Composition, transfer sheet, melamine decorative board, and method for manufacturing melamine decorative board

Abstract

This composition includes: (A) a hydrolyzed condensate of a silicon alkoxide; (B) an organosilica sol dispersed in a hydrophilic solvent; and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group. This melamine decorative board includes, in the following order, a core layer, a decorative layer, and a cured layer of the abovementioned composition. The decorative layer includes a cured product of a melamine resin layer.

Description

Cross - reference to related applications

[0001] This international application claims priority based on Japanese Patent Application No. 2020 - 76030, filed with the Japan Patent Office on April 22, 2020, and incorporates by reference the entire contents of Japanese Patent Application No. 2020 - 76030 into this international application.

Technical Field

[0002] The present disclosure relates to a composition, a transfer sheet, a melamine decorative board, and a method for manufacturing a melamine decorative board.

Background Art

[0003] A melamine decorative board is obtained by using a melamine resin - containing pattern paper as a design layer and heating and pressing the melamine resin - containing pattern paper and a core material, such as a phenol resin - impregnated paper, with a press machine. The melamine decorative board can have various finishes by changing the pattern, color tone, etc. of the pattern paper.

[0004] Such melamine decorative boards are widely used in furniture such as countertops and desks, and interior materials such as wall surfaces and floors because they are excellent in various physical properties such as surface hardness, heat resistance, and abrasion resistance.

[0005] In recent years, problems such as the easy visibility of fingerprint adhesion and oil stains on melamine decorative boards, and the problem that the living odor becomes noticeable with the increase in the airtightness of houses have emerged. In public facilities such as hospitals, a cleaner environment has been increasingly required.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Patent Document 3

Summary of the Invention

Problems to be Solved by the Invention

[0007] The applicant has disclosed a decorative board (Patent Document 1) having fingerprint resistance and oil wiping properties. However, it is difficult to uniformly disperse a substance imparting deodorizing properties in the composition of Patent Document 1, and deodorizing properties may not be sufficiently obtained. Further, the applicant has disclosed a decorative board (Patent Document 2) that imparts deodorizing performance and reduces living odor and chemical odor. However, in the method of Patent Document 2, it is difficult to uniformly apply a substance imparting antiviral or antiallergic properties, and antiviral or antiallergic properties may not be sufficiently obtained.

Means for Solving the Problems

[0008] One aspect of the present disclosure is a composition including (A) a hydrolysis condensate of a silicon alkoxide, (B) an organosilica sol dispersed in a hydrophilic solvent, and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group.

[0009] One aspect of the present disclosure is a transfer sheet having a sheet-like base material and a cured layer of the above-described composition formed on one side of the sheet-like base material.

[0010] One aspect of the present disclosure is a melamine decorative board including a core layer, a decorative layer, and a cured layer of the above-described composition in this order. The decorative layer includes a cured product of a melamine resin layer.

[0011] One aspect of the present disclosure is a method for manufacturing a melamine decorative board, the melamine decorative board including a core layer, a decorative layer including a cured product of a melamine resin, and a surface layer in this order. The method for manufacturing a melamine decorative board includes curing the above-described composition to form a surface layer.

Advantages of the Invention

[0012] According to one aspect of the present disclosure, a substance exhibiting functions such as deodorizing properties, antiviral properties, and antiallergic properties (hereinafter referred to as a function-expressing substance) can be uniformly dispersed, and a composition excellent in functionality is provided.

[0013] Further, according to one aspect of the present disclosure, there are provided a transfer sheet and a melamine decorative board having excellent functionality, which include a cured product of such a composition, and a method for manufacturing the melamine decorative board.

Brief Description of Drawings

[0014]

Figure 1

Figure 2

Figure 3

Explanation of Signs

[0015] 2 Cured layer of the functional composition 3 Melamine resin-impregnated pattern paper 4 Prepreg 5 Phenol resin-impregnated core paper 6 Core layer 7 Backer 8 Melamine resin-impregnated overlay paper 11 Melamine decorative board 12 Melamine decorative board 13 Melamine decorative board

Embodiments for Carrying Out the Invention

[0016] Hereinafter, the present disclosure will be described in detail.

[0017] (A) The hydrolysis condensate of silicon alkoxide forms a lattice-like skeleton. When the functional expression substance described later is blended, it is uniformly dispersed and exhibits an effect with a small addition amount of the functional expression substance. Specific examples of silicon alkoxides include those having the structure represented by the following Chemical Formula 1 (n is an integer). More specifically, tetramethyl orthosilicate (Si(OCH3)4), tetraethyl orthosilicate (Si(OC2H5)4), tetrapropyl orthosilicate (Si(OC3H7)4), etc. can be mentioned. Silicon alkoxides are mainly synthesized by the reaction of silicon tetrachloride with alkyl alcohol or the reaction of metallic silicon with alkyl alcohol. <Chemical Formula 1>

[0018]

Chem.

[0019]

Chem.

[0020] Examples of the organosilica sol of component (B) include colloidal solutions in which colloidal silica having an average particle diameter of 1 to 40 nm (more preferably an average particle diameter of 7 to 30 nm) is stably dispersed in an organic solvent. The silica concentration is preferably in the range of 1 to 50% by mass, and more preferably 40% by mass or less to prevent gelation. The average particle diameter of the colloidal silica is the particle diameter at 50% of the integrated value in the particle size distribution determined by the laser diffraction / scattering method.

[0021] Commercially available products of organosilica sol include "IPA-ST", "IPA-ST-ZL", "methanol silica sol", "NPC-ST-30", "MEK-AC-2140Z", "EG-ST", "DMAC-ST", etc. manufactured by Nissan Chemical Industries, Ltd., "OSCAL" manufactured by Catalysts & Chemicals Industries Co., Ltd., "Quattroon (registered trademark)" manufactured by Fuso Chemical Industry Co., Ltd., "Highlink (registered trademark) OG silica organosol" manufactured by Clariant Japan K.K., and the like.

[0022] Here, the hydrophilic (polar) solvent is a solvent having an affinity for water, and for example, it is a hydrophilic organic solvent having a hydrophilic group such as a hydroxyl group, a carboxyl group, or a carbonyl group in the molecule. Examples of the hydrophilic (polar) solvent include protic polar solvents and aprotic polar solvents. Specific examples of the protic polar solvent include alcohol solvents such as methyl alcohol, ethyl alcohol, isopropyl alcohol, ethylene dialcohol, and propanol, and cellosolve solvents such as methyl cellosolve, ethyl cellosolve, butyl cellosolve, and n-propyl cellosolve. Examples of the aprotic polar solvent include acetone, dimethyl sulfoxide (DMSO), N,N-dimethylformamide (DM F )), pyridine, and the like.

[0023] Here, a hydrophilic (polar) solvent is a solvent having an affinity for water, for example, a hydrophilic organic solvent having a hydrophilic group such as a hydroxyl group, a carboxyl group, or a carbonyl group in the molecule. Examples of the hydrophilic (polar) solvent include a protic polar solvent and an aprotic polar solvent. Specific examples of the protic polar solvent include alcohol solvents such as methyl alcohol, ethyl alcohol, isopropanol, ethylene dialcohol, and propanol, and cellosolve solvents such as methyl cellosolve, ethyl cellosolve, butyl cellosolve, and n-propyl cellosolve. Examples of the aprotic polar solvent include acetone, dimethyl sulfoxide (DMSO), N,N-dimethylformamide (DMF), and pyridine.

[0024] (C) The acrylic polymer is preferably a copolymer of a monomer having a hydrophilic group that exhibits an affinity for a pigment and a monomer having a hydrophobic group that controls compatibility and forms steric hindrance. Such an acrylic polymer can uniformly disperse the functional expression substance by adsorbing the functional expression substance with the hydrophilic group and suppressing aggregation with the hydrophobic group. In fact, although an organosilica sol having a particle diameter of about 20 to 30 nm aggregates to form an aggregate having a large particle diameter of 600 to 1000 nm, by being uniformly dispersed, the light scattering property of the cured layer of the functional composition is enhanced, and appearance defects due to light interference can be reduced.

