TWI887273B - Composition, transfer sheet, melamine decorative board and method for producing melamine decorative board - Google Patents

Abstract

The composition comprises (A) a hydrolyzed condensate of silane oxide, (B) an organic silicon sol dispersed in a hydrophilic solvent, and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group. The melamine decorative board comprises a core layer, a decorative layer, and a hardened layer of the above composition in sequence. The decorative layer comprises a hardened melamine resin layer.

Description

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

The present invention relates to a composition, a transfer sheet, a melamine decorative board and a method for manufacturing the melamine decorative board.

Melamine decorative board is obtained by using pattern paper containing melamine resin as the design layer, and heating and pressing the pattern paper containing melamine resin and the core material (such as phenol resin impregnated paper) by a press. Melamine decorative board presents a variety of finished product appearances by changing patterns or tones.

Such melamine decorative boards have excellent surface hardness, heat resistance, wear resistance and other physical properties, so they are widely used in furniture such as counters and tables, walls, floors and other interior decoration materials. In recent years, melamine decorative boards are easy to observe fingerprints and oil stains. As the airtightness of houses is improved, people are concerned about the odor in their lives, and public facilities such as hospitals need a cleaner environment.

Patent document 1 is Japanese Patent Publication No. 2012-176515, Patent document 2 is Japanese Patent Publication No. 2017-205928, and Patent document 3 is Japanese Patent Publication No. 2018-27694.

The applicant has disclosed a decorative board with fingerprint resistance and oil wiping resistance (Patent Document 1), but it is difficult to evenly disperse the substance imparting deodorizing properties in the composition of Patent Document 1, and there are cases where sufficient deodorizing properties are not obtained. In addition, the applicant has disclosed a decorative board with deodorizing properties and reduced odors of daily life and medicines (Patent Document 2), but it is difficult to evenly apply the substance imparting antiviral or antiallergenic properties using the method of Patent Document 2, and there are cases where sufficient antiviral or antiallergenic properties are not obtained.

One aspect of the present invention is a composition comprising (A) a hydrolysis condensate of silane oxide, (B) an organic silicon sol dispersed in a hydrophilic solvent, and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group.

One aspect of the present invention is a transfer sheet having a sheet substrate and a hardened layer of the above composition formed on one side of the sheet substrate. One aspect of the present invention is a melamine decorative board, which sequentially comprises a core layer, a decorative layer and a hardened layer of the above composition. The decorative layer comprises a hardened melamine resin layer.

One aspect of the present invention is a method for manufacturing a melamine decorative board, wherein the melamine decorative board sequentially comprises a core layer, a decorative layer comprising a hardened material of a melamine resin, and a surface layer. The method for manufacturing the melamine decorative board comprises hardening the above-mentioned composition to form a surface layer.

According to one aspect of the present invention, a substance exhibiting functional properties such as deodorizing, antiviral, and anti-allergenic properties (hereinafter referred to as a functional substance) can be uniformly dispersed to provide a composition with excellent functionality.

Furthermore, according to one aspect of the present invention, a transfer sheet and a melamine decorative board containing such a cured product of the composition and having excellent functionality, as well as a method for manufacturing the melamine decorative board can be provided.

2: Hardened layer of functional components

3: Melamine resin impregnated pattern paper

4: Prepreg

5: Phenolic resin impregnated core paper

6: Core layer

7: Support material

8: Melamine resin impregnated covering paper

11: Melamine decorative board

12: Melamine decorative board

13: Melamine decorative board

[Figure 1] Structural cross-sectional view of the melamine decorative board of Example 1.

[Figure 2] Structural cross-sectional view of the melamine decorative board of Example 32.

[Figure 3] Structural cross-sectional view of the melamine decorative board of Example 94.

The present invention is described in detail below. (A) The hydrolysis condensate of silane oxide forms a lattice-like skeleton, and when mixed with the functional material described below, the functional material can be uniformly dispersed, and the effect can be exerted with a small amount of the functional material added. Specific silane oxides include the structure represented by the following chemical formula 1 (n is an integer), and more specifically, tetramethyl orthosilicate (Si(OCH ₃ ) ₄ ), tetraethyl orthosilicate (Si(OC ₂ H ₅ ) ₄ ) and tetrapropyl orthosilicate (Si(OC ₃ H ₇ ) ₄ ) can be exemplified. Silane oxides are mainly synthesized by the reaction of silicon tetrachloride and alkanol, or the reaction of metallic silicon and alkanol.

