Decorative paper impregnated with resin and decorative panel impregnated with resin.

Abstract

RESIN-IMPREGNATED DECORATIVE PAPER AND RESIN-IMPREGNATED DECORATIVE BOARD. A resin-impregnated decorative paper (2) is provided, formed by impregnating a decorative paper (4) with an impregnating resin (5). The decorative paper (4) includes: a base paper (6); an image pattern layer (7) provided on one side of the surface (6a) of the base paper (6); a filler layer (8) provided on a surface (7a) of the image pattern layer (7); and a foamed resin layer (9) provided on a surface (8a) of the filler layer (8). The filler layer (8) contains at least one of an epoxy-based resin, an acrylic-based resin, a urethane-based resin, and a casein-based resin.

Description

1 / 30 Decorative paper impregnated with resin and decorative panel impregnated with resin. Technical Field

[001] The present invention relates to a resin-impregnated decorative paper and a resin-impregnated decorative plate. Technical Background

[002] Conventionally, a method for manufacturing a resin-impregnated decorative plate has been proposed that involves pressing a metal plate against a multilayer composite of a resin-impregnated decorative paper impregnated with a thermosetting resin and a base member, and then hot pressure molding, thus obtaining a resin-impregnated decorative plate in which the resin-impregnated decorative paper and the base member are integrated together (e.g., see PTL 1). In the method for manufacturing the resin-impregnated decorative plate described in PTL 1, an embossed shape is formed on a metal plate to impart asymmetrical patterns to the surface of the resin-impregnated decorative plate, thus providing a tactile feel. Furthermore, by adjusting the degree of roughness and fineness of the embossed shape, it is also possible to impart a matte gloss expression.However, in the manufacturing method of a resin-impregnated decorative plate described in PTL 1, it is necessary to prepare the metal plate for each uneven pattern to be applied, and therefore there is a possibility that the cost will increase. Consequently, it is conceivable to apply asymmetrical patterns by providing layers of foamed resin. However, since a foamed resin having an affinity with an impregnating resin such as a melamine resin easily penetrates a base paper, there is a possibility that a tactile feel or a matte sheen will be diminished. Petition 870220100090, dated 10 / 28 / 2022, pp. 64 / 101 2 / 30 List of Citations Patent Literature

[003] PTL 1: JP H09-262956 A Summary of the Invention Technical Problem

[004] The present invention was made focusing on the problems described above and aims to provide a resin-impregnated decorative paper and a resin-impregnated decorative board that are excellent in matte gloss expression and tactile feel, while suppressing cost. Solution to the Problem

[005] A resin-impregnated decorative paper according to one aspect of the present invention is a resin-impregnated decorative paper formed by impregnating a decorative paper with an impregnating resin, the decorative paper including: a base paper; an image pattern layer provided on one side of the base paper surface; a filler layer provided on a surface of the image pattern layer; and a foamed resin layer provided on a surface of the filler layer, the foamed resin layer formed by a foaming agent, wherein the filler layer contains at least one of an epoxy-based resin, an acrylic-based resin, a urethane-based resin, and a casein-based resin.

[006] A resin-impregnated decorative plate according to another aspect of the present invention includes: resin-impregnated decorative paper; and a base member integrated with the resin-impregnated decorative paper. Advantageous Effects of the Invention

[007] According to the present invention, it is possible to foam a Petition 870220100090, dated 10 / 28 / 2022, pp. 65 / 101 3 / 30 hot pressure molding foaming agent to properly form an uneven pattern on the surface of a resin-impregnated decorative paper. Since it is not necessary to prepare a metal plate for each uneven pattern, it is possible to provide a resin-impregnated decorative paper and a resin-impregnated decorative plate that are excellent in matte gloss expression and tactile feel, while suppressing cost. Furthermore, since a filler layer containing at least one of an epoxy-based resin, an acrylic-based resin, a urethane-based resin, and a casein-based resin is provided, it is possible to prevent a foamed resin forming a foamed resin layer from penetrating an image pattern layer or a base paper. Therefore, it is possible to provide a resin-impregnated decorative paper and a resin-impregnated decorative plate that are still excellent in matte gloss expression and tactile feel. Brief Description of the Drawings

[008] FIG. 1 is a cross-sectional view illustrating a decorative plate impregnated with resin after heat pressure molding; and

[009] FIG. 2 is a cross-sectional view illustrating a decorative plate impregnated with resin before hot pressure molding. Description of the Modalities

[010] Hereafter, a decorative paper, a resin-impregnated decorative paper and a resin-impregnated decorative board according to an embodiment of the present invention will be described with reference to the drawings. The present invention is not limited to the embodiment described below and may also be supplemented with a modification, such as a change in design based on the knowledge of those skilled in the art. Petition 870220100090, dated 10 / 28 / 2022, pp. 66 / 101 4 / 30 An embodiment with such modification is also included within the scope of the present invention. Each of the drawings is illustrated in an exaggerated manner, as appropriate to facilitate understanding. (Settings)