[0025] Examples of the hydrophilic group include anionic groups such as carboxyl group, sulfonic acid group, and phosphoric acid group, and cationic groups such as amino group and ammonium group. Specific examples of the monomer having a hydrophilic group include acrylic acid, acrylamide, methacrylic acid, poly(ethylene glycol) acrylate and methacrylate, dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate, t-butylaminoethyl methacrylate, dimethylaminoethyl acrylate, diethylaminoethyl acrylate, methacrylamide, dimethacrylamide, dimethylaminopropyl methacrylamide, ethylene glycol methacrylate phosphate, 2-(methacryloyloxy)methyl phthalate, 2-(methacryloyloxy)ethyl succinate, 3-sulfopropyl methacrylate, 3-sulfopropyl acrylate, and the like.

[0026] Examples of the hydrophobic group include alkyl group, phenyl group, and the like. Specifically, examples of the monomer having a hydrophobic group include methyl methacrylate, butyl methacrylate, hexyl acrylate, hexyl ethyl acrylate, benzyl acrylate, benzyl methacrylate, phenoxyethyl acrylate, phenoxyethyl methacrylate, and mixtures thereof.

[0027] In the above-described composition, the organosilica sol of component (B) is preferably blended in an amount of 0.5 to 12 parts by mass, more preferably 1 to 9 parts by mass, based on 1 part by mass (in terms of solid content) of the hydrolysis condensate of the silicon alkoxide of component (A). When the blending ratio of component (A) is at least the lower limit, the effect of expressing functionality is improved, and when it is at most the upper limit, the solvent resistance is improved.

[0028] The acrylic polymer having a hydrophilic group and a hydrophobic group as component (C) is preferably blended in an amount of 0.005 to 0.3 parts by mass, more preferably 0.01 to 0.07 parts by mass (in terms of solid content) based on 1 part by mass (in terms of solid content) of component (B). When the blending ratio of component (C) exceeds the upper limit, the aggregability of colloidal silica increases. Therefore, when the blending ratio of component (C) is below the upper limit, appearance defects due to light interference in the low refractive index layer can be suppressed. Also, when the blending ratio of component (C) is at least the lower limit, the blending liquid has an appropriate viscosity and a uniform low refractive index layer can be formed, making fingerprints less prominent and the pattern of the printed paper clearer on the melamine decorative board.

[0029] A composition containing (A) a hydrolysis condensate of silicon alkoxide, (B) an organosilica sol dispersed in a hydrophilic solvent, and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group improves the dispersibility of the functional expression substance to be added. Specifically, since the functional expression substance enters into the lattice-like coating film structure of component (A), the functional expression substance can be uniformly coated, and efficient expression of functions is possible even with a small addition amount. In particular, when the functional expression substance contains a solid, specifically solid particles having an average particle diameter of 200 to 5000 nm, such an effect is easily obtained. The average particle diameter referred to here is the particle diameter at the integrated value of 50% in the particle size distribution determined by the laser diffraction / scattering method.

[0030] The functional expression substance is preferably at least one selected from the group consisting of (m) a deodorant substance, (n) an antiviral substance, and (o) an anti-allergenic substance. It is preferable to blend the functional expression substance in the above composition and stir it at 6000 to 10000 rpm for 5 to 10 minutes with a homogenizer. Since the homogenizer pressurizes the composition to a high pressure and a strong shearing force is applied to the composition when passing through the slit (gap), it is possible to disperse it uniformly by stirring with a disperser.

[0031] Next, as an example of a functional substance, the deodorizing substance (m) that exhibits deodorizing properties will be described. Porous materials, such as physical adsorption-type deodorizing substances like activated carbon, adsorb odors (gases) in the pores of the porous material to exert a deodorizing effect. In the case of physical adsorption-type deodorizing substances, when they adsorb gases at room temperature and then come into contact with heat such as high-temperature heat or frictional heat, the adsorption performance decreases, and there is a possibility that the adsorbed gas will be re-released.

[0032] On the other hand, chemically adsorbing deodorizing substances remove odors by changing them into other substances through chemical reactions such as neutralization by acids and alkalis, oxidation-reduction reactions, etc. Once an odor (gas) is adsorbed and decomposed into other substances, it is difficult to be re-released, so it can be preferably used. Examples of chemically adsorbing deodorizing substances include metal oxides such as silica (silicon dioxide), copper oxide, alumina, titanium oxide, zinc oxide, iron oxide, zirconium oxide, and metal hydroxides such as zirconium hydroxide, magnesium hydroxide, aluminum hydroxide, ferrous hydroxide, and copper hydroxide.

[0033] These deodorizing substances (m) that exhibit deodorizing properties are melamine decorative boards with excellent heat resistance and abrasion resistance, and furthermore, they can cope with the living odors generated in a house, that is, the composite odor of acidic odors, neutral odors, and basic odors. Therefore, it is preferable to use the above-mentioned chemically adsorbing deodorizing substances. In recent years, houses have specifications that claim higher airtightness and higher heat insulation compared to the past, and they are in a sealed space without gaps. Therefore, living odors are more easily felt. To suppress such living odors, generally, commercially available deodorant products are used. However, since the melamine decorative board itself has deodorizing properties, living odors can be further reduced.

[0034] As the chemisorption type deodorant substance, specifically, at least one selected from the group consisting of zinc oxide, silica, zeolite, copper oxide, and zirconium oxide is preferable. For example, it is preferable to use zinc oxide and silica in combination as metal oxides, and set the blending ratio to the former: the latter = 45 to 85: 55 to 15 by mass ratio. The deodorant substance is particularly preferably in the form of fine particles, specifically, those having an average particle diameter of 0.2 to 10 μm, because of its good dispersibility in the composition. The average particle diameter referred to here is the particle diameter at the integrated value of 50% in the particle size distribution determined by the laser diffraction / scattering method. In particular, for neutral odors such as acetaldehyde and formaldehyde and basic odors such as ammonia and trimethylamine, modified silica, for example, amino-modified silica, is preferred. For sulfur-based gases such as hydrogen sulfide and mercaptans, and acidic odors such as acetic acid, isovaleric acid, and butyric acid, zinc oxide is preferred because of its high deodorizing effect. Further, as the zeolite, a zeolite silver-containing substance (that is, zeolite containing silver) may be used.

[0035] The blending amount of the (m) deodorant substance in the composition is preferably 30 to 60 parts by mass (in terms of solid content) with respect to 100 parts by mass of the solid content of the composition. If the (m) deodorant substance is less than the lower limit, the deodorizing effect tends to decrease. If it exceeds the upper limit, whitening unevenness tends to occur on the surface of the melamine decorative board. The whitening unevenness referred to here means a state in which a partially whitish and blurred portion occurs on the surface of the melamine decorative board.

[0036] Next, as an example of the functional expression substance, the (n) antiviral substance that exhibits antiviral properties will be described in detail. As the antiviral substance, photocatalysts such as titanium oxide are the mainstream. Photocatalysts generate active oxygen from the excitation light of light to inactivate viruses and can, in principle, exert their effects semi-permanently, but they have the drawback that they cannot exhibit their performance without light irradiation.

[0037] On the one hand, the organic antiviral substance destroys the outer wall membrane of the virus, and the virus with the destroyed outer wall membrane has its protein synthesis inhibited. Alternatively, the organic antiviral substance denatures the protein and inactivates the virus. The organic antiviral substance is characterized by an earlier onset of effect compared with the photocatalytic system.

[0038] As the organic antiviral substance, at least one selected from the group consisting of triazine-imidazole-thiazole substances, amino-modified polyvinyl alcohol, and amino-modified acrylic polymers is preferred. These organic antiviral substances are advantageous for melamine decorative boards that require solvent resistance and stain resistance. The organic antiviral substance is particularly preferably in the form of fine particles, specifically, at least one selected from the group consisting of particles carrying triazine-imidazole-thiazole substances, amino-modified polyvinyl alcohol particles, and amino-modified acrylic polymer particles. The average particle diameter of the particulate organic antiviral substance is preferably 0.5 to 3 μm for good dispersibility in the composition. Here, the average particle diameter refers to the particle diameter at the 50% integrated value in the particle size distribution determined by the laser diffraction / scattering method.

[0039] The blending amount of the (n) antiviral substance in the composition is preferably 35 to 75 parts by mass (in terms of solid content) with respect to 100 parts by mass of the solid content of the composition. If the blending amount of the (n) antiviral substance is less than the lower limit, the antiviral effect is likely to decrease, and if it exceeds the upper limit, whitening unevenness will occur on the surface of the melamine decorative board.

