Resin-impregnated decorative paper and resin-impregnated decorative plate

Abstract

The resin-impregnated decorative paper is obtained by impregnating a decorative paper with an impregnating resin. The decorative paper has a base paper, a pattern layer formed by printing on an upper UP of the base paper, and a foamed resin layer laminated on the upper UP of the pattern layer and containing a foaming agent. The foamed resin layer is foamed to expand in volume, thereby forming a concave-convex pattern part on the upper UP surface of the pattern layer, and the maximum height in the vertical direction from the concave part to the convex part of the concave-convex pattern part is 20 [mu] m to 90 [mu] m (inclusive).

Description

Technical Field

[0001] The invention relates to resin impregnated decorative paper and resin impregnated decorative board.

[0002] This application claims the benefit of priority based on Tokugan Application No. 2022-113972 filed in Japan on July 15, 2022, the contents of which are incorporated herein by reference. Background Art

[0003] The resin-impregnated decorative board formed by bonding a resin-impregnated decorative paper impregnated with a thermosetting resin to a substrate is a decorative board having high surface hardness and excellent stain resistance, wear resistance, heat resistance, and water resistance. Therefore, the resin-impregnated decorative board is used as a surface material for furniture such as tables or a surface material for fixed objects such as counters in stores. In addition, when the surface of the resin-impregnated decorative board requires a sense of touch, the sense of touch can be imparted by applying pressure to the surface of the resin-impregnated decorative board with a pressing plate having a concave-convex pattern to perform an embossing process in which the concave-convex pattern is transferred to the surface of the resin-impregnated decorative board. As a resin-impregnated decorative board, for example, there is a low-pressure melamine decorative board formed by low-pressure crimping of a resin-impregnated decorative paper impregnated with a melamine resin to a substrate such as a particle board.

[0004] As a resin-impregnated decorative plate that imparts a tactile feel to the surface, there is a resin-impregnated decorative plate described in Patent Document 1. The resin-impregnated decorative plate described in Patent Document 1 forms a concave-convex pattern by foaming a foaming agent disposed in a patterned pattern layer. As a result, a tactile feel can be imparted to the surface of the resin-impregnated decorative plate without performing an embossing process. Therefore, a pressing plate for embossing is not required, and thus production costs can be reduced.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Publication No. 2019-206109 Summary of the invention

[0008] Problems to be solved by the invention

[0009] However, in the resin-impregnated decorative plate described in Patent Document 1, the surface roughness of the concavo-convex pattern formed by the foaming of the foaming agent is large, and therefore, although it has an excellent touch, it may be inferior in scratch resistance and stain resistance.

[0010] Based on the above situation, the present disclosure relates to a resin-impregnated decorative board whose surface is given a tactile feel by foaming a foaming agent. The present disclosure is completed in view of the above problems, and its purpose is to provide a resin-impregnated decorative board having a surface roughness with excellent tactile feel and high scratch resistance and stain resistance, and a resin-impregnated decorative paper used for the resin-impregnated decorative board.

[0011] Means for solving problems

[0012] In order to solve the above-mentioned problems, the present invention proposes the following means.

[0013] The resin-impregnated decorative paper disclosed herein is a resin-impregnated decorative paper in which an impregnating resin is impregnated, the decorative paper comprising base paper, a patterned layer formed by printing on the upper side of the base paper, and a foamed resin layer stacked on the upper side of the patterned layer and containing a foaming agent, the foamed resin layer foams and expands in volume, thereby forming a concave-convex pattern portion on the upper side of the patterned layer, and the maximum height from the concave part to the convex part of the concave-convex pattern portion in the up and down direction is not less than 20 μm and not more than 90 μm.

[0014] In the resin-impregnated decorative paper, the foaming agent may have a foaming start temperature of 150° C. to 220° C., and a particle size after foaming may be 100 μm to 200 μm.

[0015] In the above resin impregnated decorative paper, the base paper may be titanium paper.

[0016] In the above resin-impregnated decorative paper, the impregnating resin may contain melamine resin.

[0017] The resin-impregnated decorative board of the present disclosure includes the above-mentioned resin-impregnated decorative paper and a base material bonded to the lower side of the resin-impregnated decorative paper.

[0018] Effects of the Invention

[0019] According to the resin-impregnated decorative paper and the resin-impregnated decorative board of the present disclosure, a resin-impregnated decorative board having a surface roughness having both excellent touch and high scratch resistance and stain resistance and a resin-impregnated decorative paper for the resin-impregnated decorative board can be provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] [ Figure 1 ] is a cross-sectional view of the resin-impregnated decorative paper before foaming involved in this embodiment.

