically limit as a method of performing the said re-adhesion, For example, it can carry out by passing the PF decorative board after performing a bending process between 1 or more pairs of pinch rolls. Although it does not specifically limit as a pressure given to a PF decorative board here, It is preferable to adjust the clearance between pinch rolls and to re-adhere at 1.96-7.84 MPa, and this pressure is PF decorative board before a bending process. It is preferable that the pressure is substantially equal to the pressure at the time of manufacturing and the pressure at the time of bending. In addition, when re-adhering using a pinch roll, it is preferable that the diameter of a pinch roll is smaller than the diameter of the curve part of the PF decorative board which performed the bending process. Thereby, even the curved part of a PF decorative board can be completely adhered.

  According to the method for producing a PF decorative board of the present invention, unlike the conventional method, it is possible to omit bending the base substrate layer material in advance. Moreover, a general-purpose processing apparatus can be used by performing a bending process and the re-bonding after a bending process in normal temperature range. In addition, such processing at room temperature can substantially eliminate the occurrence of warpage due to heating of the PF decorative board and the decrease in dimensional accuracy and bending angle precision, so that the processing accuracy of the PF decorative board is improved. In addition, when the PF decorative board is used as a member, attachment workability can be improved. For these reasons, a significant cost reduction can be achieved as compared with a conventional decorative board.

  EXAMPLES Next, although an Example is given and this invention is demonstrated more concretely, this is only an illustration and does not restrict | limit this invention. In the examples and comparative examples, “parts” represents “parts by weight” and “%” represents “% by weight”.

(Manufacture of intermediate product of PF decorative board)
The following decorative layer material, adhesive layer material, and base substrate layer material were sequentially stacked and bonded with a pinch roll having a roll diameter of 20 mm by applying a pressure of 5.88 MPa to produce an intermediate product of a PF decorative board. .

Production of decorative layer material The following melamine resin-impregnated decorative paper, phenolic resin-impregnated thin paper, and aluminum foil were sequentially superposed in this order to produce two laminates. Next, the laminate was assembled back-to-back with each other so that the stainless steel mirror plate and the melamine resin-impregnated decorative paper were in contact with each other between the two stainless steel mirror plates. This was heated and pressed using a flat plate press to obtain a decorative layer material having a thickness of 0.28 mm. The molding conditions were such that the hot platen temperature was 160 ° C., the product was heated for 40 minutes so that the maximum product temperature was in the range of 143 to 148 ° C., and then cooled to 40 ° C. The pressure was maintained at 9.8 MPa.

(1-1) Production of melamine-impregnated resin decorative paper 50% solid content, number average molecular weight 230, viscosity 0 reacted with a molar ratio (F / M) of formaldehyde (F) to melamine (M) of 1.6 .04 Pa · s / 20 ° C. water-soluble melamine resin and an aqueous acrylic resin emulsion having a solid content of 45% and a viscosity of 0.035 Pa · s / 20 ° C. are mixed at a weight ratio of 100: 35. After adding water to adjust the viscosity to 0.02 Pa · s / 25 ° C., the curing catalyst (“Nitto Chemical Co., Ltd.“ Catanit A ”, organic sulfamic acid catalyst) 1 Melamine for impregnation by adding 0.5 part of a mold release agent (manufactured by Chukyo Yushi Co., Ltd., “SEVAL”) and 1 part of powdered cellulose (Nippon Paper Chemical Co., Ltd., “KC Flock”) as an organic filler. A resin varnish was obtained. This impregnating melamine resin varnish was impregnated into a decorative paper, a monochromatic paper with a basis weight of 130 g / m ² and dried by heating to obtain a melamine resin-impregnated decorative paper having a resin amount of 50% and a volatile content of 6%. .

(1-2) Metal foil A rolled aluminum foil having a thickness of 25 μm was used.

(1-3) Production of Phenol Resin-Impregnated Thin Paper A molar ratio (F / P) of formaldehyde (F) to phenol (P) was reacted as 1.3 to obtain a resol type phenolic resin solution for impregnation having a solid content of 55%. It was. This resin solution was impregnated into a thin paper having a basis weight of 37 g / m ² and dried by heating to obtain a phenol resin-impregnated thin paper having a resin amount of 58% and a volatile content of 5%.