[0040] Next, as an example of the functional expression substance, the (o) anti-allergenic substance that exhibits anti-allergenicity will be described in detail. In the air, invisible dust floats, and the dust contains allergenic substances such as cedar pollen, dead mites, and feces, which cause allergies. As the (o) anti-allergenic substance, a composite of an anion-modified organic compound and a carrier is preferred. The composite exhibits a reducing effect on allergenic substances by chemically adsorbing to the protein of the allergenic substance.

[0041] (o) Even only the anion-modified organic compound that constitutes the anti-allergenic substance exhibits a similar reduction effect, but it is difficult to fix only the anion-modified organic compound on the surface of the melamine decorative board, and the durability of the anti-allergenic property tends to be poor. Therefore, it is preferable to include the anion-modified organic compound in the form of a composite with a carrier that is a solid component. The composite with the carrier can be physically fixed on the surface of the melamine decorative board, so it is particularly preferable for the melamine decorative board that requires durability.

[0042] Examples of the anion-modified organic compound include anion-modified linear alkanes and anion-modified polyvinyl alcohols. Specific examples of the anion-modified linear alkane include linear alkanes modified with acidic anion groups such as carboxyl groups, phosphate groups, and sulfonic acid groups. Examples of the counter ions of the acidic anion groups include sodium ions and potassium ions. Examples of the anion-modified polyvinyl alcohol include polyvinyl alcohols modified with acidic anion groups such as carboxyl groups and sulfonic acid groups. Examples of the carrier include inorganic particles or organic particles, such as acrylic particles such as base-modified acrylic particles, styrene particles such as base-modified styrene particles, and silver oxide particles. At least one selected from the group consisting of styrene particles and silver oxide is preferable as the carrier. (o) The anti-allergenic substance is preferably in the form of fine particles, specifically, those having an average particle diameter of 1 to 8 μm. Here, the average particle diameter refers to the particle diameter at the integrated value of 50% in the particle size distribution determined by the laser diffraction / scattering method.

[0043] The blending amount of the (o) anti-allergenic substance in the composition is preferably 3 to 50 parts by mass (in terms of solid content) with respect to 100 parts by mass of the solid content of the composition. If the blending amount of the (o) anti-allergenic substance is less than the lower limit, the anti-allergenic effect tends to be reduced, and if it exceeds the upper limit, whitening unevenness tends to occur on the surface of the melamine decorative board.

[0044] Next, the blending amounts when these functional expression substances, namely, (m) deodorant substances, (n) antiviral substances, and (o) anti-allergenic substances are used in combination will be described.

[0045] When (m) deodorant substances and (n) antiviral substances are combined, the blending ratio is preferably (m) deodorant substances : (n) antiviral substances = 1:0.5 to 2.50 by mass ratio, more preferably 1:0.60 to 2.0. When the blending ratio is less than the lower limit or exceeds the upper limit, the balance as a product having both deodorant and antiviral properties is slightly inferior.

[0046] Also, the total blending amount of (m) deodorant substances and (n) antiviral substances in the composition is preferably 60 to 150 parts by mass, more preferably 75 to 115 parts by mass, based on 100 parts by mass of the solid content of the composition. If the total blending amount is within this range, a decorative board particularly excellent in appearance, deodorant property, and antiviral property can be obtained. That is, when the total blending amount is less than the lower limit, the deodorant property and antiviral property are slightly inferior, and when it exceeds the upper limit, uneven whitening is likely to occur in appearance.

[0047] Also, the total blending amount of (m) deodorant substances and (o) anti-allergenic substances in the composition is preferably 30 to 16 0 parts by mass, more preferably 35 to 110 parts by mass, based on 100 parts by mass of the solid content of the composition. If the total blending amount is within this range, a decorative board particularly excellent in appearance, deodorant property, and anti-allergenic property can be obtained. That is, when the total blending amount is less than the lower limit, the deodorant property and anti-allergenic property are slightly inferior, and when it exceeds the upper limit, uneven whitening is likely to occur in appearance.

[0048] In addition, the total blending amount of (m) deodorant substance and (o) anti-allergenic substance in the composition is preferably 30 to 16 parts by mass, more preferably 35 to 110 parts by mass, based on 100 parts by mass of the solid content of the composition. If the total blending amount is within this range, a decorative board that is particularly excellent in appearance, deodorizing property, and anti-allergenic property can be obtained. That is, when the total blending amount is less than the lower limit, the deodorizing property and anti-allergenic property are slightly inferior, and when it exceeds the upper limit, uneven whitening is likely to occur in appearance.

[0049] When (n) antiviral substance and (o) anti-allergenic substance are combined, the blending ratio is preferably (n) antiviral substance:(o) anti-allergenic substance = 1:0.01 to 2.0 by mass ratio, more preferably 1:0.06 to 1.50. When the blending ratio is less than the lower limit or exceeds the upper limit, the balance as a product having both antiviral property and anti-allergenic property is slightly inferior.

[0050] In addition, the total blending amount of (n) antiviral substance and (o) anti-allergenic substance in the composition is preferably 15 to 200 parts by mass, more preferably 35 to 125 parts by mass, based on 100 parts by mass of the solid content of the composition. If the total blending amount is within this range, a decorative board that is particularly excellent in appearance, antiviral property, and anti-allergenic property can be obtained. That is, when the total blending amount is less than the lower limit, the antiviral property and anti-allergenic property are slightly inferior, and when it exceeds the upper limit, uneven whitening is likely to occur in appearance.

[0051] When combining (m) deodorant substance, (n) antiviral substance, and (o) anti-allergenic substance, the blending ratio is by mass, and (m) deodorant substance : (n) antiviral substance : (o) anti-allergenic substance = 1:0.20 - 7.0:0.05 - 5.5 is preferred, and more preferably 1:0.6 - 4.5:0.15 - 3.0. Also, the total blending amount of (m) deodorant substance, (n) antiviral substance, and (o) anti-allergenic substance in the composition is preferably 30 - 170 parts by mass with respect to 100 parts by mass of the solid content of the composition, and more preferably 50 - 120 parts by mass. If the blending ratio and the total blending amount are within this range, the appearance, deodorizing property, antiviral property, and anti-allergenic property are excellently balanced, and due to the synergistic effect, it becomes a decorative board that exhibits functions equivalent to or better than those exhibited individually even with a small coating amount. Of course, the blending amounts of (m) deodorant substance, (n) antiviral substance, and (o) anti-allergenic substance can be appropriately adjusted to highlight each function within the desired range.

[0052] The decorative layer contains a cured product of a melamine resin. The decorative layer includes a melamine resin-impregnated pattern paper in which a resin liquid mainly composed of a melamine resin (hereinafter referred to as a melamine resin liquid) is impregnated and dried on decorative paper with a basis weight of about 80 - 140 g / m 2 On the melamine resin-impregnated pattern paper, there is a protective paper for the pattern of the decorative paper with a basis weight of 16 - 60 g / m 2Melamine resin-impregnated overlay paper is arranged on the degree overlay paper, which is impregnated with melamine resin solution and dried. An overlay layer may be provided. The overlay layer also contains a cured product of melamine resin. On the surface of the decorative layer or the surface of the overlay layer, a cured layer of the above-mentioned composition or a composition containing a functional expression substance (hereinafter referred to as a functional composition) is formed as the surface layer. As a means of forming the cured layer, when impregnating the decorative paper or overlay paper with melamine resin solution, after impregnating with melamine resin solution, a coating method of applying a coating liquid containing a composition or a functional composition on the surface, a transfer method using a transfer sheet obtained by applying a functional composition on a sheet-like substrate, etc. are adopted. For example, in the transfer method, first, a laminate having a transfer sheet with a cured layer of a functional composition formed on one side of a sheet-like substrate, a melamine resin-impregnated pattern paper, and a core material in this order is hot-pressed and formed. Or, when using melamine resin-impregnated overlay paper, the melamine resin-impregnated overlay paper is further arranged on the melamine resin-impregnated pattern paper and hot-pressed and formed. In the laminate, the cured layer side in the transfer sheet faces the melamine resin-impregnated pattern paper or the melamine resin-impregnated overlay paper. Then, the sheet-like substrate is removed.

[0053] The impregnation rate defined by the mathematical formula 1 of the melamine resin solution is preferably in the range of 70 to 160%. <Mathematical formula 1>

[0054]

Number

[0055] Examples of metal foils include gold foils, silver foils, copper foils, zinc foils, indium foils, aluminum foils, tin foils, iron foils (including stainless steel (SUS) foils), titanium foils, etc.