[0021] [ Figure 2 ] is a cross-sectional view of the resin-impregnated decorative panel after foaming involved in this embodiment. DETAILED DESCRIPTION

[0022] Reference Figure 1 and Figure 2 One embodiment of the present invention will be described.

[0023] Figure 1 It is a cross-sectional view of the resin-impregnated decorative paper 10 before foaming according to the present embodiment. Figure 2 is Figure 12 is a cross-sectional view of a resin-impregnated decorative board 100 formed by bonding a base material 20 to a resin-impregnated decorative paper 10 and foaming a foamed resin layer 1.

[0024] In this embodiment, if Figure 1 and Figure 2 As shown, the thickness direction of the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 is defined as the "up-down direction V", the side on which the substrate 20 is bonded to the resin-impregnated decorative paper 10 is defined as the "lower side LO" in the up-down direction V, and the side opposite to the side on which the substrate 20 is bonded to the resin-impregnated decorative paper 10 is defined as the "upper side UP" in the up-down direction V.

[0025] In addition, if Figure 2 As shown in FIG. 1 , a plurality of concave portions 100b and a plurality of convex portions 100t are formed by foaming the foamed resin layer 1. The maximum height in the vertical direction V from the bottom surface of the concave portion 100b (in this embodiment, between adjacent convex portions 100t) of the concave-convex pattern portion 100p to the top of the convex portion 100t is defined as "surface roughness R". The number of the concave portions 100b and the convex portions 100t is plural, but the number of the concave portions 100b and the convex portions 100t is not particularly limited.

[0026] The resin-impregnated decorative board 100 includes a resin-impregnated decorative paper 10 and a base material 20. The base material 20 is bonded to the lower side LO of the resin-impregnated decorative paper 10 by heat-pressing molding. As the base material 20, a particle board or a medium-density fiberboard (MDF) or the like can be used.

[0027] The resin-impregnated decorative paper 10 is formed by drying the decorative paper 10a impregnated with the impregnating resin 10b. By impregnating the impregnating resin 10b in the decorative paper 10a, the impregnating resin 10b penetrates into the inside of the decorative paper 10a and covers the upper surface of the decorative paper 10a. By drying the decorative paper 10a impregnated with the impregnating resin 10b, the impregnating resin 10b is cured. As a result, the resin-impregnated decorative paper 10 has excellent properties such as high surface hardness, stain resistance, wear resistance, heat resistance, and water resistance.

[0028] The impregnating resin 10b is a well-known thermosetting resin used for resin-impregnated decorative panels. In the present embodiment, the impregnating resin 10b includes melamine resin. Melamine resin has high strength and excellent stain resistance, wear resistance, heat resistance and water resistance, so melamine resin is preferably used as the impregnating resin 10b.

[0029] It should be noted that the impregnating resin 10b does not necessarily need to contain melamine resin.

[0030] The decorative paper 10 a includes a foamed resin layer 1 , a pattern layer 2 , and a base paper 3 .

[0031] The base paper 3 is a layer stacked on the lower side LO of the decorative paper 10a. The base paper 3 is a known fibrous sheet material that can be impregnated with the impregnating resin 10b. As the base paper 3, for example, titanium paper or thin paper can be used. In order to prevent the color and texture of the base material 20 from being transmitted after bonding with the base material 20, it is preferred to use titanium paper with excellent concealment as the base paper 3.

[0032] The pattern layer 2 is a layer printed on the upper side UP of the base paper 3, and is formed by printing, for example, wood grain, stone grain, sand grain, etc. As a printing method, for example, a known printing method such as gravure printing, offset printing, flexographic printing, screen printing, or inkjet printing can be used.

[0033] The foamed resin layer 1 is a layer printed on the upper side UP of the patterned layer 2, and is formed of a foamed resin layer resin 1a mixed with a foaming agent 1b. The foamed resin layer 1 is a layer used to give a three-dimensional effect to the surface 2s of the upper side UP of the patterned layer 2, and is printed at any position of the surface 2s of the upper side UP of the patterned layer 2. The foamed resin layer 1 can be printed at a position synchronized with the pattern of the patterned layer 2 or at an asynchronous position. As a printing method, for example, a known printing method such as gravure printing, offset printing, flexographic printing, screen printing or inkjet printing can be used. The foamed resin layer resin 1a can use a known printing ink suitable for the printing method used.

[0034] The foaming agent 1b is a heat-expandable microcapsule. The heat-expandable microcapsule used in the foaming agent 1b is a resin capsule containing foaming components such as hydrocarbons, which foams and expands in volume when heated. As the resin forming the heat-expandable microcapsule used in the foaming agent 1b, epoxy resin, casein resin or acrylic resin can be used.