[011] As illustrated in FIGS. 1 and 2, a resin-impregnated decorative plate 1 according to an embodiment of the present invention is a decorative plate obtained by applying hot pressure molding to a multilayer composite of a resin-impregnated decorative paper 2 and a base member 3 to integrate the resin-impregnated decorative paper 2 and the base member 3 together. Specifically, the resin-impregnated decorative plate 1 includes the base member 3 and the resin-impregnated decorative paper 2 provided on one side of the surface 3a of the base member 3.The resin-impregnated decorative plate 1 according to the embodiment of the present invention is a resin-impregnated decorative plate used for, for example, interior decoration of floor surfaces, wall surfaces, ceilings and the like in buildings, decorative surface materials for furniture, various cabinets and the like, surface decoration for furniture, interior decoration of vehicles and the like. FIG. 1 illustrates a resin-impregnated decorative plate 1 after hot pressure molding, and FIG. 2 illustrates a resin-impregnated decorative plate 1 before hot pressure molding. (Base member)

[012] The type of base member 3 is not particularly limited. It is possible to use an arbitrary base member according to the intended use of the resin-impregnated decorative board 1. For example, one could adopt a wood-based base member, such as a wood veneer, plywood, laminated wood, particleboard, medium-density fiberboard or high-density fiberboard, a Petition 870220100090, dated 10 / 28 / 2022, pp. 67 / 101 5 / 30 fibrous base member, such as cardboard, flat fabric, non-woven fabric, resin-impregnated paper or resin-impregnated fabric, an inorganic base member, such as gypsum board, slate board, calcium silicate board, gypsum slag board, wood wool cement board, cemented slag board, autoclaved lightweight concrete board or glass fiber reinforced concrete board, a metal base member, such as a steel plate, brass plate, aluminum plate, duralumin plate or stainless steel plate, a synthetic resin base member, such as an acrylic resin board, styrene resin board, ABS (Acrylonitrile butadiene styrene) resin board, polycarbonate resin board, nylon resin board, polystyrene resin board, polypropylene resin board,a polyester resin board or a fiberglass reinforced plastic board or similar, or a composite or a multilayer composite of two or more types selected from such base members or similar. (Decorative paper impregnated with resin)

[013] The resin-impregnated decorative paper 2 according to the embodiment of the present invention is formed by impregnating the entire decorative paper 4 with an impregnation resin 5 and then drying the decorative paper 4. The decorative paper 4 includes a base paper 6, an image pattern layer 7, filler layers 8 and foamed resin layers 9. The image pattern layer 7 is provided on a surface 6a of the base paper 6. The filler layers 8 are provided on a surface 7a of the image pattern layer 7. The foamed resin layers 9 are provided on surfaces 8a of the filler layers 8. (Base paper) Petition 870220100090, dated 10 / 28 / 2022, pp. 68 / 101 6 / 30

[014] As base paper 6, a fibrous sheet-type object can be used, such as paper with high water absorption, which allows impregnation of the impregnation resin 5. For example, thin paper, titanium paper, high-quality paper, bleached or unbleached kraft paper, and the like can be adopted. In particular, considering both suitability for printing and suitability for resin impregnation, titanium paper is the most suitable. By taking advantage of the surface texture 3a of the base member 3, it is preferable to use so-called transparent paper having the property of becoming transparent by impregnation with the impregnation resin 5. The thickness of the base paper 6 is not particularly limited, but the base weight is preferably in the range of 20 g / m2 or more and 200 g / m2 or less. (Image pattern layer)

[015] Image pattern layer 7 is a layer for imparting a design property by an image pattern to resin-impregnated decorative paper 2. Image pattern layer 7 is formed by using a printing ink or similar in which a coloring agent, such as a dye or pigment, is dissolved or dispersed in a diluent solvent together with an appropriate binder resin. The type of printing ink is not particularly limited and can be an oil-based ink or a water-based ink. Specifically, as printing ink, it is possible to use a common printing ink without liquid repellency.

[016] In particular, considering the suitability for impregnation of the impregnation resin 5, a water-based ink is the most suitable. Water-based ink has good affinity with an aqueous solution of an impregnation resin compared to oil-based ink. Therefore, when water-based ink is used, the decorative paper 4 can be quickly and uniformly impregnated with the impregnation resin 5 in a process of Petition 870220100090, dated 10 / 28 / 2022, pp. 69 / 101 7 / 30 impregnation in the manufacture of the resin-impregnated decorative plate 1 and, moreover, the resistance can be exhibited in the excellent image pattern layer 7 by integration with the impregnation resin 5. The type of water-based ink is not particularly limited, but it is preferable that the water-based ink contains a binding resin composed mainly of casein and an emulsion resin.

[017] This binder resin has the property of becoming insoluble in water through a drying process after ink printing. Therefore, when a binder resin containing such a binder resin is used, it is difficult to redissolve the image pattern layer 7 in an aqueous solution of the impregnation resin 5 in a resin impregnation process in the manufacture of the resin-impregnated decorative plate 1, so that it is possible to maintain the image pattern and it is still possible to avoid contamination of the impregnation resin 5.

[018] As an emulsion resin, it is possible to adopt, for example, an acrylic-based emulsion resin, a vinyl acetate-based emulsion resin, a styrene-based emulsion resin, a urethane-based emulsion resin or similar. In the binder resin, for example, a water-soluble resin such as polyvinyl alcohol or polyacrylamide, a water-soluble polymer such as polysaccharide or cellulose derivatives or similar may be used in addition to casein and the emulsion resin to improve the stability of the ink.

[019] A method for forming the image pattern layer 7 is not particularly limited. It is possible to use an arbitrary printing method, such as, for example, a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a method of Petition 870220100090, dated 10 / 28 / 2022, pp. 70 / 101 8 / 30 relief printing or an inkjet printing method. Between the image pattern layer 7 and the base paper 6, a solid ink layer intended for base coloring may be provided. When the solid ink layer is provided, an arbitrary coating method, such as a roller coating method, an engraving coating method, a rod coating method, a blade coating method, an air blade coating method, a spray coating method, a lip coating method, and a die coating method, for example, may also be used as a method to form the solid ink layer, as well as various printing methods described above.