[0056] When applying a coating liquid containing a functional composition to the sheet-like base material by the transfer method, known methods can be used, such as spray coating method, gravure coating method, bar coating method, knife coating method, roll coating method, blade coating method, die coating method, curtain coating method, reverse coating method, comma coating method, etc. The transfer sheet obtained by such a method is laminated on the melamine resin impregnated paper so that the coating surface, that is, the surface on the cured layer side of the functional composition, abuts on the melamine resin impregnated paper, which becomes the top layer, and is thermocompression molded together with the core material forming the core layer.

[0057] The coating thickness of the coating liquid containing the functional composition will be described in detail. (m) When containing a deodorant substance, the coating thickness of the coating liquid containing the functional composition (hereinafter referred to as the deodorant functional expression composition) is preferably 2.0 to 6.5 μm in the dry state, regardless of the coating method or the transfer method. When the coating thickness is equal to or greater than the lower limit, the deodorant performance is further exerted. When the coating thickness exceeds the upper limit, whitening unevenness of the appearance is likely to occur. (n) When containing an antiviral substance, the coating thickness of the coating liquid containing the functional composition (hereinafter referred to as the antiviral functional expression composition) is preferably 1.5 to 3.5 μm in the dry state, regardless of the coating method or the transfer method. When the coating thickness is less than the lower limit, the antiviral performance is difficult to be exerted. When the coating thickness exceeds the upper limit, whitening unevenness of the appearance is likely to occur. The above-mentioned (o) When containing an anti-allergen substance, the coating thickness of the coating liquid containing the functional composition (hereinafter referred to as the anti-allergen functional expression composition) is preferably 2.0 to 8.0 μm in the dry state, regardless of the coating method or the transfer method. When the coating thickness is less than the lower limit, the anti-allergen performance is difficult to be exerted. When the coating thickness exceeds the upper limit, whitening unevenness of the appearance is likely to occur.

[0058] Also, the pH of the coating liquid containing the functional composition is preferably 3 or more, regardless of the coating method or the transfer method. When the pH is less than 3, the lattice structure of the (A) component is destroyed, and whitening unevenness is likely to occur on the surface of the decorative board. The pH of the coating liquid refers to the pH measured in the coating liquid adjusted so that the solid content concentration (the concentration of the above-mentioned solid content contained in the functional composition in the coating liquid) is 20% by mass. Also, the value of pH is determined based on the operation of the glass electrode method in accordance with JIS Z8802:2011 "pH Measurement Method".

[0059] In addition, the coating thickness of the coating liquid containing a composition not containing a functional expression substance is preferably 2.0 to 8.0 μm in the dry state, regardless of the coating method or the transfer method. When the coating thickness is less than the lower limit, fingerprint adhesion is likely to be conspicuous, and when the coating thickness exceeds the upper limit, whitening unevenness of the appearance is likely to occur. Also, the pH of the coating liquid is preferably 3 or more as in the case of containing a functional expression substance. The pH measurement method is also the same as in the case of containing a functional expression substance.

[0060] As the core material, a thermosetting resin-impregnated core paper obtained by impregnating an organic fibrous base material such as kraft paper or bleached kraft paper with a resin liquid mainly composed of a thermosetting resin as a binder, such as a phenol-formaldehyde resin or a melamine-formaldehyde resin, and drying it can be used.

[0061] In addition to the above-mentioned thermosetting resin-impregnated core paper, a prepreg obtained by impregnating a non-woven fabric, a woven fabric, etc. made of inorganic fibers such as glass fiber, rock wool, carbon fiber, and ceramic fiber as a base material with a slurry containing an inorganic filler and a binder component and drying it may be used. This is because it can impart non-combustibility. In particular, a glass fiber non-woven fabric having excellent heat resistance and flame resistance and excellent impregnability of the slurry is preferable.

[0062] Examples of the inorganic filler include endothermic metal hydroxides such as aluminum hydroxide and magnesium hydroxide. Examples of inorganic substances other than endothermic metal hydroxides include calcium carbonate, talc, fly ash, etc. One or more of these can be used. As the endothermic metal hydroxide, since it contains crystal water and decomposes at high temperature to absorb heat and release bound water, it is excellent in non-combustibility. Therefore, it is preferable to use aluminum hydroxide or magnesium hydroxide.

[0063] When using a combination of an endothermic metal hydroxide and an inorganic substance other than an endothermic metal hydroxide, when the blending amount of the endothermic metal hydroxide is 2 to 15 parts by mass with respect to 1 part by mass of the inorganic substance other than the endothermic metal hydroxide, a smooth and good surface appearance can be obtained, which is preferable. In addition, when the blending amount of the endothermic metal hydroxide is 2 parts by mass or more with respect to 1 part by mass of the inorganic substance other than the endothermic metal hydroxide, the non-combustion performance is excellent. Also, when the blending amount of the endothermic metal hydroxide is 15 parts by mass or less with respect to 1 part by mass of the inorganic substance other than the endothermic metal hydroxide, the metal hydroxide in the slurry is less likely to settle. As a result, the impregnation amount of the slurry can be easily controlled. Further, when the blending amount of the endothermic metal hydroxide is 15 parts by mass or less with respect to 1 part by mass of the inorganic substance other than the endothermic metal hydroxide, the wear of the cutting tool used for cutting the decorative board can be reduced.

[0064] Examples of the binder include thermosetting resins such as amino-formaldehyde resins, phenol-formaldehyde resins, and mixed resins thereof. The mixing ratio of the solid content of the binder component and the inorganic filler is preferably 5 to 20:95 to 80 by mass ratio. If the binder component is too much, the non-combustible performance is likely to decrease, and if it is too little, the adhesion between prepregs is likely to be poor.

[0065] The impregnation rate (%) of the slurry into the inorganic fiber base material is preferably in the range of 500 to 3000% by the calculation method shown in the above formula (1). If the impregnation rate exceeds the upper limit, there will be a lot of solid content dropping off and it will be difficult to handle, and if the impregnation rate is less than the lower limit, delamination between layers is likely to occur.

[0066] As other core materials, calcium silicate, plywood, medium density fiberboard, particle board, etc. can be used, and there are no particular restrictions on the core material.

[0067] When the backing material suppresses warping due to the shrinkage of the melamine decorative board, it is arranged on the back surface of the core material, laminated, and hot-press formed. Examples of the backing material include melamine impregnated paper, phenol impregnated paper, etc. using a fibrous base material as the base material. As the fibrous base material, α-cellulose paper, titanium paper, kraft paper, sun-dried kraft paper, etc. can be used.

Example

[0068] Hereinafter, the present disclosure will be described by way of examples, experimental examples, and comparative examples, but the present disclosure is not limited to the examples shown below.

[0069] [Example 1] 1. Production of a composition containing component (A), component (B), and component (C) (A) As a hydrolytic condensate of silicon alkoxide, 100 parts by mass (in terms of solid content) of a hydrolysis solution of tetraethyl orthosilicate (ethyl silicate) (trade name "HAS-1", manufactured by Colcoat Co., Ltd.), and (B) As an organosilica sol dispersed in a hydrophilic solvent, "NPC-ST-30" (trade name, manufactured by Nissan Chemical Industries, Ltd., average particle size 10 - 15 nm, ethylene glycol mono n-propyl ether dispersed silica sol, SiO2 30% by mass) 600 parts by mass (in terms of solid content), and (C) As an acrylic polymer having a hydrophilic group and a hydrophobic group, "DISPERBYK-2009" (solution of acrylic copolymer, acrylic copolymer 44% by mass, 1-methoxy-2-propyl acetate, ethylene glycol monobutyl ether) (trade name, manufactured by BYK Japan K.K.) 13.2 parts by mass (in terms of solid content) were included to obtain a composition.

[0070] 2. Production of deodorant functional composition Based on 100 parts by mass of the solid content of the composition containing components (A), (B), and (C) produced in 1. above, 40 parts by mass of a deodorant substance (m) containing 74% by mass of zinc oxide and 26% by mass of amino-modified silica with an average particle size of 350 nm was blended, and stirred with a homogenizer at 8100 rpm for 10 minutes to obtain a deodorant functional composition (M).