[0035] The foamed resin layer 1 forms a concavo-convex pattern portion 100 p on the upper side UP surface 2 s of the pattern layer 2 due to foaming of the foaming agent 1 b .

[0036] The particle size of the foaming agent 1b after foaming is preferably 100 μm or more and 200 μm or less. When the particle size of the foaming agent 1b after foaming is less than 100 μm, the surface roughness R of the concavo-convex pattern portion 100p formed by the foaming of the foaming agent 1b is small, so the touch may become weak. On the other hand, when the particle size of the foaming agent 1b after foaming is greater than 200 μm, the surface roughness R of the concavo-convex pattern portion 100p is large, so the scratch resistance and stain resistance may be reduced.

[0037] In addition, the foaming start temperature of the foaming agent 1b is preferably 150°C or more and 220°C or less. When the foaming start temperature of the foaming agent 1b is lower than 150°C, when the resin-impregnated decorative paper 10 and the base material 20 are bonded together by heat-pressing molding, the foaming agent 1b starts to foam in the early stage of heat-pressing molding, so the pressurization time after the foaming agent 1b foams becomes longer, and the foamed resin layer 1 is flattened. As a result, the touch of the concavo-convex pattern portion 100p may become weak. On the other hand, when the foaming start temperature of the foaming agent 1b is higher than 220°C, the foaming agent 1b cannot be fully foamed during heating, and the touch of the concavo-convex pattern portion 100p may become weak.

[0038] Next, a method for manufacturing the resin-impregnated decorative board 100 will be described.

[0039] First, a patterned pattern layer 2 is formed by printing on the upper side UP of the base paper 3. A foamed resin layer 1 formed of a foamed resin layer resin 1a mixed with a foaming agent 1b is printed on the upper side UP of the patterned pattern layer 2. As a result, a decorative paper 10a including the base paper 3, the patterned pattern layer 2, and the foamed resin layer 1 is formed.

[0040] At this time, the foamed particle size of the foaming agent 1b contained in the foamed resin layer 1 after foaming is 100 μm or more and 200 μm or less. In addition, the foaming start temperature of the foaming agent 1b is 150° C. or more and 220° C. or less.

[0041] Next, the decorative paper 10a is impregnated with the impregnating resin 10b and then dried in an oven to form the resin-impregnated decorative paper 10. The base material 20 is bonded to the lower side LO of the resin-impregnated decorative paper 10 by heat and pressure molding to obtain the resin-impregnated decorative board 100.

[0042] The foamed resin layer 1 reaches the foaming start temperature and foams under the heating of the hot press molding for bonding the resin impregnated decorative paper 10 and the base material 20, and forms a concavo-convex pattern portion 100p on the upper side UP surface 2s of the patterned layer 2. At this time, the surface roughness R of the concavo-convex pattern portion 100p is 20 μm or more and 90 μm or less.

[0043] As for the heat-pressing molding method for bonding the resin-impregnated decorative paper 10 and the substrate 20, a heat-pressing molding method known as a heat-pressing method for a decorative plate can be used. For example, as the heat-pressing molding method, there are: a method of heat-pressing the resin-impregnated decorative paper 10 and the substrate 20 facing each other in the vertical direction V by heating and pressing them flatly with a flat plate, a method of heat-pressing the resin-impregnated decorative paper 10 and the substrate 20 facing each other in the vertical direction V by continuously heating and pressing them with a rotating circular pressing endless belt that sandwiches the resin-impregnated decorative paper 10 and the substrate 20 facing each other in the vertical direction V, and the like.

[0044] According to the resin-impregnated decorative paper 10 and the resin-impregnated decorative board 100 of the present embodiment, the surface roughness R of the concave-convex pattern portion 100p formed by the foaming of the foamed resin layer 1 is greater than 20 μm and less than 90 μm. Since the surface roughness R is greater than 20 μm, the resin-impregnated decorative board 100 has an excellent touch. In addition, since the surface roughness R of the concave-convex pattern portion 100p is less than 90 μm, the resin-impregnated decorative board 100 has high scratch resistance and stain resistance. As a result, a resin-impregnated decorative board 100 having a surface roughness R with both excellent touch and high scratch resistance and stain resistance, and a resin-impregnated decorative paper 10 for the resin-impregnated decorative board 100 can be provided.

[0045] Above, an embodiment of the present invention is described in detail with reference to the accompanying drawings, but the specific structure is not limited to this embodiment, and also includes design changes within the scope of the main purpose of the present disclosure. In addition, the components shown in the above-mentioned embodiment and the modified examples shown below can be appropriately combined and constituted.