[020] The type of image formed by the image pattern layer 7 is not particularly limited. It is possible to use an arbitrary image according to the intended use of the resin-impregnated decorative plate 1. For example, one can adopt a wood grain pattern, a stone grain pattern, a fabric grain pattern, an abstract pattern, a geometric figure, a character, a symbol, a plain monochromatic pattern, or similar patterns, or a combination of two or more types selected from these patterns or similar patterns. (Fill layer)

[021] The filler layers 8 are coating layers partially formed on the image pattern layer 7 to prevent the penetration of a foamed resin into the base paper 6. As a resin forming the filler layers 8, it is possible to use, for example, a curable resin, such as a thermosetting resin having a urethane bond, such as a two-component curable urethane resin, or a radiation-curable resin. As the curable resin, it is possible to use, for example, a thermosetting resin such as an epoxy-based resin, Petition 870220100090, dated 10 / 28 / 2022, pp. 71 / 101 9 / 30 an acrylic-based resin, a urethane-based resin, a casein-based resin, a melamine-based resin, a urea-based resin, a phenol-based resin, an unsaturated polyester-based resin, a diallyl phthalate-based resin, a benzoguanamine-based resin, an aminoalkyd-based resin or a silicone-based resin, a radiation-curable resin such as a (meth)acrylate-based resin or an unsaturated polyester-based resin, or similar.

[022] A method for printing the fill layers 8 is not particularly limited as the image pattern layer 7. It is possible to use an arbitrary printing method, such as, for example, a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a relief printing method or an inkjet printing method.

[023] As positions for forming the 8 fill layers, those aligned in design terms with a pattern (image pattern) formed by the image pattern layer 7 can be used. For example, the 8 fill layers are formed in portions where a matte or glossy texture should be expressed in the pattern (image pattern) formed by the image pattern layer 7. This makes it possible to further improve the design property of the resin-impregnated decorative plate 1. The resin for forming the 8 fill layers can be colorless or colored.

[024] The thickness of the filler layer film 8 is satisfactorily 0.5 μm or more and 15 μm or less and, in particular, more preferably 1 μm or more and 10 μm or less. When the film thickness is less than 0.5 μm, the foamed resin (thermoplastic resin) may penetrate the base paper 6. When the film thickness is greater than 15 μm, the design property decreases. Petition 870220100090, dated 10 / 28 / 2022, pp. 72-101 10 / 30

[025] It is satisfactory that the filler layer 8 be provided in a range of 100% or more of the surface area (coating area) of the foamed resin layer 9 and, in particular, it is more preferable that the filler layer 8 be provided in a range of 150% or less of the surface area of ​​the foamed resin layer 9. When less than 100% of the surface area of ​​the foamed resin layer 9, the foamed resin forming the foamed resin layer 9 may penetrate the image pattern layer or the base paper. When greater than 150% of the surface area of ​​the foamed resin layer 9, the design property decreases. In the case where the arrangement position of the foamed resin layer 9 is aligned with an image formed by the image pattern layer 7, it may be reshaped as follows.It is satisfactory for fill layer 8 to be provided in a range of 100% or more of the image area formed by image pattern layer 7, and it is more preferable that fill layer 8 be provided in a range of 150% or less of the image area formed by image pattern layer 7. (Layer of foamed resin)

[026] The foamed resin layers 9 are layers to impart a matte gloss expression and a tactile feel by asymmetrical patterns 10 on a surface of the resin-impregnated decorative paper 2. The type of foaming agent is not particularly limited and an arbitrary foaming agent may be used. For example, it is possible to adopt a pyrolytic chemical foaming agent, such as an azo-based foaming agent, such as azodicarbonamide or azobisformamide, or a hydrazide-based foaming agent, such as oxybenzenesulfonyl hydrazide or paratoluenesulfonyl hydrazide, a microcapsule foaming agent or the like. Petition 870220100090, dated 10 / 28 / 2022, pp. 73 / 101 11 / 30

[027] In particular, the microcapsule foaming agent is the most suitable. The microcapsule foaming agent has a capsule and a volatile substance contained within the capsule. The microcapsule foaming agent enters a foamed state when the volatile substance is volatilized to expand the capsule. As capsule material, it is possible to use, for example, a vinylidene-acrylonitrile chloride copolymer or similar. As volatile substance material, it is possible to use, for example, an aliphatic hydrocarbon or similar.

[028] As the foaming agent, it is preferable that the average particle diameter before foaming be 2 / 3 times or more and 50 times or less the thickness of the image pattern layer 7. When the average particle diameter is less than 2 / 3 times the thickness of the image pattern layer 7, there is a possibility that the matte gloss feel and the touch feel may become weakened. On the other hand, when the average particle diameter is greater than 50 times the thickness of the image pattern layer 7, there is a possibility that the foamed resin layers 9 after foaming may detach from the decorative paper 4, or similar, so that the scratch resistance decreases. In the present invention, the average particle diameter is an average particle diameter as determined by microscopic observation.The average particle diameter obtained by microscopic observation can be achieved, for example, by microscopically observing the foaming agent, measuring the particle diameters of 100 microscopically observed foaming agent particles using image processing software or similar methods, and then calculating the numerical average of the measurement results. As for the particle diameter of the foaming agent, it is possible to adopt an average value of the diameters of the major and minor axes of the foaming agent particles.