(2-1) Adjustment of pressure-sensitive adhesive 72.5 parts of butyl acrylate (BA) as a tacky monomer, 15.0 parts of ethyl acrylate (EA) as a non-tacky monomer, vinyl acetate as a non-tacky monomer (VAC) 7.5 parts, cross-linkable monomer acrylic acid (AA) 5.0 parts is charged into the polymerization solvent ethyl acetate 150 parts, the polymerization initiator benzoyl peroxide (BPO) 0.2 The reaction was carried out in a reaction vessel equipped with a stirrer at 80 ° C. for 5 hours in a nitrogen atmosphere to obtain a transparent and uniform reaction solution. The nonvolatile content (acrylic pressure sensitive adhesive) in the reaction solution was 40%.

  Immediately before coating, 100 parts of this acrylic pressure-sensitive adhesive was mixed with 1 part of Coronate L (non-volatile content: 75%, Nippon Polyurethane Industry Co., Ltd.), which is an organic isocyanate, as a crosslinking agent.

(2-2) Adhesive layer material Adhesive layer material (double-sided tape) with a thickness of 0.1 mm by applying the acrylic pressure-sensitive adhesive obtained in the previous section to both sides of a 30 μm thick organic nonwoven fabric as a support. Got.

Base substrate layer material A 1.2 mm thick aluminum plate (material: 1100-H14) degreased with an organic solvent (MEK) was used.

The decorative layer material, the adhesive layer material (double-sided tape), and the base substrate layer material obtained in the previous section were pressure-bonded with a pinch roll to produce a PF decorative board intermediate product. The thickness of the adhesive layer of this PF decorative board intermediate product was 100 μm, and the tensile shear force in the normal state of this PF decorative board intermediate product (adhesive layer) was 100 N / 100 mm ² .

(Manufacture of PF decorative board)
The intermediate product of the PF decorative board obtained by the above method was cut into a size of 910 mm long × 900 mm wide by shearing, and a hole of φ500 mm was processed in the center with a laser cutter. Next, an outer bending process (feed speed 1 m / min, pressure 5.8 MPa) having an inner diameter R of 30 mm was performed using a roll bender apparatus having a top roll diameter of φ60 mm. Furthermore, the upper mold and the lower mold were subjected to inward bending in the lateral (900 mm) direction of the decorative board using a brake press device having R15 mm (φ30 mm). This was pressure-bonded with a pinch roll having a roll outer diameter of φ20 mm by applying a pressure of 5.8 MPa, and the longitudinal direction was cut to 900 mm by shearing to obtain a PF decorative board shown in FIG. The outer bending process, the inner bending process, and the pressure bonding were performed at room temperature.

(Adhesive layer material)
A rubber-based pressure-sensitive adhesive (G6520: manufactured by Konishi Co., Ltd.) was applied to both surfaces of an organic nonwoven fabric having a thickness of 5 μm as a support to obtain an adhesive layer material having a thickness of 0.1 mm. The rubber-based pressure-sensitive adhesive is composed of natural rubber and a styrene-isoprene block copolymer (SIS) as main components and a tackifier and an antioxidant.

An intermediate product of a PF decorative board and a PF decorative board were obtained in the same manner as in Example 1 except that the adhesive layer material described in the previous section was used. The tensile shear force in the normal state of the intermediate product (adhesive layer) of the PF decorative board was 80 N / 100 mm ² .

  The acrylic pressure-sensitive adhesive prepared in Example 1 was applied to the back surface of the decorative layer material so as to have a thickness of 80 μm (dry).

The decorative layer material coated with an acrylic pressure-sensitive adhesive on the back surface and the base substrate layer material were pressure bonded with a pinch roll to produce a PF decorative board intermediate product. The tensile shear force in the normal state of the intermediate product (adhesive layer) of the PF decorative board was 80 N / 100 mm ² .

(Comparative Example 1)
Instead of the double-sided tape coated with an acrylic pressure-sensitive adhesive, the same procedure as in Example 1 was performed except that a chloroprene rubber adhesive was used for the adhesive layer. Obtained.

(Comparative Example 2)
The same procedure as in Example 1 was carried out except that the amount of pressure-sensitive adhesive applied in Example 1 was increased and a material for a bonding layer (double-sided tape) having a thickness of 0.3 mm was obtained. A PF decorative board was obtained.