[0071] 3. Production of transfer sheet A coating solution containing the deodorant functional composition (M) was applied to a plastic film so that the film thickness after drying was 4.5 μm to obtain a transfer sheet (M). The coating solution was prepared so that the solid content concentration, that is, the concentration of the above-mentioned solid content contained in the functional composition in the coating solution was 20% by mass. Also, the pH of the coating solution was 5.8. The pH of the coating solution was measured using a glass electrode type pH meter (product name: LAQUA model number F-71, manufactured by Horiba, Ltd.). The same applies to other examples, comparative examples, and experimental examples below.

[0072] 4. Production of melamine resin-impregnated pattern paper (M) Grammage 100 g / m 2A decorative paper for a brown decorative board was impregnated with a resin solution (AA) mainly composed of a melamine-formaldehyde resin to obtain a melamine resin-impregnated pattern paper (M). The impregnation rate defined by Mathematical Formula 1 of the melamine resin-impregnated pattern paper (M) was 140%. Incidentally, a wood grain pattern with a conduit part was printed on the surface of the decorative paper.

[0073] 5. Production of prepreg 50 g / m 2 A glass fiber base material of was immersed in a slurry containing a melamine-formaldehyde resin and a phenol-formaldehyde resin as binder components and inorganic fillers such as aluminum hydroxide and calcium carbonate so that the impregnation rate based on Mathematical Formula 1 was 1200%, and then dried to obtain a prepreg. The mass ratio of the solid content of the binder component and the inorganic filler in the slurry was 8:92.

[0074] 6. Production of backing 80 g / m 2 A decorative paper for a decorative board of was impregnated with a resin solution mainly composed of a melamine-formaldehyde resin so that the impregnation rate shown by Mathematical Formula 1 was 150%, and then dried to obtain a backing.

[0075] 7. Production of decorative board In order from the bottom, one piece of backing, five pieces of prepreg, one piece of melamine resin-impregnated pattern paper (M), and one piece of transfer sheet (M) were laminated, and the laminate was hot-pressed and formed at 140 °C and 100 kg / cm 2 under the conditions of 90 minutes, and the plastic film was peeled off to obtain a melamine decorative board.

[0076] [Example 2] In Example 1, it was carried out in the same manner except that 60 parts by mass of (m) deodorant substance was blended.

[0077] [Example 3] In Example 1, it was carried out in the same manner except that 30 parts by mass of (m) deodorant substance was blended.

[0078] [Example 4] In Example 1, the procedure was the same except that 9.3 parts by mass of "DISPERBYK-2009" as the component (C) was blended.

[0079] [Example 5] In Example 1, the procedure was the same except that 16.8 parts by mass of "DISPERBYK-2009" as the component (C) was blended.

[0080] [Example 6] In Example 1, the procedure was the same except that 400 parts by mass of "NPC-ST-30" as the component (B) was blended.

[0081] [Example 7] In Example 1, the procedure was the same except that 900 parts by mass of "NPC-ST-30" as the component (B) was blended.

[0082] [Example 8] In Example 1, the procedure was the same except that the average particle diameter of the (m) deodorant substance was made 200 nm.

[0083] [Example 9] In Example 1, the procedure was the same except that the average particle diameter of the (m) deodorant substance was made 1000 nm.

[0084] [Example 10] In Example 1, the procedure was the same except that the coating was performed so that the film thickness after drying of the coating liquid containing the deodorant function-expressing composition (M) became 2.0 μm.

[0085] [Example 11] In Example 1, the procedure was the same except that the coating was performed so that the film thickness after drying of the coating liquid containing the deodorant function-expressing composition (M) became 6.5 μm.

[0086] [Example 12] In Example 1, the procedure was the same except that a (m) deodorant substance containing 45% zinc oxide and 55% amino-modified silica was used.

[0087] [Example 13] In Example 1, the procedure was the same except that a deodorant substance (m) containing 85% zinc oxide and 15% amino-modified silica was used.

[0088] [Example 14] 1. Production of antiviral function-expressing composition To 100 parts by mass of the solid content of the composition containing components (A), (B), and (C) of Example 1, 50 parts by mass of a triazine-imidazole-thiazole-based organic synthetic antiviral substance with an average particle diameter of 1000 nm (n) was blended, and the mixture was stirred with a homogenizer at 8100 rpm for 10 minutes to obtain an antiviral function-expressing composition (N).

[0089] 2. Production of transfer sheet A coating liquid containing the antiviral function-expressing composition (N) was applied to a plastic film so that the film thickness after drying was 2.2 μm to obtain a transfer sheet (N). The pH of the coating liquid was 8.3.

[0090] 3. Production of decorative board In Example 1, the procedure was the same except that the above transfer sheet (N) was used instead of the transfer sheet (M).

[0091] [Example 15] In Example 14, the procedure was the same except that 26.4 parts by mass of "DISPERBYK-2009" as component (C) was blended and 35 parts by mass of the antiviral substance (n) was blended.

[0092] [Example 16] In Example 14, the procedure was the same except that 26.4 parts by mass of "DISPERBYK-2009" as component (C) was blended and 75 parts by mass of the antiviral substance (n) was blended.

[0093] [Example 17] In Example 14, the procedure was the same except that 9.3 parts by mass of "DISPERBYK-2009" as component (C) was blended.

[0094] [Example 18] In Example 14, the procedure was the same as in Example 14, except that 16.8 parts by mass of "DISPERBYK-2009" as the component (C) was blended.

[0095] [Example 19] In Example 14, 26.4 parts by mass of "DISPERBYK-2009" as the component (C) was blended, and a coating liquid containing an antiviral function-expressing composition was applied in the same manner as in Example 14, except that the film thickness after drying was adjusted to 3.5 μm.

[0096] [Example 20] In Example 19, the procedure was the same as in Example 19, except that a coating liquid containing an antiviral function-expressing composition was applied so that the film thickness after drying was 1.5 μm.

[0097] [Example 21] In Example 19, the average particle diameter of the (n) antiviral substance was set to 3000 nm, and a coating liquid containing an antiviral function-expressing composition was applied in the same manner as in Example 19, except that the film thickness after drying was adjusted to 2.2 μm.

[0098] [Example 22] In Example 21, the procedure was the same as in Example 21, except that the average particle diameter of the (n) antiviral substance was set to 500 nm.

[0099] [Example 23] 1. Production of anti-allergenic function-expressing composition With respect to 100 parts by mass of the solid content of the composition containing the components (A), (B), and (C) of Example 1, as the (o) anti-allergenic substance, 10 parts by mass of an organic synthetic anti-allergenic substance which is a complex of a sodium salt of a linear alkane modified with an acidic anionic group having an average particle diameter of 2000 nm and styrene particles ("Allerbuster BV", manufactured by Sekisui Materials Solutions Co., Ltd.) was blended, and the mixture was stirred with a homogenizer at 8100 rpm for 10 minutes to obtain an anti-allergenic function-expressing composition (O).

[0100] 2. Production of transfer sheet A coating liquid containing an anti-allergenic functional expression composition (O) was applied to a plastic film so that the film thickness after drying was 4.0 μm to obtain a transfer sheet (O). The pH of the coating liquid was 6.8.

[0101] 3. Manufacture of decorative board In Example 1, the same procedure was carried out except that the above transfer sheet (O) was used instead of the transfer sheet (M).

[0102] [Example 24] In Example 23, the same procedure was carried out except that 3 parts by mass of an anti-allergenic substance (o) was blended.

[0103] [Example 25] In Example 23, the same procedure was carried out except that 50 parts by mass of an anti-allergenic substance (o) was blended.

[0104] [Example 26] In Example 23, the same procedure was carried out except that an organic synthetic anti-allergenic substance ( "Allerbuster BV", manufactured by Sekisui Materials Solutions Co., Ltd.), which is a composite of a sodium salt of an acidic anionic group-modified linear alkane with an average particle diameter of 5000 nm and styrene particles, was used as the anti-allergenic substance (o).

[0105] [Example 27] In Example 23, the same procedure was carried out except that an organic synthetic anti-allergenic substance ( "Allerbuster BV", manufactured by Sekisui Materials Solutions Co., Ltd.), which is a composite of a sodium salt of an acidic anionic group-modified linear alkane with an average particle diameter of 1000 nm and styrene particles, was used as the anti-allergenic substance.

[0106] [Example 28] In Example 23, the same procedure was carried out except that the coating liquid containing the anti-allergenic composition was applied so that the film thickness after drying was 2.0 μm.

[0107] [Example 29] In Example 23, the same procedure was carried out except that the coating liquid containing the anti-allergenic composition was applied so that the film thickness after drying was 8.0 μm.