[0046] (Variant 1)

[0047] In the above embodiment, the decorative paper 10a includes the foamed resin layer 1, the patterned layer 2 and the base paper 3, but the form of the decorative paper is not limited thereto. The decorative paper may also include a layer having a conduit display for visually giving a three-dimensional effect, a filler layer for preventing the foamed resin layer 1 or the patterned layer 2 from penetrating into the base paper 3, and the like.

[0048] (Variant 2)

[0049] In the above embodiment, the foamed resin layer 1 contains the foaming agent 1b as the thermally expandable microcapsules, but the form of the foamed resin layer is not limited thereto. The foamed resin layer may also contain a thermally decomposable chemical foaming agent.

[0050] (Variant 3)

[0051] In the above embodiment, the heating process for foaming the foamed resin layer 1 is performed when the resin-impregnated decorative paper 10 and the substrate 20 are heated and pressed, but the process of foaming the foamed resin layer is not limited thereto. The process of foaming the foamed resin layer may also be performed before or after the resin-impregnated decorative paper and the substrate are bonded together.

[0052] (Variant 4)

[0053] In the above embodiment, the resin impregnated decorative paper 10 and the substrate 20 are bonded by heating and pressing, but the bonding method of the resin impregnated decorative paper and the substrate is not limited thereto. The bonding method of the resin impregnated decorative paper and the substrate may also be a bonding method without heating.

[0054] The present invention is described in detail below by way of examples. The present invention is not limited to the following examples.

[0055] (Example 1)

[0056] Titanium paper was prepared as the base paper 3. A patterned pattern layer 2 was formed on the upper side UP of the base paper 3 by gravure printing. A foamed resin layer 1 was formed on the upper side UP of the patterned pattern layer 2 by gravure printing. As shown in Table 1, the foaming agent 1b contained in the foamed resin layer 1 used heat-expandable microcapsules made of epoxy resin. In addition, the foaming start temperature of the foaming agent 1b was 220°C, and the particle size after foaming was 220μm.

[0057] The decorative paper 10a thus obtained was impregnated with melamine resin as the impregnating resin 10b, and then fully dried in an oven to form the resin-impregnated decorative paper 10. The resin-impregnated decorative paper 10 and the particle board as the base material 20 were bonded together by heat-pressing molding, and the foaming agent 1b was foamed to form the resin-impregnated decorative board 100 of Example 1. At this time, the resin-impregnated decorative board 100 was not embossed by a press plate.

[0058] (Example 2)

[0059] As shown in Table 1, the foaming starting temperature of the foaming agent 1b used was 200° C., and the particle size after foaming was 200 μm. The resin-impregnated decorative board 100 of Example 2 was formed in the same manner as Example 1 except for the above.

[0060] (Example 3)

[0061] As shown in Table 1, the foaming agent 1b used thermally expandable microcapsules made of casein resin. The foaming starting temperature of the foaming agent 1b was 180°C, and the particle size after foaming was 150 μm. The resin-impregnated decorative board 100 of Example 3 was formed in the same manner as Example 1 except for the above.

[0062] (Example 4)

[0063] As shown in Table 1, the foaming agent 1b used thermally expandable microcapsules made of acrylic resin. The foaming starting temperature of the foaming agent 1b was 150°C, and the particle size after foaming was 100 μm. The resin-impregnated decorative board 100 of Example 4 was formed in the same manner as Example 1 except for the above.

[0064] (Comparative Example 1)

[0065] As shown in Table 1, the foaming agent used was a thermally expandable microcapsule made of casein resin. The foaming starting temperature of the foaming agent was 220° C., and the particle size after foaming was 250 μm. A resin-containing decorative board of Comparative Example 1 was formed in the same manner as Example 1 except for the above.

[0066] (Comparative Example 2)

[0067] As shown in Table 1, the foaming agent used was a heat-expandable microcapsule made of casein resin. The foaming starting temperature of the foaming agent was 100° C., and the particle size after foaming was 50 μm. Except for this, the resin-containing decorative board of Comparative Example 2 was formed in the same manner as in Example 1.

[0068] [Table 1]

[0069]

[0070] (Measurement 1)

[0071] In the resin-containing decorative boards of Examples 1 to 4 and Comparative Examples 1 and 2, the surface roughness R of the concavo-convex pattern portion formed by foaming of the foamed resin layer was measured. The surface roughness measuring instrument SURFCOM120A manufactured by Tokyo Seimitsu Co., Ltd. was used for the measurement.