[029] As the foaming agent, it is preferable that the diameter Petition 870220100090, dated 10 / 28 / 2022, pp. 74 / 101 12 / 30 average particle diameter after foaming is 15 μm or more and 250 μm or less. When the average particle diameter is less than 15 μm, there is a possibility that the matte gloss sensation and the tactile sensation may become weakened. On the other hand, when the average particle diameter is greater than 250 μm, there is a possibility that the foamed resin layers 9 after foaming may detach from the decorative paper 4, or similar, so that the scratch resistance decreases. The average particle diameter after foaming is more preferably 30 μm or more and 200 μm or less. In the present invention, the average particle diameter of the foaming agent after foaming is an average particle diameter by microscopic observation as the average particle diameter of the foaming agent before foaming.Since the particle diameter of the foaming agent after foaming is used to obtain the average particle diameter, it is possible to adopt an average value of the major axis diameters and the minor axis diameters of a gap formed by the foaming of the foaming agent.

[030] The initial foaming temperature of the foaming agent is preferably 100 °C or higher and 220 °C or lower. When the initial foaming temperature is lower than 100 °C, the foaming start time is premature and therefore the time during which the foamed resin layers 9 after foaming are heated and pressed is prolonged, so that the foamed resin layers 9 after foaming are crushed, leading to the possibility of the matte gloss sensation and the touch sensation becoming weakened. On the other hand, when the initial foaming temperature is higher than 220 °C, the foamed resin layers 9 are not sufficiently foamed by the hot pressure molding performed by pressing a metal sheet (mirrored plate) in the manufacture of the resin-impregnated decorative plate 1, so there is a possibility that the matte gloss sensation Petition 870220100090, dated 10 / 28 / 2022, pp. 75 / 101 13 / 30 and the tactile sensation may become weakened. The initial foaming temperature is preferably 120 °C or higher and 200 °C or lower.

[031] The type of uneven pattern 10 formed by the foamed resin layer 9 after foaming is not particularly limited and may or may not be aligned in design terms with the image formed by the image pattern layer 7. In particular, when considering obtaining the resin-impregnated decorative board 1 with excellent design properties, the most suitable is one that is aligned in design terms with the image formed by the image pattern layer 7. When the image formed by the image pattern layer 7 and the asymmetrical pattern 10 are aligned with each other in design terms, the arrangement position of the foamed resin layer 9 is aligned with the image formed by the image pattern layer 7. Specifically, the foamed resin layer 9 is arranged in a portion where a matte texture should be expressed in the image formed by the image pattern layer 7.For example, foamed resin layer 9 is placed on the surface of image pattern layer 7 to cover a dark-colored portion where the brightness is relatively lower than in other portions of the image in the image formed by image pattern layer 7. The ratio of the area covered with foamed resin layer 9 to the area of ​​the dark-colored portion is preferably 70% or more. In particular, 90% or more is most suitable. When the image of image pattern layer 7 is adjusted to a wood grain pattern, the foamed resin layers 9 are placed in the shape of a vase pattern aligned in terms of design with the wood grain pattern of image pattern layer 7. The color of foamed resin layer 9 is not particularly limited. Foamed resin layer 9 can be colorless or colored.

[032] When the foamed resin layer 9 is placed in the layer Petition 870220100090, dated 10 / 28 / 2022, pp. 76 / 101 14 / 30 of image pattern 7, the foamed resin layer 9 is arranged in the image pattern layer 7 so as to be mixed into a dark-colored portion where the brightness is relatively lower than in other portions of the image in the image formed by the image pattern layer 7. The ratio of the volume of the foamed resin layer 9 to the total volume of the dark-colored portion and the volume of the foamed resin layer 9 is preferably 70% or more. In particular, 90% or more is most suitable.

[033] A method for disposing of the foamed resin layers 9 is not particularly limited. It is possible to employ, for example, a method for printing a printing ink obtained by dispersing the foamed resin layers 9 in a diluent solvent together with a suitable binder resin in the image pattern layer 7. As a binder resin, it is possible to use, for example, a curable resin, such as a thermosetting resin having a urethane bond, such as a two-component curable urethane resin, or a radiation-curable resin, or one composed mainly of casein and an emulsion resin.As a thermosetting resin, it is possible to adopt, for example, a melamine-based resin, an epoxy-based resin, a urea-based resin, a phenol-based resin, an unsaturated polyester-based resin, a diallyl phthalate-based resin, a benzoguanamine-based resin, a urethane-based resin, an aminoalkyd-based resin, a silicone-based resin, and the like. As a radiation-curable resin, it is possible to adopt, for example, a (meth)acrylate-based resin, an unsaturated polyester-based resin, or the like.

[034] A method for printing the printing ink from the foamed resin layers 9 is not particularly limited as the image pattern layer 7. It is possible to use an arbitrary printing method, such as, by Petition 870220100090, dated 10 / 28 / 2022, pp. 77 / 101 15 / 30 example, a gravure printing method, an offset printing method, a screen printing method, a flexographic printing method, a relief printing method or an inkjet printing method.

