JPS605188B2 - Thermosetting resin decorative board with high wear resistance - Google Patents

Description

Detailed Description of the Invention At least the decorative surface layer is coated with a synthetic resin mainly composed of phenolic resin, epoxy resin, other amino resin, diallyl phthalate resin or other polyester resin, or is made of impregnated paper or cloth, so-called heating. In a pressurized thermosetting synthetic resin decorative board, the decorative surface layer is amorphous hydrated silicic acid powder (hereinafter simply referred to as silicic acid powder).

) and crystalline cellulose powder, the content of which is 2 to 5 parts by weight of Buddha's silicate powder with a particle size of 10 to 20, and crystalline cellulose per 10 parts by weight of the thermosetting resin. The present invention relates to a thermosetting sidewall board having high abrasion resistance and containing 5 to 1 parts by weight of powder. That is, the present invention aims to economically obtain a decorative board with high abrasion resistance by incorporating silicic acid powder and crystalline cellulose powder into the heat-pressing type synthetic resin decorative board. That is.

Generally, as a method of imparting high abrasion resistance to the IQ plate, an overlay paper is used on top of the decorative paper, and a transparent resin layer made of the overlay paper is provided on the A8 salmon layer.

This overlay paper is mainly made of Q cellulose and has a thickness of 2.
It is a high-quality paper of ~4 mils, and is impregnated with a resin liquid and dried to make an impregnated paper for overlay. Conventional decorative laminates typically constructed using overlay impregnated paper suffer from the following drawbacks due to the provision of an overlay layer.

The overlay paper is a high-quality paper mainly made of Q cellulose and is therefore expensive. Since the overlay paper is thin (2 to 4 mils), its strength is weak compared to other papers, and it is easily broken during the soaking process, resulting in a poor yield of impregnated paper. Although the overlay paper is very thin, it impairs its transparency and makes the appearance and color pattern, which is the life of the decorative board, unclear. Overlay paper tends to attract small particles due to electricity during handling, which reduces the yield of the product during the production of decorative laminates. By providing an overlay layer, the surface resin layer becomes thicker, and the decorative board is likely to warp. In order to eliminate the above-mentioned drawbacks, methods that do not use overlay paper have been studied, especially since a clear appearance is required.

With conventional methods, decorative laminates that do not use overlay paper naturally have excellent surface clarity, but because the decorative layer is only coated with a small amount of resin to protect it, the practical characteristics of the decorative laminate are Starting with the most important abrasion resistance,
It is inevitable that the surface properties will deteriorate significantly.

There have been attempts to incorporate inorganic powders such as alumina and glass powder into the decorative layer as a method of improving wear resistance without impairing the clarity of the surface. There is a difference between the refractive index of the powder and the refractive index of the synthetic resin, which impairs the transparency of the synthetic resin layer, making the color pattern unclear, and the unavoidable drawback of cracking due to dimensional changes in the resin. It is difficult to achieve this goal.

In order to obtain a decorative board, the present inventors coated and impregnated resin-impregnated decorative paper with a resin solution in which silicic acid powder and crystalline cellulose powder were suspended, and used this decorative impregnated paper as the surface layer of the decorative board. It has been found that by forming a resin layer containing silicic acid powder and crystalline cellulose powder on the surface, it is possible to obtain a decorative board with high wear resistance and a clear colored pattern. In the present invention, in order to form a resin layer containing silicic acid powder and crystalline cellulose powder on the surface layer of the decorative board, a resin solution in which silicic acid powder and crystalline cellulose powder are suspended is applied only to the surface side of the decorative paper or on both sides. It may be impregnated and made into a decorative board according to a conventional method.

The decorative board in the present invention is paper, cloth, or a porous thin film on which printing or pigment is applied.

According to the present invention, by using oxalic acid powder and crystalline cellulose powder as a resin support, even though no overlay paper is used, the same resin layer as when using overlay paper can be applied to the surface of the decorative paper. It was found that the surface resin layer has high wear resistance and good crack resistance due to the effects of the silicic acid powder and crystalline cellulose powder contained in the surface resin layer.

The silicic acid powder used in the present invention is extremely cheaper per unit weight than the base paper used for overlay paper, and compared to the conventional method of forming an overlay layer on top of a decorative layer.
The process of applying and impregnating a resin liquid is reduced by one step in the method of the present invention, and therefore it is possible to produce a decorative board at a significantly lower cost than conventional decorative boards, and it is an object of the present invention to provide a decorative board that is extremely useful industrially. Become.

Furthermore, the silicic acid powder used in the present invention needs to have a particle size of 10 to 20 grains.

In other words, as a result of various studies, the particle size is within this range, and when suspended in a resin solution, the silicic acid powder remains stable for a very long time without settling, allowing it to be uniformly applied and impregnated onto the decorative board. This makes it possible. Moreover, when used as a decorative board, it becomes transparent and does not damage the appearance, which is the life of the decorative board. Furthermore, it has high wear resistance in terms of performance. Examples of the present invention will be described below.

Example 1 40 pieces of amorphous silicate powder with a particle size of 18 mm and 80 pieces of crystalline cellulose powder were mixed into a melamine resin solution (resin content: 50%) 2
The decorative paper was soaked in this solution, which was mixed and uniformly dispersed in a 120° C. dryer for 5 minutes.

Thus, the resin content of the decorative paper is 55% compared to the impregnated decorative paper.
%. This decorative paper was used as the surface layer, and as the lower layer, several sheets of kraft paper impregnated with phenolic resin were layered and placed between stainless steel plates for 10 minutes at 160 oo for 50 minutes.
The printed pattern on the surface of the product that was heat-pressed at 0k9/m and taken out after cooling was extremely clear, and when compared with the makeup made using the same resin but not using so-called overlay, it was as follows. It will look like Table 1.

Table 1 Example 2 Surface characteristics of decorative board
) A wood grain pattern printed decorative paper with a base paper weight of 80 mm/m is soaked in the varnish that has been mixed and uniformly dispersed in 2,000 mm.
Dry for 5 minutes in a 105qo dryer to obtain coated and impregnated decorative paper.

The resin content of this coated and impregnated paper is 59% of the decorative paper. This decorative paper was used as the surface layer, 3-wall thick lauan plywood was layered as the core material, and an aluminum plate (3-wall thick duralumin cover) was fixed using a 7-stage press machine to produce 130 qo.
When we took out the decorative plywood after applying 10 kg' of hot pressure for 7 minutes, we found that the printed pattern on the surface was extremely clear, and its surface properties were superior to that of conventional diallyl phthalate resin plywood. The performance is as shown in Table 2 below.

Table 2 Surface characteristics of decorative board

Claims (1)

[Claims] 1 At least the decorative surface layer is made of paper or cloth coated with or impregnated with a thermosetting resin, i.e., a synthetic resin mainly composed of phenolic resin, epoxy resin, melamine resin, other amino resin, diallyl phthalate resin, or other polyester resin. In the so-called heat-pressing type thermosetting synthetic resin decorative board, the decorative surface layer forms a resin layer containing amorphous hydrated silicic acid powder and crystalline cellulose fine powder, and the content thereof is 100 parts by weight of thermosetting resin. For particle size 10~20m
A thermosetting resin decorative board having high abrasion resistance, which contains 2 to 5 parts by weight of amorphous hydrated silicic acid powder and 5 to 10 parts by weight of microcrystalline cellulose powder.