[0108] [Example 30] In Example 23, the same procedure was carried out except that 900 parts by mass of “NPC-ST-30” as the component (B) was blended.

[0109] [Example 31] In Example 23, the same procedure was carried out except that 300 parts by mass of “NPC-ST-30” as the component (B) was blended.

[0110] [Example 32] 1. Production of thermosetting resin-impregnated core paper A kraft paper with a basis weight of 200 g / m 2 was impregnated with a resin liquid mainly composed of a phenol-formaldehyde resin so that the impregnation rate defined by Formula 1 was 50%, and then dried to obtain a phenol resin-impregnated core paper as a thermosetting resin-impregnated core paper.

[0111] 2. Production of decorative board In order from the bottom, 5 sheets of phenol resin-impregnated core paper, 1 sheet of melamine resin-impregnated pattern paper (M) similar to Example 1, and 1 sheet of transfer sheet (M) were laminated, and the laminate was hot-pressed and formed at 140 °C and 100 kg / cm 2 under the conditions of 90 minutes, and the plastic film was peeled off to obtain a melamine decorative board.

[0112] [Example 33] In Example 2, the same procedure was carried out except that a phenol resin-impregnated core paper was used instead of the prepreg and no backing was used.

[0113] [Example 34] In Example 3, the same procedure was carried out except that a phenol resin-impregnated core paper was used instead of the prepreg and no backing was used.

[0114] [Example 35] In Example 32, the procedure was the same except that the average particle diameter of the (m) deodorant substance was 200 nm.

[0115] [Example 36] In Example 32, the procedure was the same except that the average particle diameter of the (m) deodorant substance was 1000 nm.

[0116] [Example 37] In Example 32, the procedure was the same except that the coating liquid containing the deodorant function-expressing composition was applied so that the film thickness after drying was 2.5 μm.

[0117] [Example 38] In Example 32, the procedure was the same except that the coating liquid containing the deodorant function-expressing composition was applied so that the film thickness after drying was 6.5 μm.

[0118] [Example 39] In Example 14, the procedure was the same except that phenolic resin-impregnated core paper was used instead of prepreg and no backer was used.

[0119] [Example 40] In Example 15, the procedure was the same except that phenolic resin-impregnated core paper was used instead of prepreg and no backer was used.

[0120] [Example 41] In Example 16, the procedure was the same except that phenolic resin-impregnated core paper was used instead of prepreg and no backer was used.

[0121] [Example 42] In Example 19, the procedure was the same except that phenolic resin-impregnated core paper was used instead of prepreg and no backer was used.

[0122] [Example 43] In Example 20, the procedure was the same except that phenolic resin-impregnated core paper was used instead of prepreg and no backer was used.

[0123] [Example 44] In Example 39, the procedure was carried out in the same manner except that the average particle diameter of the antiviral substance (n) was changed to 3000 nm.

[0124] [Example 45] In Example 39, the procedure was carried out in the same manner except that the average particle diameter of the antiviral substance (n) was changed to 500 nm.

[0125] [Example 46] In Example 23, the procedure was carried out in the same manner except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0126] [Example 47] In Example 24, the procedure was carried out in the same manner except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0127] [Example 48] In Example 25, the procedure was carried out in the same manner except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0128] [Example 49] In Example 26, the procedure was carried out in the same manner except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0129] [Example 50] In Example 27, the procedure was carried out in the same manner except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0130] [Example 51] In Example 28, the procedure was carried out in the same manner except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0131] [Example 52] In Example 29, the same procedure was carried out except that phenolic resin-impregnated core paper was used instead of prepreg and no backing was used.

[0132] [Example 53] In Example 1, the same procedure was carried out except that zeolite was used as the (m) deodorant substance.

[0133] [Example 54] In Example 1, the same procedure was carried out except that copper oxide was used as the (m) deodorant substance.

[0134] [Example 55] In Example 1, the same procedure was carried out except that zirconium oxide was used as the (m) deodorant substance.

[0135] [Example 56] In Example 14, the same procedure was carried out except that amino-modified polyvinyl alcohol particles were used as the (n) antiviral substance.

[0136] [Example 58] In Example 23, ( o ) The same procedure was carried out except that acidic anion group-modified polyvinyl alcohol was used instead of the sodium salt of acidic anion group-modified linear alkane as the anion-modified organic compound of the (

[0137] [Example 59] In Example 23, ( o ) The same procedure was carried out except that silver oxide particles were used instead of styrene particles as the carrier of the (

[0138] [Example 59] In Example 23, (n) The same procedure was carried out except that silver oxide particles were used instead of styrene particles as the carrier of the anti-allergenic substance.

[0139] [Example 60] In Example 1, the procedure was the same as in Example 1, except that the composition containing components (A), (B), and (C) obtained in Example 1 was used instead of the deodorizing functional composition (M).

[0140] [Example 61] In Example 1, the procedure was the same as in Example 1, except that the following melamine resin-impregnated patterned paper (Mt) was used and the following production method was used.

[0141] <Production of Melamine Resin-Impregnated Patterned Paper (Mt)> A decorative paper for a brown decorative board with a basis weight of 100 g / m 2 was impregnated with a resin liquid (AA) mainly composed of a melamine-formaldehyde resin so that the impregnation rate defined by Formula 1 became 140%. Then, the decorative paper was coated with a coating liquid containing the deodorizing functional composition (M) of Example 1 so that the film thickness after drying became 4.5 μm to obtain a melamine resin-impregnated patterned paper (Mt). Incidentally, a wood grain pattern with conduit parts was printed on the surface of the decorative paper.

[0142] <Production of Decorative Board> In order from the bottom, one barca, five prepregs, and one melamine resin-impregnated patterned paper (Mt) were laminated, and hot press molding was performed at 140 °C and 100 kg / cm 2 for 90 minutes to obtain a melamine decorative board.

[0143] [Example 62] In Example 14, the procedure was the same as in Example 14, except that the following melamine resin-impregnated patterned paper (Nt) was used and the following production method was used.

[0144] <Production of Melamine Resin-Impregnated Patterned Paper (Nt)> A decorative paper for a brown decorative board with a basis weight of 100 g / m 2A decorative paper for a brown decorative board was impregnated with a resin solution (AA) mainly composed of a melamine-formaldehyde resin so that the impregnation rate defined by Mathematical Formula 1 was 140% to obtain an impregnated paper. Then, a coating liquid containing the anti-viral function expression composition (N) of Example 14 was applied to the surface of the impregnated paper so that the film thickness after drying was 2.2 μm to obtain a melamine resin impregnated pattern paper (Nt). Incidentally, a wood grain pattern with a conduit part was printed on the surface of the decorative paper.

[0145] <Manufacture of Decorative Board> In order from the bottom, one backing board, five prepregs, and one melamine resin impregnated pattern paper (Nt) were laminated, and hot press molding was performed at 140 ° C and 100 kg / cm 2 under the conditions of 90 minutes to obtain a melamine decorative board.

[0146] [Example 63] In Example 23, the following melamine resin impregnated pattern paper (Ot) was used, and the same procedure was carried out except for using the following manufacturing method.

[0147] <Manufacture of Melamine Resin Impregnated Pattern Paper (Ot)> A decorative paper for a brown decorative board with a basis weight of 100 g / m 2 was impregnated with a resin solution (AA) mainly composed of a melamine-formaldehyde resin so that the impregnation rate defined by Mathematical Formula 1 was 140% to obtain an impregnated paper. Then, a coating liquid containing the anti-allergenic function expression composition (O) of Example 23 was applied to the surface of the impregnated paper so that the film thickness after drying was 4.0 μm to obtain a melamine resin impregnated pattern paper (Ot). Incidentally, a wood grain pattern with a conduit part was printed on the surface of the decorative paper.

[0148] <Manufacture of Decorative Board> In order from the bottom, one backing board, five prepregs, and one melamine resin impregnated pattern paper (Ot) were laminated, and hot press molding was performed at 140 ° C and 100 kg / cm 2 under the conditions of 90 minutes to obtain a melamine decorative board.

[0149] [Comparative Example 1] In Example 1, the procedure was the same except that a siloxane graft polymer (trade name “ZX-036”, hydroxyl value 119, solvent type butyl acetate / 2-propanol, manufactured by Fuji Kasei Kogyo Co., Ltd.) in which an acrylic resin and a siloxane were compounded was used instead of the hydrolysis condensate of silicon alkoxide.