(Comparative Example 3)
Example 1 except that the support in Example 1 was a 75 μm PET film, and an acrylic pressure-sensitive adhesive was applied to both sides to obtain a 0.20 mm thick adhesive layer material (double-sided tape). The intermediate product of the PF decorative board and the PF decorative board were obtained.

(Comparative Example 4)
(Manufacture of melamine decorative board for post foam)
Laminate 1 prepreg for decorative layer and 4 prepregs for core layer, and heat for 60 minutes using a flat plate press at a hot platen temperature of 150 ° C and 10MPa, and a maximum product temperature of 135 ° C. Pressure molding was performed to obtain a melamine decorative board for post foam having a thickness of 0.8 mm.

(1-1) Preparation of decorative layer prepreg The melamine (M) and formaldehyde (F) are mixed so that the reaction molar ratio (F / M) is 1.6, and the water miscibility is 95 ° C at a reaction temperature of 95 ° C. It was made to react until it became 16 ml / 5ml, and the melamine resin varnish was obtained. The melamine resin content in this melamine resin varnish was 54%, and the solvent component ratio (methanol: water) was 5:95. This melamine resin varnish was impregnated into gravure printing paper having a weight of 90 g / m ² and then dried with a hot air drying device to prepare a prepreg for a decorative layer having a weight of 195 g / m ² and a volatile content of 8%.

(1-2) Preparation of prepreg for core material layer Phenol (P) and formaldehyde (F) are mixed and reacted so that the reaction molar ratio (F / P) is 1.2, and a resol type phenol resin is obtained. A varnish was obtained. The phenol resin content in this phenol resin varnish was 50%, and the solvent was methanol. This phenolic resin varnish was impregnated into craft paper weighing 190 g / m ² and then dried with a hot air drying device to prepare a prepreg for a core material layer weighing 270 g / m ² .

(Preparation of PF decorative board)
Using a plywood having a thickness of 19 mm, a base substrate having the shape shown in FIG. 2 and an upper and lower wooden mold for inward bending shown in FIG. 3 were produced. In the final shape, the internal bending angle is 90 °, but considering the return of the angle after bending, the wooden shape is 85 °. The melamine decorative board for post foam with a thickness of 0.8 mm obtained by the above method was cut into a 910 mm square, and a portion of about 130 mm from the end was heated to 135 ° C. with a microwave heater, and prepared beforehand. The inner bending wood mold was bent so that a margin of 5 mm from the positive dimension was taken into account, and the size of the front sag was 105 mm. Apply chloroprene rubber adhesive to the adhesive surface of the processed post-form melamine decorative board and the base substrate, leave it for about 5 minutes, and then hand roll the back guard of the base material and the inner bent part of the post-form melamine decorative board. Affixed while crimping. The front drooping part was affixed with an iron bender while being thermoformed along the shape of the base substrate. Next, a pattern paper for φ500 punching was prepared, and a hole was made in the center of the top board with a hand router. Since there was a gap between the inwardly bent R portion and the base substrate, this gap was filled by injecting urethane resin. Finally, the whole was trimmed with a trimmer to obtain a processed decorative board shown in FIG.

(Comparative Example 5)
A 1.2 mm-thick aluminum plate (material: 5052-H34) was cut into 900 mm squares by shearing, and a base substrate was prepared with the outer dimensions shown in FIG. 1 using a roll bender and a brake press. Next, the post-form melamine decorative board used in Comparative Example 4 was cut into a 910 mm square, and a PF processed product as shown in FIG.

  The following characteristics were evaluated for the PF decorative boards obtained in the examples and comparative examples. The results are shown in Table 1.