[035] The foamed resin layers 9 contain a colored ink. As a vehicle for the colored ink, one obtained by using one type or a mixture of two or more types of chlorinated polyolefin, such as chlorinated polyethylene or chlorinated polypropylene, polyester, isocyanate and polyol compound polyurethane, polyacrylic, polyvinyl acetate, polyvinyl chloride, a vinyl chloride-vinyl acetate copolymer, a cellulose-based resin, a polyamide-based resin and the like, and adding thereto a pigment, a solvent, various adjuvants and the like to form an ink, may be used. (Method for manufacturing decorative resin-impregnated plaque)

[036] A method for manufacturing the resin-impregnated decorative plate 1 according to the embodiment of the present invention will be described below.

[037] First, the image pattern layer 7 is applied to the surface 6a of the base paper 6, the filler layers 8 are applied to the surface 7a of the image pattern layer 7, and the foamed resin layers 9 are applied to the surfaces 8a of the filler layers 8, thus forming the decorative paper 4. Then, the decorative paper 4 is immersed in a water-based impregnation liquid in which the impregnation resin 5 is dissolved or dispersed in water, to impregnate the decorative paper 4 with the impregnation resin 5.

[038] As with impregnation resin 5, it is possible to use a thermosetting resin used in the manufacture of a decorative plate impregnated with a known resin. For example, a melamine-based resin, an epoxy-based resin, or a diallyl phthalate-based resin can be used. Petition 870220100090, dated 10 / 28 / 2022, pp. 78 / 101 16 / 30 a benzoguanamine-based resin, a urethane-based resin, an alkyd-based resin, an unsaturated polyester-based resin, a phenol-based resin, a urea-based resin, and the like. The impregnation of the impregnation resin 5 can be carried out from the side of the decorative paper surface 4 where the image pattern layer 7 is formed, or it can be carried out from the opposite side of the surface. Furthermore, the impregnation can be carried out for each surface, i.e., twice separately, or the impregnation can be carried out simultaneously for both surfaces. An impregnation ratio of the impregnation resin 5 (the ratio of the mass of the impregnation resin to the mass of the decorative paper 4 after impregnation) is preferably 20% or more and 80% or less. In particular, 40% or more and 70% or less is most suitable.In order to obtain a decorative board impregnated with resin 1 that has excellent physical properties, it is important to uniformly impregnate the entire base paper 6 with the impregnation resin 5.

[039] Then, the decorative paper 4 impregnated with the impregnating resin 5 is dried to obtain the resin-impregnated decorative paper 2. Then, the resin-impregnated decorative paper 2 is placed on the base member 3 (FIG. 2), a metal plate (mirrored plate) rests against the surface, where the foamed resin layers 9 are formed, of the resin-impregnated decorative paper 2, then hot pressure molding is applied to a multilayer composite of the resin-impregnated decorative paper 2 and the base member 3 to integrate the resin-impregnated decorative paper 2 and the base member 3 with each other, thus obtaining the resin-impregnated decorative plate 1 of Example 1. At this point, the foaming agent is foamed by heat in the hot pressure molding so that the positions where the foamed resin layers 9 are arranged are Petition 870220100090, dated 10 / 28 / 2022, pp. 79 / 101 17 / 30 protruding to form asymmetrical patterns 10 (FIG. 1). Then, a matte sheen and a tactile sensation are exhibited on the resin-impregnated decorative plate 1 by the asymmetrical patterns formed 10. In the present invention, the case where foaming is performed after impregnation is described, but not limited to it. There are also cases where impregnation and foaming are performed simultaneously.

[040] Between the base member 3 and the resin-impregnated decorative paper 2, an adhesive or similar may be interposed, or an adhesive or similar may not be interposed. Furthermore, a core paper may be interposed as required, as in a method employed for a known melamine resin decorative board. As a core paper, it is possible to use, for example, a paper in which a suitable base paper, such as a titanium paper, a bleached or unbleached kraft paper, or a nonwoven fiberglass fabric, is impregnated with a thermosetting resin in an uncured state. As the thermosetting resin, an arbitrary thermosetting resin may be used according to the physical and similar properties required for the resin-impregnated decorative board 1 to be targeted.For example, one could adopt a melamine-based resin, an epoxy-based resin, a diallyl phthalate-based resin, a benzoguanamine-based resin, a urethane-based resin, an alkyd-based resin, an unsaturated polyester-based resin, a phenol-based resin, a urea-based resin, and the like. As an example of a core paper, one could provide kraft paper impregnated with phenolic resin, which is conventional and widely used as a core paper for a melamine resin decorative board.

[041] As a hot pressure molding method for bonding resin-impregnated decorative paper 2 in a state to be deposited Petition 870220100090, dated 10 / 28 / 2022, pp. 80 / 101 18 / 30 on base member 3, it is possible to use, for example, a method of placing a metal plate against the base and then pressing the plate, a continuous lamination method of the cylinder press type or similar. In particular, a continuous lamination method using an endless metal belt is preferred. According to the continuous lamination method, the decorative plate impregnated with high-quality resin 1, which is densely cured and integrated without deformation, waviness or similar surface defects and with good interlayer adhesion, can be manufactured continuously at high speed.

[042] When the continuous lamination method is used, the surface shape of the resin-impregnated decorative plate 1 is given by the surface shape, as is, of the metal sheet or endless metal belt used in the continuous lamination method, or of an embossed sheet produced by a curable resin or similar. Therefore, a resin-impregnated decorative plate 1 with excellent gloss or surface smoothness can be obtained by using one whose surface is smoothly polished, such as a mirrored surface, such as the metal sheet, the endless metal belt or the embossed sheet produced by the curable resin or similar.