[0150] [Comparative Example 2] In Example 1, the procedure was the same except that a hydrophobic silica sol (trade name “Silophobic”, manufactured by Fuji Silysia Chemical Ltd.) was used instead of the organosilica sol dispersed in a hydrophilic solvent.

[0151] [Comparative Example 3] In Example 1, 100 parts by mass of a methacryloyl functional group-containing acrylic polymer (trade name “RA-3705MB”, manufactured by Negami Kogyo Co., Ltd.) was used as the reactive (meth)acrylic polymer (x), and 0.4 parts by mass of 1,6-bis(t-butylperoxycarbonyloxy)hexane (trade name “Kaylene 6-70”, manufactured by Kayaku Akzo Co., Ltd.) was blended as a thermal polymerization initiator, and the procedure was the same except for this.

[0152] [Comparative Example 4] In Comparative Example 3, the procedure was the same except that it did not contain a function-expressing substance.

[0153] [Comparative Examples 5 to 9] In Comparative Example 3, the procedure was the same except that the conditions shown in Tables 4-1 and 4-2 were changed.

[0154] [Examples 64 to 78] In Example 1, the procedure was the same except that the conditions shown in Tables 5-1 and 5-2 were changed. In Examples 64 to 78, the same deodorant substance as in Example 1 was used as the deodorant substance (m), the same antiviral substance as in Example 14 was used as the antiviral substance (n), and the same anti-allergenic substance as in Example 23 was used as the anti-allergenic substance (o).

[0155] [Examples 79 to 93] In Example 1, the procedure was the same except that the conditions shown in Tables 6-1 and 6-2 were changed. In Examples 79 to 93, (m) the same deodorant substance as in Example 1 was used as the deodorant substance, (n) the same antiviral substance as in Example 14 was used as the antiviral substance, and (o) the same anti-allergenic substance as in Example 23 was used as the anti-allergenic substance, respectively.

[0156] However, in Example 88, as the component (A), "HAS-6", which is a hydrolytic condensate of tetraethyl orthosilicate (ethyl silicate), was used instead of "HAS-1". In Example 89, as the component (A), "HAS-10", which is a hydrolytic condensate of tetraethyl orthosilicate (ethyl silicate), was used instead of "HAS-1". In Example 90, as the component (B), "IPA-ST" (trade name, manufactured by Nissan Chemical Industries, Ltd., average particle size 10 to 15 nm, isopropyl alcohol-dispersed silica sol, SiO2 30% by mass) was used instead of "NPC-ST-30". In Example 91, as the component (B), "MEK-AC-2140Z" (trade name, manufactured by Nissan Chemical Industries, Ltd., average particle size 10 to 15 nm, methyl ethyl ketone-dispersed silica sol, SiO2 40% by mass) was used instead of "NPC-ST-30". In Example 92, as the component (C), "DISPERBYK-2000" (solution of acrylic copolymer, acrylic copolymer 40% by mass, 1-methoxy-2-propyl acetate, ethylene glycol monobutyl ether) (trade name, manufactured by BYK-Chemie Japan Co., Ltd.) was used instead of "DISPERBYK-2009". In Example 93, as the component (C), "DISPERBYK-2008" (solution of acrylic copolymer, acrylic copolymer 60% by mass, polypropylene glycol 40%, trade name, manufactured by BYK-Chemie Japan Co., Ltd.) was used instead of "DISPERBYK-2009".

[0157] [Example 94] <Manufacture of melamine resin-impregnated overlay paper> Grammage 22 g / m2 The overlay paper of 2 was impregnated with the same resin solution (AA) as in Example 1 to obtain a melamine resin-impregnated overlay paper. The impregnation rate defined by Formula 1 of the melamine resin-impregnated overlay was 260%.

[0158] <Manufacture of Decorative Board> A transfer sheet similar to that of Example 79 was prepared.

[0159] Also, a melamine resin-impregnated pattern paper was obtained in the same manner as in Example 1, except that the impregnation rate defined by Formula 1 was set to 100%.

[0160] Also, a phenol resin-impregnated core paper similar to that of Example 32 was prepared.

[0161] In order from the bottom, 5 sheets of phenol resin-impregnated core paper, 1 sheet of melamine resin-impregnated pattern paper, 1 sheet of melamine resin-impregnated overlay paper, and 1 sheet of transfer sheet were laminated, and the laminate was hot-pressed at 140 °C and 100 kg / cm 2 under the conditions of 90 minutes to obtain a melamine decorative board by peeling off the plastic film.

[0162] [Example 95] In Example 94, the same procedure was carried out except that the transfer sheet of Example 80 was used.

[0163] [Example 96] In Example 94, the same procedure was carried out except that the transfer sheet of Example 81 was used.

[0164] [Experimental Examples 1 to 6] In Example 1, the same procedure was carried out except that the conditions shown in Tables 7-1 and 7-2 were changed.

[0165] [Experimental Examples 7 to 10] In Example 1, the same procedure was carried out except that the conditions shown in Tables 8-1 and 8-2 were changed.

[0166] [Experimental Examples 11 to 22] In Example 1, the procedure was the same except that the conditions shown in Tables 9-1 and 9-2 were changed.

[0167] For the above Examples, Experimental Examples, and Comparative Examples, the blending ratios of the compositions and functional compositions containing Component (A), Component (B), and Component (C), the particle diameters and pH of the functional expression substances, the coating amounts, and the types of core materials of the core layers are shown in Tables 1-1 to 9-2.

[0168] In addition, A, B, C, m, n, and o in the tables are as follows.

[0169] A: Hydrolysis condensate of silicon alkoxide B: Organosilica sol dispersed in a hydrophilic solvent C: Acrylic polymer having a hydrophilic group and a hydrophobic group m: Deodorant substance n: Antiviral substance o: Anti-allergenic substance Also, the numerical values of the parts by mass of A, B, and C in the tables are values based on the solid content.

[0170] Also, the numerical values of the blending amounts of m, n, and o are the blending ratios of the solid content with respect to 100 parts by mass of the solid content of the composition.

[0171]

Table 1-1

[0172]

Table 1-2

[0173]

Table 2-1

[0174]

Table 2-2

[0175]

Table 3-1

[0176]

Table 3-2

[0177]

Table 4-1

[0178]

Table 4-2

[0179]

Table 5-1

[0180]

Table 5-2

[0181]

Table 6-1

[0182]

Table 6-2

[0183]

Table 7-1

[0184]

Table 8-1

[0185]

Table 8-1

[0186] [Table 8-2]

[0187] [Table 9-1]

[0188] [Table 9-2] [Evaluation method] The melamine decorative boards according to the above-mentioned Examples, Experimental Examples, and Comparative Examples were evaluated in terms of appearance, functionality (deodorizing property, antiviral property, or antiallergenic property), chemical resistance, and non-flammability by the following methods.

[0189] (1) Appearance The appearance of the melamine decorative board was inspected based on JIS K 6902:2007 "Test method for thermosetting resin high pressure decorative boards". In addition, the surface of the melamine decorative board was touched with the palm of the hand for 5 seconds, then the hand was removed and the surface was visually observed to evaluate whether fingerprints were noticeable or not. The appearance of the melamine decorative board was evaluated according to the following criteria.

[0190] ○: No abnormality (no uneven whitening on the surface, no noticeable fingerprints).

[0191] △1: Slightly uneven whitening occurs on the surface, but the vessels of the wood grain pattern on the decorative layer can be recognized. Fingerprints are not noticeable.

[0192] Δ2: There is no whitening unevenness on the surface, but fingerprints are somewhat noticeable.

[0193] ×: Significant whitening unevenness occurs on the surface, the wood grain pattern of the decorative layer is unclear, and the vessels cannot be recognized. Fingerprints are not noticeable.

[0194] Furthermore, when whitening unevenness occurs on the surface, fingerprints become less noticeable.

[0195] (2) Deodorization rate (%) (2-1) Hydrogen sulfide deodorization performance: A test piece cut into 100 mm × 200 mm was covered on the back and side surfaces with aluminum tape so that the effective area became 200 cm 2 . After placing the test piece in a Tedlar bag, 3 L of hydrogen sulfide gas was injected into the bag so that the concentration became 4 ppm, and the residual hydrogen sulfide concentration after 24 hours was measured. Based on this measured value, the total amount of deodorized hydrogen sulfide was calculated and taken as the deodorization rate (%) of the hydrogen sulfide gas.