When silane oxide is mixed with water for reaction, hydrolysis is carried out according to the reaction formula represented by chemical formula 2 (m is an integer). In order to stabilize the hydrolysis solution, methanol, ethanol, isopropanol, ethyl solvent, mixed alcohol, etc. are used as solvents.

Commercially available hydrolysis condensates of silane oxides include "HAS-1" ( _SiO2 content 20.7~21.5% by mass, ethanol/isopropanol/methanol mixed solvent), "HAS-6" ( _SiO2 content 17.6~18.4% by mass, ethanol/methanol mixed solvent), and "HAS-10" ( _SiO2 content 10.0~10.4% by mass, ethanol/isopropanol/methanol mixed solvent) (the above are trade names, manufactured by Colcoat Co., Ltd.).

The organic silicon sol of component (B) can be, for example, colloidal silicon dioxide with an average particle size of 1 to 40 nm (preferably an average particle size of 7 to 30 nm) stably dispersed in a colloidal solution of an organic solvent. The concentration of silicon dioxide is preferably in the range of 1 to 50% by mass, and more preferably below 40% by mass to prevent gelation. In addition, the average particle size of colloidal silicon dioxide is the particle size of 50% of the cumulative value in the particle size distribution obtained by laser diffraction scattering method.

Commercially available organosilicon sols 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 Catalyst Chemical Industries, Ltd., "Quartron (registered trademark)" manufactured by Fuso Chemical Industries, Ltd., and "Highlink (registered trademark) OG organosilicon sol" manufactured by Clariant Japan Co., Ltd.

The organosilicon sol dispersed in an organic solvent, especially a hydrophilic solvent, has sufficient hydroxyl groups on the surface of the silica particles, which are closely attached to the melamine resin, and the surface durability of the decorative board is excellent. The organosilicon sol dispersed in a hydrophobic solvent has insufficient hydroxyl groups on the surface of the silica particles, and the adhesion with the melamine resin tends to become poor.

Here, the 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) organic solvent include protic polar solvents and aprotic polar solvents. Specific examples of the protic polar solvent include alcohol solvents such as methanol, ethanol, isopropanol, ethylene glycol, and propanol, and solvent-based solvents such as methyl solvent, ethyl solvent, butyl solvent, and n-propyl solvent. Aprotic polar solvents include acetone, dimethyl sulfoxide (DMSO), N,N-dimethylformamide (DMF), pyridine, etc.

The acrylic polymer of component (C) is preferably a copolymer of a monomer having a hydrophilic group and a monomer having a hydrophobic group, wherein the hydrophilic group exhibits affinity with the pigment, and the hydrophobic group controls the compatibility and forms a steric barrier. Such an acrylic polymer adsorbs the functional material by the hydrophilic group, and the hydrophobic group inhibits aggregation, so that the functional material is uniformly dispersed. In fact, an organosilicon sol with a particle size of about 20-30nm will aggregate to form aggregates with a particle size as large as 600-1000nm, but by being uniformly dispersed, the light scattering of the hardened layer of the functional composition is improved, which can reduce the poor appearance caused by light interference.

Examples of hydrophilic groups include anionic groups such as carboxyl, sulfonic acid, and phosphoric acid groups, and cationic groups such as amino and ammonium groups. Specifically, monomers having hydrophilic groups include acrylic acid, acrylamide, methacrylic acid, poly(ethylene glycol) acrylate and methacrylate, dimethylaminoethyl methacrylate, diethylaminoethyl methacrylate, tertiary butylaminoethyl methacrylate, dimethylaminoethyl acrylate, diethylaminoethyl acrylate, methacrylamide, dimethylacrylamide, dimethylaminopropyl methacrylamide, ethylene glycol acrylate phosphonate, 2-(methacryloxy)methylphthalate, 2-(methacryloxy)ethylsuccinate, 3-sulfonic acid propyl methacrylate, 3-sulfonic acid propyl acrylate, etc.

