Decorative melamine board

Patent metadata

Field	Value
Publication number	US-10279571-B2
Application number	US-201113884739-A
Country	US
Kind code	B2
Filing date	Nov 25, 2011
Priority date	Nov 30, 2010
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

The present invention provides a decorative melamine board that maintains the surface hardness associated with melamine resin while having superior non-combustibility, being able to accommodate reductions in thickness and having superior bending workability at normal temperatures. The decorative melamine board has a structure obtained by laminating a surface layer and a core layer. The surface layer includes a surface layer material composed of a surface layer base material that carries a resin containing a melamine resin on a first surface side serving as a design surface, and carries a solid content of a thermoplastic resin emulsion on a second surface side that contacts the core layer. The core layer includes a core layer material composed of glass cloth or a prepreg having glass cloth as a base material thereof.

First claim

The invention claimed is:

1. A decorative melamine board having a structure obtained by laminating a surface layer and a core layer, wherein
the surface layer comprises a surface layer material composed of a surface layer base material that carries a resin containing a melamine resin on a first surface side serving as a design surface, and carries a solid content of a thermoplastic resin emulsion on a second surface side that contacts the core layer, wherein the design surface is an outermost surface of the decorative melamine board, and
the core layer comprises a core layer material composed of glass cloth or a prepreg having glass cloth as a base material thereof, wherein the core layer consists of a prepreg having glass cloth impregnated with a thermoplastic resin.

2. The decorative melamine board according to claim 1 , wherein the total thickness is 0.4 mm or less.

3. The decorative melamine board according to claim 1 , wherein the thickness of the core layer is 100 μm to 350 μm.

4. The decorative melamine board according to claim 1 , wherein the solid content of the thermoplastic resin emulsion contains emulsion resin particles having a mean particle diameter of 30 nm to 100 nm.

5. The decorative melamine board according to claim 1 , wherein the solid content of the thermoplastic resin emulsion is non-water-soluble.

6. The decorative melamine board according to claim 1 , wherein the solid content of the thermoplastic resin emulsion contains urethane-acrylic composite particles having a heterogeneous phase structure consisting of an acrylic resin phase and urethane resin phase in a single particle thereof.

7. The decorative melamine board according to claim 6 , wherein the urethane-acrylic composite particles are of the aqueous clear type having a core-shell structure consisting of an acrylic component for the core and a urethane component for the shell.

8. The decorative melamine board according to claim 1 , wherein the prepreg having glass cloth as a base material thereof is obtained by impregnating glass cloth with a resin composition containing 10% by weight to 50% by weight of a thermoplastic resin in terms of the solid content thereof.

9. The decorative melamine board according to claim 8 , wherein the thermoplastic resin contains an acrylic resin and/or a urethane resin.

10. The decorative melamine board according to claim 1 , having bending workability such that the minimum bending radius R at normal temperature (normally about 20° C. to 30° C.) is 10 mm or less.

11. The decorative melamine board according to claim 1 , wherein the core layer consists of glass cloth.

Assignees

• Kifuku Toshinori
• Sumitomo Bakelite Co

Inventors

• Kifuku Toshinori

Classifications

• B32B17/10743

  containing acrylate (co)polymers or salts thereof · CPC title

• B32B2305/076

  Prepregs · CPC title

• B32B27/42 Primary

  comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines · CPC title

• B32B17/02 Primary

  in the form of fibres or filaments · CPC title

• B32B17/04

  bonded with or embedded in a plastic substance · CPC title