[043] Naturally, using a metal plate, an endless metal belt or an embossed sheet produced by a curable resin or the like, in an arbitrary desired matte state or texture state as required, it is also possible to obtain the resin-impregnated decorative plate 1 in an arbitrary surface finish state, according to a use of the resin-impregnated decorative plate 1 to be targeted.

[044] The resin-impregnated decorative plate 1 of the present invention is not limited to the embodiment described in detail above and can be implemented by adding various modifications in a range without departing from the essence of the present invention. Petition 870220100090, dated 10 / 28 / 2022, pp. 81 / 101 19 / 30

[045] As described above, the resin-impregnated decorative paper 2 according to the embodiment of the present invention is formed by impregnating the decorative paper 4 with the impregnating resin 5, and the decorative paper 4 includes the base paper 6, the image pattern layer 7, the filler layers 8 and the foamed resin layers 9. The image pattern layer 7 is provided on the surface side 6a of the base paper 6. The filler layers 8 contain at least one of an epoxy-based resin, an acrylic-based resin, a urethane-based resin and a casein-based resin and are provided on the surface 7a of the image pattern layer 7. The foamed resin layers 9 are provided on the surfaces 8a of the filler layers 8. Consequently, it is possible to foam the foaming agent to properly form the asymmetrical patterns on the surface of the resin-impregnated decorative paper.Since it is not necessary to prepare a metal sheet for each asymmetrical pattern 10, it is possible to supply resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that are excellent in matte gloss expression and tactile feel, while suppressing cost. Furthermore, it is possible to prevent the foamed resin that forms the foamed resin layers 9 from penetrating the image pattern layer 7 or the base paper 6. Therefore, it is possible to supply resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that are additionally excellent in matte gloss expression and tactile feel.

[046] Furthermore, the thickness of the filler layer 8 was adjusted to 0.5 μm or more and 15 μm or less. Consequently, it is possible to suppress deterioration in design properties and thus provide resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that are excellent in matte gloss expression and tactile feel. Petition 870220100090, dated 10 / 28 / 2022, pp. 82 / 101 20 / 30

[047] Furthermore, the thickness of the filler layer 8 was adjusted to 1 μm or more and 10 μm or less. Consequently, it is possible to suppress deterioration in design properties and thus provide resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that are excellent in matte gloss expression and tactile feel.

[048] Furthermore, the filler layer 8 is provided in the range of 100% or more of the surface area of ​​the foamed resin layer 9. Consequently, it is possible to provide resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that are excellent in matte gloss expression and tactile feel.

[049] Furthermore, the filler layer 8 is provided in the range of 150% or less of the surface area of ​​the foamed resin layer 9. Consequently, it is possible to provide resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that effectively suppress deterioration in design properties.

[050] Furthermore, the foamed resin layers 9 contain the colored ink. Consequently, it is possible to supply resin-impregnated decorative paper 2 and resin-impregnated decorative board 1 that suppress the bleaching of the foamed resin layers 9 to improve the design property.

[051] Furthermore, the decorative paper 4 according to the embodiment of the present invention can form the resin-impregnated decorative plate 1 in which the image formed by the image pattern layer 7 and the asymmetric pattern 10 on the surface of the resin-impregnated decorative plate 1 are aligned with each other in terms of design because the image formed by the image pattern layer 7 and the arrangement position of the foamed resin layer 9 are aligned with each other. Petition 870220100090, dated 10 / 28 / 2022, pp. 83 / 101 21 / 30

[052] Furthermore, the resin-impregnated decorative plate 1 according to the embodiment of the present invention includes the resin-impregnated decorative paper 2 and the base member 3 integrated with the resin-impregnated decorative paper 2. Therefore, it is possible to provide the resin-impregnated decorative plate 1 which is excellent in matte gloss expression and tactile feel, while suppressing cost. Example 1

[053] Hereafter, Examples and Comparative Examples of the resin-impregnated decorative plate 1 according to the present invention will be described. The present invention is not limited to the Examples described below. (Example 1)

[054] First, a titanium paper for decorative paper with high water absorption was prepared as the base paper 6. Then, a wood grain pattern was printed on the surface 6a of the base paper 6 with a water-based ink containing casein as the main component to form the image pattern layer 7 having a layer thickness of 10 μm. As a printing method, an gravure printing method was used. Then, a vase pattern aligned in terms of design with the wood grain pattern of the image pattern layer 7 was printed in line on a surface 7a of the image pattern layer 7 with a water-based ink containing epoxy as the main component and containing a foaming agent to provide the filler layers 8 in the vase pattern. An gravure printing method was used as the printing method and an epoxy-based resin was used as the filler layer 8.The thickness of the filler layer 8 was defined as 3 μm and the range for providing the filler layer 8 was defined as 100% of the surface area of ​​the foamed resin layer 9, that is, the area of ​​an image. Petition 870220100090, dated 10 / 28 / 2022, pp. 84 / 101 22 / 30 formed by the image pattern layer 7. Although there was a plurality of foamed resin layers 9, the filler layers 8 were each provided in the range of 100% of the surface area of ​​the corresponding one of all foamed resin layers 9.