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

In the above composition, the organic silicon sol of component (B) is formulated in an amount of 0.5 to 12 parts by mass, preferably 1 to 9 parts by mass, relative to 1 part by mass (solid content conversion) of the hydrolyzed condensate of silane oxide of component (A). When the formulation ratio of component (B) is above the lower limit, the effect of functional performance is enhanced, and when it is below the upper limit, the solvent resistance is enhanced.

The acrylic polymer with hydrophilic and hydrophobic groups of component (C) is mixed in an amount of 0.005-0.3 parts by mass, preferably 0.01-0.07 parts by mass (solid content) relative to 1 part by mass of component (B) (solid content conversion). When the mixing ratio of component (C) exceeds the upper limit, the agglomeration of colloidal silica increases. Therefore, when the mixing ratio of component (C) is below the upper limit, the poor appearance caused by the light interference of the low refractive index layer can be suppressed. In addition, when the mixing ratio of the above-mentioned component (C) is above the lower limit, the mixing liquid forms an appropriate viscosity, a uniform low refractive index layer can be formed, fingerprints become less noticeable, and a melamine decorative board with a more vivid pattern of printed paper is formed.

The composition comprising (A) a hydrolyzed condensate of silane oxide, (B) an organic silicon sol dispersed in a hydrophilic solvent, and (C) an acrylic polymer having a hydrophilic group and a hydrophobic group improves the dispersibility of the added functional material. Specifically, the functional material will enter the lattice-shaped coating structure of the (A) component, so the functional material can be evenly coated, and the function can be effectively exhibited with a small amount of addition. This effect is particularly easy to obtain when the functional material includes solids, specifically solid particles with an average particle size of 200~5000nm. Here, the average particle size is the particle size of 50% of the cumulative value in the particle size distribution obtained by the laser diffraction scattering method.

The functional substance preferably includes at least one substance selected from the group consisting of (m) deodorizing substances, (n) anti-viral substances and (o) anti-allergenic substances. The functional substance is preferably mixed in the above composition and stirred at 6000-10000 rpm for 5-10 minutes by a homogenizer. Since the homogenizer applies high pressure to the composition and a strong shear force is applied to the composition when passing through the gap, it can be evenly dispersed by stirring with a disperser.

Next, we will describe the deodorizing (m) deodorizing substance as an example of a substance that exhibits function. Physical adsorption type deodorizing substances such as porous materials such as activated carbon absorb odor (gas) in the small pores of the porous material to exert a deodorizing effect. When the physical adsorption type deodorizing substance absorbs gas at room temperature and then comes into contact with high temperature heat, friction heat, etc., the adsorption performance decreases, and the adsorbed gas may be released again.

On the other hand, chemical adsorption type deodorizing substances remove odors by converting them into other substances through chemical reactions such as acid and alkali neutralization, oxidation, and reduction. Once the odor (gas) is adsorbed and decomposed into other substances, it is difficult to release again, so it is suitable for use. Chemical adsorption type deodorizing substances include metal oxides such as silicon dioxide, copper oxide, aluminum oxide, titanium oxide, zinc oxide, iron oxide, and zirconium oxide, and metal hydroxides such as zirconium hydroxide, magnesium hydroxide, aluminum hydroxide, ferrous hydroxide, and copper hydroxide.

(m) Deodorizing substances that exhibit such deodorizing properties, due to the excellent heat resistance and wear resistance of melamine decorative boards, can further cope with the life odors generated in the house, that is, the complex odors of acidic odors, neutral odors and alkaline odors. It is better to use the above-mentioned chemical adsorption type deodorizing substances. Compared with the past, the residential buildings in recent years have emphasized the specifications of high air tightness and high heat insulation to form a seamless closed space. Therefore, it has become easier to feel the life odor. In order to suppress this life odor, commercially available deodorant products are generally used. However, melamine decorative boards themselves have deodorizing properties, which can further reduce the life odor.