[0196] (2-2) Ammonia deodorization performance: A test piece cut into 100 mm × 200 mm was covered on the back and side surfaces with aluminum tape so that the effective area became 200 cm 2 . After placing the test piece in a Tedlar bag, 3 L of ammonia gas was injected into the bag so that the concentration became 100 ppm, and the residual ammonia concentration after 24 hours was measured. Based on this measured value, the total amount of deodorized ammonia was calculated and taken as the deodorization rate (%).

[0197] (3) Antiviral performance phage test Test virus: Bacteriophage Qβ Test standard: JIS R 1756:2020 "Fine ceramics - Test method for antiviral properties of visible light-responsive photocatalytic materials - Method using bacteriophage Qβ" Measurement time: 24 hours The test virus bacteriophage Qβ was brought into contact with a test piece cut into 50 mm × 50 mm, and after 24 hours, the test bacterial solution was collected and the virus infection titer was calculated. Based on the calculated virus infection titer, the antiviral activity value was calculated according to the following calculation formula.

[0198] Antiviral activity value = log (virus infection titer of unprocessed product) - log (virus infection titer of processed product) The unprocessed product is a melamine decorative board without a cured layer of the composition, and the processed product is the melamine decorative board according to each example, each experimental example, and each comparative example.

[0199] (4) Anti-allergen performance Ammonia Test bacteria: Mite allergen (Der fII), Cedar allergen (Cry jI) Measurement time: 24 hours Measurement method: ELISA method A 40 mm × 40 mm frame was made on a test piece cut into 50 mm × 50 mm with an adhesive. 0.4 ml of an allergen solution prepared at a certain concentration was dropped into the frame, and a film was adhered.

[0200] The solution after 24 hours was collected, and the allergen concentration was measured by the ELISA method (enzyme immunoassay).

[0201] The concentration difference from the unprocessed product of the measured value was calculated and used as the reduction rate (%) of the allergen.

[0202] (5) Chemical resistance <Chemicals used> q: Osban solution 0.025% solution r: Cresol soap solution 5.0% solution s: Sodium hypochlorite 6.0% solution t: 1% hydrochloric acid aqueous solution u: 1% sodium hydroxide aqueous solution <Test method> After washing and drying the test piece, 0.2 ml of the test solution was dropped onto the test piece, left for 24 hours, then the test solution was washed off with water, and the change of the test piece was observed with the naked eye and evaluated according to the following evaluation method.

[0203] <Evaluation method> ○: No change △: No erosion, but color tone and gloss change ×: Eroded (6) Non-combustibility A heat release test of a 20-minute test was conducted using a cone calorimeter conforming to ISO5660. In the evaluation method, the total heat release is 8 MJ / m2 is as follows, and the maximum heat release rate continues for 10 seconds or more and does not exceed 200 kW / m 2 ○ was defined as the case where there are no cracks, fissures, etc. that penetrate to the back surface in the test piece after the test. × was defined as the case where any of these three conditions is not satisfied.

[0204] The evaluation results are shown in Tables 10-1 to 18-2.

[0205]

Table 10-1

[0206]

Table 10-2

[0207]

Table 11-1

[0208]

Table 11-2

[0209]

Table 12-1

[0210]

Table 12-2

[0211]

Table 13-1

[0212]

Table 13-2

[0213]

Table 14-1

[0214]

Table 14-2

[0215]

Table 15-1

[0216]

Table 15-2

[0217]

Table 16-1

[0218]

Table 16-2

[0219]

Table 17-1

[0220]

Table 17-2

[0221]

Table 18-1

[0222]

Table 18-2

[0223] As shown in Table 17-1, in Experimental Example 7, although the functional composition contained components (A), (B), and (C), the blending amount of component (B) was less than 0.5 parts by mass with respect to 1 part by mass of the solid content of component (A), the deodorizing performance was slightly inferior, and the chemical resistance was also slightly inferior. In Experimental Example 8, although the functional composition contained components (A), (B), and (C), the blending amount of component (B) exceeded 12 parts by mass with respect to 1 part by mass of the solid content of component (A). In terms of appearance, although fingerprints were not prominent, slightly uneven whitening occurred (△1). In Experimental Example 9, although the functional composition contained components (A), (B), and (C), the blending amount of component (C) was less than 0.005 parts by mass with respect to 1 part by mass of the solid content of component (B). Although uneven whitening did not occur, fingerprints were slightly prominent (△2). In Experimental Example 10, although the functional composition contained components (A), (B), and (C), the blending amount of component (C) exceeded 0.3 parts by mass with respect to 1 part by mass of the solid content of component (B). In terms of appearance, although fingerprints were not prominent, slightly uneven whitening occurred (△1).

[0224] As shown in Table 18-1, in Experimental Example 11, the deodorizing property was slightly inferior. In Experimental Example 12, in terms of appearance, although fingerprints were not prominent, slight whitening unevenness occurred (△1). In Experimental Example 13, the antiviral property was slightly inferior. In Experimental Example 14, in terms of appearance, although fingerprints were not prominent, slight whitening unevenness occurred (△1). In Experimental Example 15, the deodorizing property was slightly inferior. In Experimental Example 16, in terms of appearance, although fingerprints were not prominent, slight whitening unevenness occurred (△1). In Experimental Example 17, the anti-allergenic property was slightly inferior. In Experimental Example 18, in terms of appearance, although fingerprints were not prominent, slight whitening unevenness occurred (△1). In Experimental Example 19, the antiviral property was slightly inferior. In Experimental Example 20, in terms of appearance, although fingerprints were not prominent, slight whitening unevenness occurred (△1). In Experimental Example 21, the anti-allergenic property was slightly inferior. In Experimental Example 22, in terms of appearance, although fingerprints were not prominent, slight whitening unevenness occurred (△1).

Claims

1. (A) a hydrolysis condensate of a silicon alkoxide, and (B) an organosilica sol dispersed in a hydrophilic solvent, and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group, wherein the composition contains: the (B) organosilica sol dispersed in the hydrophilic solvent is blended in an amount of 0.5 to 12 parts by mass based on 1 part by mass of the solid content of the (A) hydrolysis condensate of the silicon alkoxide; and the (C) acrylic polymer having a hydrophilic group and a hydrophobic group is blended in an amount of 0.005 to 0.3 parts by mass based on 1 part by mass of the solid content of the (B) organosilica sol dispersed in the hydrophilic solvent.

2. The composition according to claim 1, comprising at least one substance selected from the group consisting of (m) a deodorant substance, (n) an antiviral substance, and (o) an anti-allergenic substance.

3. comprising the (m) deodorant substance, wherein the (m) deodorant substance is a chemisorption-type deodorant substance, the composition according to claim 2.

4. The composition according to claim 3, wherein the chemisorption-type deodorant substance contains at least one selected from the group consisting of zinc oxide, silica, zeolite, copper oxide, and zirconium oxide.

5. comprising the (n) antiviral substance, wherein the (n) antiviral substance is at least one selected from the group consisting of a triazine-thiazole-imidazole-based substance, an amino-modified polyvinyl alcohol, and an amino-modified acrylic polymer, the composition according to any one of claims 2 to 4.

6. comprising the (o) anti-allergenic substance, wherein the (o) anti-allergenic substance is a composite of an anion-modified organic compound and a carrier, the composition according to any one of claims 2 to 5.

7. The composition according to claim 6, wherein the anion-modified organic compound is at least one selected from the group consisting of an anion-modified linear alkane and an anion-modified polyvinyl alcohol.

8. The composition according to claim 6 or claim 7, wherein the carrier contains at least one selected from the group consisting of styrene particles and silver oxide particles.

9. The composition according to any one of claims 1 to 8, which is for a melamine decorative board.

10. a sheet-like substrate, and a cured layer of the composition according to any one of claims 1 to 9 formed on one side of the sheet-like substrate, wherein the transfer sheet has the above.

11. a core layer, and a decorative layer containing a cured product of a melamine resin, A melamine decorative board comprising, in this order, a cured layer of the composition according to any one of claims 1 to 9.

12. A method for manufacturing a melamine decorative board, wherein the melamine decorative board comprises, in this order, a core layer, a decorative layer containing a cured product of a melamine resin, and a surface layer, A method for manufacturing a melamine decorative board, comprising curing the composition according to any one of claims 1 to 9 to form the surface layer.

Images