[055] Then, the foamed resin layers 9 were printed onto the surfaces 8a of the filler layers 8 to form the decorative paper 4. A direct engraving printing method was used as the printing method. For the foamed resin layer 9, a particle with an average diameter before foaming of 100 μm (10 times the thickness of the image pattern layer 7) was used, the average particle diameter after foaming was 120 μm, and the initial foaming temperature was 180 °C. Then, the decorative paper 4 was impregnated with the impregnation resin 5, and then dried in an oven to form the resin-impregnated decorative paper 2. A water-based melamine resin liquid was used as the impregnation resin 5. Then, the resin-impregnated decorative paper 2 was placed on the base member 3. A base member particleboard was used as the base member 3.Then, hot pressing at approximately 160 °C was applied to the surface, where the foamed resin layers 9 were formed, of the resin-impregnated decorative paper 2 to apply hot pressure molding to a multilayer composite of the resin-impregnated decorative paper 2 and the base member 3, thus integrating the resin-impregnated decorative paper 2 and the base member 3 together to form the resin-impregnated decorative plate 1 of Example 1. A flat plate was used as the plate in the hot pressing. In the resin-impregnated decorative plate 1, a region without the foamed resin layer 9 of the image pattern layer 7 has a glossy finish and a region with the foamed resin layer 9 of the... Petition 870220100090, dated 10 / 28 / 2022, pp. 85 / 101 The 23 / 30 image pattern layer 7 has a matte finish. (Example 2)

[056] In Example 2, a casein-based resin was used as the filler layers 8. In addition, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 3)

[057] In Example 3, an acrylic-based resin was used as the filler layers 8. In addition, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 4)

[058] In Example 4, a urethane-based resin was used as the filler layers 8. In addition, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 5)

[059] In Example 5, the thickness of the filler layers 8 was defined as 0.5 μm. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 6)

[060] In Example 6, the thickness of the filler layers 8 was defined as 1 μm. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 7)

[061] In Example 7, the thickness of the fill layers 8 was Petition 870220100090, dated 10 / 28 / 2022, pp. 86 / 101 24 / 30 defined as 5 μm. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 8)

[062] In Example 8, the thickness of the filler layers 8 was defined as 7 μm. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 9)

[063] In Example 9, the thickness of the filler layers 8 was defined as 10 μm. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 10)

[064] In Example 10, the thickness of the filler layers 8 was defined as 15 μm. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 11)

[065] In Example 11, the range of the fill layer 8 was increased by 10% and thus defined as 110% of the surface area of ​​the foamed resin layer 9, that is, the area of ​​an image formed by the image pattern layer 7. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 12)

[066] In Example 12, the range of the fill layer 8 was increased by 30% and thus defined as 130% of the surface area of ​​the foamed resin layer 9, that is, the area of ​​an image formed by Petition 870220100090, dated 10 / 28 / 2022, pp. 87 / 101 25 / 30 image pattern layer 7. In addition, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 13)

[067] In Example 13, the range of the filler layer 8 was increased by 50% and thus defined as 150% of the surface area of ​​the foamed resin layer 9, that is, the area of ​​an image formed by the image pattern layer 7. Furthermore, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Example 14)

[068] In Example 14, a colored ink was added to the foamed resin layers 9. In addition, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Comparative Example 1)

[069] In Comparative Example 1, the 8 filler layers were omitted. In addition, the resin-impregnated decorative plate 1 was produced using the same materials and procedures as in Example 1. (Evaluation of performance)

[070] The performance evaluation described below was carried out for the resin-impregnated decorative plates of Examples 1 to 14 and Comparative Example 1. (Cross-sectional test)

[071] In a cross-section test, a cross-section was made in the resin-impregnated decorative plate 1 with a cutter, and an assessment was made as to whether or not flaking occurred. A case in which there was no significant flaking at the time of the cross-section was evaluated as Petition 870220100090, dated 10 / 28 / 2022, pp. 88 / 101 26 / 30 “O”, and a case in which there was significant scaling at the time of cross-sectional cutting was evaluated as x. (Contamination test)

[072] In a contamination test, the decorative plate impregnated with resin 1 was coated with black crayon and red paint and then cleaned with alcohol after one hour, and the degree of cleaning residue was evaluated. A case in which the degree of cleaning residue was less than 30% was evaluated as 0”, a case in which the degree of cleaning residue was 30% or more and less than 70% was evaluated as Δ and a case in which the degree of cleaning residue was 70% or more was evaluated as x. (Assessment of the sense of touch)

[073] In the assessment of the sense of touch, the assessments were made by 10 assessors as a sensory test. A case in which the number of assessors who gave a good assessment was from 7 to 10 was assessed as 0”, a case in which the number of assessors who gave a good assessment was from 1 to 6 was assessed as Δ”, and a case in which the number of assessors who gave a good assessment was zero was assessed as x. (Project evaluation)

[074] In the project evaluation, the evaluations were carried out by 10 evaluators as a sensory test. A case in which the number of evaluators who gave a good evaluation was from 7 to 10 was evaluated as 0”, a case in which the number of evaluators who gave a good evaluation was from 1 to 6 was evaluated as Δ”, and a case in which the number of evaluators who gave a good evaluation was zero was evaluated as x. (Long-term environmental test)

[075] In a long-term environmental test, the resin-impregnated decorative plate 1 was left in an environment with a temperature of 40 °C and Petition 870220100090, dated 10 / 28 / 2022, pp. 89 / 101 27 / 30 humidity of 90% for 2 months and then evaluations were made by 10 evaluators as a sensory test for design change. A case where the number of evaluators who gave a good evaluation was from 7 to 10 was evaluated as “O”, a case where the number of evaluators who gave a good evaluation was from 1 to 6 was evaluated as Δ, and a case where the number of evaluators who gave a good evaluation was zero was evaluated as x. (Comprehensive judgment)