Specifically, the chemical adsorption type deodorant is preferably at least one selected from the group consisting of zinc oxide, silicon dioxide, zeolite, copper oxide and zirconium oxide. For example, it is preferred to use zinc oxide and silicon dioxide as metal oxides, and the mixing ratio is calculated by mass ratio of the former: the latter = 45~85:55~15. The deodorant is particularly preferably in the form of microparticles, specifically, an average particle size of 0.2~10μm, and has good dispersibility in the composition. Here, the average particle size is the particle size of 50% of the cumulative value in the particle size distribution obtained by the laser diffraction scattering method. In particular, for neutral odors such as acetaldehyde and formaldehyde and alkaline odors such as trimethylamine, modified silica, such as amino-modified silica, has a better deodorizing effect, and for sulfur-based gases such as hydrogen sulfide and mercaptans, acetic acid, isovaleric acid, butyric acid and other acidic odors, zinc oxide has a better deodorizing effect. In addition, the zeolite may be a substance containing zeolite silver (i.e., zeolite containing silver).

The amount of the deodorizing substance (m) in the composition is preferably 30 to 60 parts by mass (converted to solid content) relative to 100 parts by mass of the solid content of the composition. When the deodorizing substance (m) is less than the lower limit, the deodorizing effect is likely to decrease, and when it exceeds the upper limit, white spots are likely to occur on the surface of the melamine decorative board. Here, white spots are a state in which a part of the surface of the melamine decorative board is white and blurred.

Next, we will describe in detail the (n) antiviral substance that exhibits antiviral properties as an example of a function-exhibiting substance. Antiviral substances are photocatalysts, with titanium oxide as the mainstream. Photocatalysts generate active oxygen by light excitation to deactivate viruses. In principle, the effect can be exerted semi-permanently, but there is a disadvantage that the performance cannot be exerted when not irradiated with light.

On the other hand, organic antiviral substances destroy the protein coat of the virus, and the protein synthesis of the virus with the coat destroyed is hindered. Alternatively, organic antiviral substances denature the protein to inactivate the virus. Organic antiviral substances have the characteristic of showing their effects faster than photocatalysts.

The organic antiviral substance is preferably at least one selected from the group consisting of triazine-thiazole-imidazole substances, amino-modified polyvinyl alcohol and amino-modified acrylic polymer. Such organic antiviral substances are just suitable for melamine decorative boards that are required to be solvent-resistant and stain-resistant. The organic antiviral substance is particularly preferably in the form of microparticles, specifically at least one selected from the group consisting of particles carrying triazine-thiazole-imidazole substances, amino-modified polyvinyl alcohol particles and amino-modified acrylic polymer particles. The average particle size of the organic antiviral substance in the form of particles is preferably 0.5~3μm because of its good dispersibility in the composition. In addition, the average particle size here is the particle size of 50% of the cumulative value in the particle size distribution obtained by the laser diffraction scattering method.

The amount of the (n) antiviral substance in the composition is preferably 35 to 75 parts by weight (converted to solid content) relative to 100 parts by weight of the solid content of the composition. When the amount of the (n) antiviral substance is less than the lower limit, the antiviral effect is likely to decrease, and when it exceeds the upper limit, white spots are likely to form on the surface of the melamine decorative board.

Next, we will describe in detail the (o) anti-allergenic substance that exhibits anti-allergenic properties as an example of a substance that exhibits function. Dust that is invisible to the naked eye floats in the air. The dust contains allergens such as cedar pollen or the dead bodies and feces of mites, which become the cause of allergies. (o) Anti-allergenic substances are preferably complexes of anion-modified organic compounds and carriers. The complex chemically adsorbs the protein of the allergen substance, thereby exerting the effect of reducing the allergen substance.

Only anion-modified organic compounds that constitute (o) antiallergenic substances can also exert the same reduction effect, but only anion-modified organic compounds are difficult to fix on the surface of melamine decorative boards, and the antiallergenicity is likely to lack durability. Therefore, it is better to include anion-modified organic compounds in a carrier of solid components to form a composite. The composite with the carrier can be physically fixed on the surface of melamine decorative boards, so it is suitable for melamine decorative boards that require durability.