[0072] (Experiment 1)

[0073] A scratch resistance test was performed on the resin-containing decorative plates of Examples 1 to 4 and Comparative Examples 1 and 2. In the scratch resistance test, a coin scratch test was performed on the resin-containing decorative plates to evaluate scratches on the concavo-convex pattern portion.

[0074] The evaluation criteria were set to three levels, and those other than × were considered pass.

[0075] ◎(Excellent): No scratches.

[0076] 0(Good): There are no obvious scratches.

[0077] ×(Poor): There are obvious scratches.

[0078] (Experiment 2)

[0079] The stain resistance test was performed on the resin-containing decorative plates of Examples 1 to 4 and Comparative Examples 1 and 2. In the stain resistance test, the concave and convex pattern of the resin-containing decorative plate was covered with black crayon and red ink, and wiped with alcohol after 1 hour, and the degree of wiped residue was evaluated.

[0080] The evaluation criteria were set to three levels, and those other than × were considered pass.

[0081] ◎(Excellent): Less than 30% of the residue remains after wiping.

[0082] ○ (Good): The wiping residue is 30% or more and less than 70%.

[0083] × (Poor): The wiping residue is 70% or more and 100% or less.

[0084] (Experiment 3)

[0085] A touch evaluation test was performed on the resin-containing decorative plates of Examples 1 to 4 and Comparative Examples 1 and 2. In the touch evaluation test, 10 testers performed a sensory test of the touch of the concavo-convex pattern portion of the resin-containing decorative plate and evaluated the degree of hand touch.

[0086] The evaluation criteria were set to three levels, and those other than × were considered pass.

[0087] ◎(Excellent): The number of people who evaluated that the hand touch was good was 7 or more and 10 or less.

[0088] ○ (Good): The number of people who evaluated that the hand touch was good was 1 or more and 6 or less.

[0089] × (Poor): No one evaluated that the touch was good.

[0090] (Measurement results and experimental results)

[0091] Table 2 shows the results of Measurement 1 and Experiments 1 to 3.

[0092] Examples 1 to 4 showed good results in all evaluation tests. Examples 2 and 3, whose surface roughness R was smaller than that of Example 1 and larger than that of Example 4, showed better results.

[0093] Among Examples 1 to 4 and Comparative Examples 1 and 2, Comparative Example 1, which had the largest surface roughness R of 102.1 μm, failed the scratch resistance test and the stain resistance test. Comparative Example 2, which had the smallest surface roughness of 8.6 μm, failed the touch evaluation test.

[0094] [Table 2]

[0095]

[0096] Industrial Applicability

[0097] According to the resin-impregnated decorative paper and the resin-impregnated decorative board of the present disclosure, a resin-impregnated decorative board having a surface roughness having both excellent touch and high scratch resistance and stain resistance and a resin-impregnated decorative paper for the resin-impregnated decorative board can be provided.

[0098] Explanation of symbols

[0099] 100 resin impregnated decorative board

[0100] 100p concave and convex pattern

[0101] 100t convex part

[0102] 100b concave part

[0103] 10Resin impregnated decorative paper

[0104] 10a Decorative paper

[0105] 10b Impregnation resin

[0106] 1 Foam resin layer

[0107] 1a Resin for foaming resin layer

[0108] 1b Foaming agent

[0109] 2 Pattern layer

[0110] 2s The upper side of the pattern layer UP

[0111] 3. Base paper

[0112] 20 substrate

[0113] V Up and down direction

[0114] UP

[0115] LO lower side

[0116] RSurface roughness

Claims

1. A resin impregnated decorative paper, which is a resin impregnated decorative paper in which an impregnating resin is impregnated, The decorative paper has: Original paper, a patterned layer formed by printing on the upper side of the base paper, and a foamed resin layer stacked on the upper side of the patterned layer and containing a foaming agent, The foamed resin layer expands in volume by foaming, thereby forming a concavo-convex pattern portion on the upper surface of the patterned layer. The maximum height in the vertical direction from the concave portion to the convex portion of the concavo-convex pattern portion is 20 μm or more and 90 μm or less.

2. The resin impregnated decorative paper according to claim 1, wherein: The foaming starting temperature of the foaming agent is 150° C. to 220° C., and the particle size of the foaming agent after foaming is 100 μm to 200 μm.

3. The resin-impregnated decorative paper according to claim 1 or 2, wherein: The base paper is titanium paper.

4. The resin-impregnated decorative paper according to any one of claims 1 to 3, wherein: The impregnating resin comprises melamine resin.

5. A resin-impregnated decorative panel comprising: The resin-impregnated decorative paper according to any one of claims 1 to 4; and A substrate is bonded to the underside of the resin impregnated decorative paper.

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