[076] A comprehensive assessment was made based on the five items, namely, the cross-sectional test, the contamination test, the tactile feel assessment, the design assessment and the long-term environmental test described above. A particularly excellent assessment was given as ◎, an excellent assessment was given as 0”, an assessment with almost no problems was given as Δ, and an assessment with one problem was given as x”. (Evaluation results)

[077] These evaluation results are illustrated in Table 1. Petition 870220100090, dated 10 / 28 / 2022, pp. 90 / 101 [Table 1] Cross-sectional Test Contamination Test Touch Sensation Assessment Design Assessment Long-Term Environmental Test Comprehensive Judgment Example 1 (epoxy) OOOOO ◎ Example 2 (casein) OO Δ OOO Example 3 (acrylic) O Δ O Δ O Δ Example 4 (urethane) O Δ Δ Δ Δ Δ Example 5 (0.5 µm) OO Δ OOO Example 6 (1 µm) OOOOO ◎ Example 7 (5 µm) OOOOO ◎ Example 8 (7 µm) OOO Δ OO Example 9 (10 µm) O Δ O Δ O Δ Example 10 (15 µm) O Δ Δ Δ O Δ Example 11 (110%) OOO Δ OO Example 12 (130%) O Δ O Δ Δ Δ Example 13 (150%) O Δ O Δ Δ Δ Example 14 (ink) OOOOO ◎ Comparative Example 1 OXXXXX 28 / 30 Petition 870220100090, dated 10 / 28 / 2022, pp. 91 / 101 29 / 30

[078] As illustrated in Table 1, with respect to the cross-sectional test, flaking was not observed in any of Examples 1 to 14 and in Comparative Example 1, and therefore there was no problem with adhesion. However, compared to Comparative Example 1 in which the 8 filler layers were omitted, the tactile feel assessment and the design assessment were improved in Examples 1 to 14 in which the 8 filler layers were provided. In particular, as revealed by the results of the assessment of Examples 1 to 4, the resin-impregnated decorative boards employing, respectively, epoxy-based resin, acrylic-based resin, urethane-based resin and casein-based resin as the 8 filler layers were excellent or had almost no problems with respect to the tactile feel assessment and the design assessment.Furthermore, as revealed by the evaluation results of Examples 5 to 10, there was a tendency for a decrease in design property as the thickness of filler layer 8 increased. Additionally, as revealed by the evaluation results of Examples 11 to 13, there was a tendency for a decrease in design property as the coating area of ​​filler layer 8 increased. On the other hand, when filler layer 8 is very thin (less than 0.5 μm), the foamed resin penetrates, so that a tactile feel and a matte sheen feel decrease, and the design property also decreases. Furthermore, as revealed by the evaluation results of Example 14, the degree of freedom for design expression was improved and the design property was improved by adding colored paint to the foamed resin layers 9.According to the comprehensive assessment, the resin-impregnated decorative plates of Examples 1, 6, 7, and 14 were particularly excellent. Although epoxy-based resin was used as the filler layers 8. Petition 870220100090, dated 10 / 28 / 2022, pp. 92-101 30 / 30 in Examples 5 to 14, even when casein-based resin, acrylic-based resin, urethane-based resin, or similar resins are used instead of epoxy-based resin, there is no significant difference in the basic physical properties, so approximately the same results are obtained.

[079] Although the description given above refers to a limited number of modalities, the scope of the right is not limited to them and changes to the modalities based on the disclosure described above are evident to those skilled in the art.

[080] List of Reference Signs resin-impregnated decorative plate resin-impregnated decorative paper base member 3rd surface decorative paper resin impregnation paper base 6th surface layer image pattern 7th surface filler layer 8th surface layer of foamed resin, asymmetrical pattern. Petition 870220100090, dated 10 / 28 / 2022, pp. 93 / 101

Claims

1 / 2 CLAIMS 1. Resin-impregnated decorative paper formed by impregnating a decorative paper with an impregnating resin, the decorative paper characterized in that it comprises: a base paper; an image pattern layer provided on one surface side of the base paper; a filler layer provided on one surface of the image pattern layer; and a foamed resin layer provided on one surface of the filler layer, the foamed resin layer formed by a foaming agent, wherein the filler layer contains at least one of an epoxy-based resin, an acrylic-based resin, a urethane-based resin and a casein-based resin, wherein the filler layer has a thickness of 0.5 μm or more and less than 7 μm.

2. Decorative paper impregnated with resin, according to claim 1, characterized in that the filler layer is provided in a range of 100% or more of the surface area of ​​the foamed resin layer.

3. Decorative paper impregnated with resin, according to claim 2, characterized in that the filler layer is provided in a range of 150% or less of the surface area of ​​the foamed resin layer.

4. Decorative paper impregnated with resin, according to any one of claims 1 to 3, characterized in that the foamed resin layer contains a colored ink. Petition 870240102421, dated 02 / 12 / 2024, page 12 / 13 2 / 2 5. Decorative paper impregnated with resin, according to any one of claims 1 to 4, characterized in that an image formed by the image pattern layer and a positioning of the foamed resin layer are aligned with each other.

6. Resin-impregnated decorative plate, characterized in that it comprises: resin-impregnated decorative paper, as defined in any one of claims 1 to 5; and a base member integrated with the resin-impregnated decorative paper. Petition 870240102421, dated 02 / 12 / 2024, p. 13 / 13

Images