Examples of organic compounds modified by anions include anion-modified straight-chain alkanes and anion-modified polyvinyl alcohols. Specifically, examples of anion-modified straight-chain alkanes include straight-chain alkanes modified by acidic anion groups such as carboxyl groups, phosphoric acid groups, and sulfonic acid groups. Examples of relative ions of the acidic anion groups include sodium ions and potassium ions. Examples of anion-modified polyvinyl alcohols include polyvinyl alcohols modified by acidic anion groups such as carboxyl groups and sulfonic acid groups. In addition, examples of carriers include inorganic particles or organic particles, such as acrylate particles such as alkali-modified acrylate particles, styrene particles such as alkali-modified styrene particles, and silver oxide particles. The carrier includes at least one selected from the group consisting of styrene particles and silver oxide. (o) The antiallergenic substance is preferably in the form of microparticles, specifically, having an average particle size of 1 to 8 μm. In addition, the average particle size here is the particle size of 50% of the cumulative value in the particle size distribution obtained by laser diffraction scattering method.

The amount of the antiallergenic substance (o) in the composition is preferably 3 to 50 parts by weight (converted to solid content) relative to 100 parts by weight of the solid content of the composition. When the amount of the antiallergenic substance (o) is less than the lower limit, the antiallergenic effect is likely to be reduced, and when it exceeds the upper limit, white spots are likely to form on the surface of the melamine decorative board.

Next, the dosage when combining these functional substances, i.e., combining (m) deodorant, (n) antiviral, and (o) antiallergenic substances, is described. When combining (m) deodorant and (n) antiviral, the mixing ratio is preferably (m) deodorant: (n) antiviral = 1:0.5~2.50, and more preferably 1:0.60~2.0, calculated by mass ratio. When the mixing ratio is less than the lower limit or exceeds the upper limit, the balance of properties of the product with both deodorant and antiviral properties is poor.

In addition, the total amount of the deodorizing substance (m) and the antiviral substance (n) in the composition is preferably 60 to 150 parts by mass, and more preferably 75 to 115 parts by mass, relative to 100 parts by mass of the solid content of the composition. As long as the total amount is within this range, a decorative board with particularly excellent appearance, deodorizing properties, and antiviral properties can be formed. That is, when the total amount is less than the lower limit, the deodorizing properties and antiviral properties are poor, and when it exceeds the upper limit, the appearance is more likely to produce white spots.

When combining (m) deodorant and (o) antiallergenic substances, the mixing ratio calculated by mass ratio is preferably (m) deodorant: (o) antiallergenic substance = 1: 0.03~2.0, and more preferably 1: 0.08~1.8. When the mixing ratio is less than the lower limit or exceeds the upper limit, the balance of properties of the product with both deodorant and antiallergenic properties is poor.

In addition, the total amount of the deodorant (m) and the antiallergenic substance (o) in the composition is preferably 30 to 160 parts by mass, and more preferably 35 to 110 parts by mass, relative to 100 parts by mass of the solid content of the composition. As long as the total amount is within this range, a decorative board with particularly excellent appearance, deodorant properties, and antiallergenic properties can be formed. That is, if the total amount is less than the lower limit, the deodorant and antiallergenic properties are poor, and if it exceeds the upper limit, the appearance is more likely to produce white spots.

When combining (n) antiviral substances and (o) antiallergenic substances, the mixing ratio calculated by mass ratio is preferably (n) antiviral substances: (o) antiallergenic substances = 1: 0.01~2.0, and more preferably 1: 0.06~1.50. When the mixing ratio is less than the lower limit or exceeds the upper limit, the balance of properties of the product with both antiviral and antiallergenic properties is poor.

Furthermore, the total amount of the antiviral substance (n) and the antiallergenic substance (o) in the composition is preferably 15 to 200 parts by mass, and more preferably 35 to 125 parts by mass, relative to 100 parts by mass of the solid content of the composition. As long as the total amount is within this range, a decorative board with particularly excellent appearance, antiviral properties, and antiallergenic properties can be formed. That is, if the total amount is less than the lower limit, the antiviral and antiallergenic properties are poor, and if it exceeds the upper limit, the appearance is more likely to produce white spots.