(1) <Appearance>: Visually.
<Work man-hour>: The man-hour time required for the process of manufacturing the PF decorative board by processing the intermediate product of the PF decorative board is measured.
<Bending workability after adhesion to base substrate>: The curved surface R portion is visually observed after processing.
<Warpage>: In accordance with the method for measuring warpage described in JIS R3205 “Laminated glass” item 7.4, when the measurement surface of the processed decorative board is set up vertically and the ruler is applied horizontally, the processed decorative board The gap formed between the ruler and the ruler is measured with a taper gauge which is a gap gauge.
<Heat-resistant environmental test of a workpiece>: Leave in an oven at 60 ° C. for 24 hours, and determine that the appearance is not particularly changed as “good”.
<Tensile shear bond strength>: In Examples 1 to 3 and Comparative Examples 1 to 4, between the decorative layer and the base substrate, and in Comparative Examples 4 and 5, between the melamine resin decorative board and the base substrate. The tensile shear adhesive force is measured by a test method based on JIS Z 1541.
<Flammability>: According to the flammability test method for railcar material according to the notification of the Director General of Railway Inspection No.81. That is, a B5 plate (182 mm × 257 mm) specimen was held at an angle of 45 °, and a metal container containing 0.5 ml of pure ethyl alcohol as a fuel was placed 25.4 mm vertically below the center of the specimen. 1 inch), ignite this fuel, and let it stand until it burns out. During and after combustion of the fuel, the state of the specimen is observed to determine the combustibility. Non-flammability means that there is no ignition or flame for the test specimen during combustion, there is almost no smoke generation, and for the test specimen after combustion, the carbonization of the portion hit by the flame is 100 mm or less and the deformation is 100 mm or less. Say. In addition, flame retardancy means ignition and ignition of the test specimen during combustion, but the flame does not exceed the upper end, the smoke is moderate, and the carbonized specimen that reaches the upper end of the specimen after combustion reaches the edge. The case where there is no deformation. In addition, the failure means ignition and ignition of the test specimen during combustion, the flame exceeds the upper end of the test specimen, the smoke generation is moderate or higher, and the carbonization reaches the upper end of the test specimen after combustion. Say when the deformation to reach occurs.

  Compared with the PF decorative board obtained in the comparative example, the PF decorative boards of Examples 1 to 3 can obtain the non-combustible performance in the rail vehicle material flammability standard, and the appearance of the part subjected to bending is good. It was excellent in shape accuracy such as warpage. Moreover, the processing man-hour of the PF decorative board was able to be reduced significantly.

It is the schematic of the PF decorative board obtained in Examples 1-3, Comparative Examples 1-3, and Comparative Example 5. FIG. In the comparative example 4, it is the schematic of the base base material shape used for manufacture of PF decorative board. In the comparative example 4, it is the schematic of the up-and-down wooden type for internal bending used for manufacture of PF decorative board. 6 is a schematic view of a PF decorative board obtained in Comparative Example 4. FIG.

Explanation of symbols

1 Wooden top 2 Wooden bottom

Claims (8)

A decorative layer, a base substrate layer, and an adhesive layer formed by bonding the decorative layer and the base substrate layer;
The decorative layer contains a melamine resin and an aqueous thermoplastic resin,
The adhesive layer contains one or two pressure-sensitive adhesives selected from a synthetic rubber pressure-sensitive adhesive and an acrylic pressure-sensitive adhesive ;
The post-form decorative board, wherein the base substrate layer is made of an aluminum plate.   The post-form decorative board according to claim 1, wherein the decorative layer has a thickness of 0.15 to 0.8 mm, and the base substrate layer has a thickness of 0.1 to 3 mm.   The said adhesive layer is only a pressure-sensitive adhesive layer, or has a support layer for reinforcing a pressure-sensitive adhesive between the pressure-sensitive adhesive layers. Post foam decorative board as described.   The post-form decorative board according to claim 3, wherein the adhesive layer has a thickness of 30 μm or more and less than 250 μm, and the support layer has a thickness of 50 μm or less. The post-form decorative board according to any one of claims 1 to 4, wherein the adhesive layer has a tensile shear adhesive strength of 50 N / 100 mm ² or more. A method for producing the post-foam decorative board according to any one of claims 1 to 5,
Adhesive layer material containing one or two pressure-sensitive adhesives selected from a decorative layer material containing a melamine resin and an aqueous thermoplastic resin , a synthetic rubber-based pressure-sensitive adhesive, and an acrylic pressure-sensitive adhesive And a base substrate layer material made of an aluminum plate is laminated in this order, and the laminate is pressed and bonded to form a post-form decorative board manufacturing method. 7. The method for producing a post-form decorative board according to claim 6 , further comprising bending after pressing and bonding. 8. The method for manufacturing a post-form decorative board according to claim 7 , wherein the bending is performed at room temperature.

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