When (m) a deodorant, (n) an antiviral, and (o) an antiallergenic are combined, the blending ratio calculated by mass ratio is preferably (m) a deodorant: (n) an antiviral: (o) an antiallergenic = 1: 0.20-7.0: 0.05-5.5, more preferably 1: 0.6-4.5: 0.15-3.0. In addition, the total blending amount of (m) a deodorant, (n) an antiviral, and (o) an antiallergenic in the composition is preferably 30-170 parts by mass, more preferably 50-120 parts by mass, relative to 100 parts by mass of the solid content of the composition. As long as the blending ratio and total blending amount are within this range, a decorative board with a balanced and excellent appearance, deodorizing, antiviral and antiallergenic properties can be formed, and through the synergistic effect, only a smaller amount of coating can be used to exert functions that exceed the functions exerted individually. In order to emphasize each function within the desired range, of course, the blending amount of (m) deodorizing substances, (n) antiviral substances and (o) antiallergenic substances can also be appropriately adjusted.

The decorative layer includes a cured product of melamine resin. The decorative layer includes melamine resin impregnated pattern paper, which is obtained by impregnating a resin liquid (hereinafter referred to as melamine resin liquid) with melamine resin as the main component in a decorative paper with a basis weight of about 80 to 140 g/ ^m2 and drying. A melamine resin impregnated covering paper for protecting the pattern of the decorative paper may be arranged on the melamine resin impregnated pattern paper and a covering layer is provided, wherein the melamine resin impregnated covering paper is obtained by impregnating a covering paper with a basis weight of about 16 to 60 g/ ^m2 with melamine resin liquid and drying. The covering layer also includes a cured product of melamine resin. The surface of the decorative layer or the surface of the covering layer is formed with a hardened layer of the above-mentioned composition or a composition further containing a function-displaying substance (hereinafter referred to as a functional composition) as a surface layer. The means for forming the hardened layer is to adopt a coating method or a transfer method, etc. The coating method is to impregnate the decorative paper or the covering paper with melamine resin liquid, and then apply a coating liquid containing the composition or the functional composition on the surface. The transfer method is to use a transfer sheet with a functional composition applied to a sheet-like substrate. For example, in the transfer method, a laminate is first formed by heat pressing, and the laminate is sequentially composed of a transfer sheet having a hardened layer of a functional composition formed on one side of a sheet substrate, a melamine resin impregnated pattern paper, and a core material. Alternatively, when a melamine resin impregnated cover paper is used, a melamine resin impregnated cover paper is further arranged on the melamine resin impregnated pattern paper and heat pressed. In the laminate, the hardened layer side of the transfer sheet faces the melamine resin impregnated pattern paper or the melamine resin impregnated cover paper. The sheet substrate is then removed.

The impregnation rate of melamine resin liquid defined by mathematical formula 1 is preferably in the range of 70~160%.

Sheet substrates used in the transfer method include plastic films, metal foils, etc. Plastic films include polyester films, polyethylene films, polypropylene films, cellophane, cellulose diacetate films, cellulose triacetate films, cellulose acetate butyrate films, polyvinyl chloride films, polyvinylidene chloride films, polyvinyl alcohol films, ethylene vinyl alcohol films, polystyrene films, polycarbonate films, polymethylpentene films, polysulfone films, polyether ketone films, polyethersulfone films, polyetherimide films, polyimide films, fluororesin films, nylon films, acrylic films, etc.

Examples of metal foil include gold foil, silver foil, copper foil, zinc foil, indium foil, aluminum foil, tin foil, iron foil (including stainless steel (SUS) foil), and titanium foil. When the coating liquid containing the functional composition is applied to the sheet-like substrate by transfer, known methods such as spray coating, gravure coating, bar coating, knife coating, roll coating, blade coating, die coating, curtain coating, reverse coating, comma coating, etc. can be used. The transfer sheet obtained in this way is laminated on the melamine resin impregnated paper so that the coated surface abuts the melamine resin impregnated paper as the top layer, that is, the surface on the side of the hardened layer of the functional composition, and after lamination, it is heat-pressed together with the core material forming the core layer.

The coating thickness of the coating liquid containing the functional composition is described in detail. The coating thickness of the coating liquid containing the functional composition containing (m) a deodorizing substance (hereinafter referred to as a deodorizing function-exhibiting composition) is preferably 2.0 to 6.5 μm in a dry state in either the coating method or the transfer method. When the coating thickness is above the lower limit, the deodorizing performance can be further exerted. When the coating thickness exceeds the upper limit, white spots are likely to be formed in appearance. The coating thickness of the coating liquid containing the functional composition containing (n) an antiviral substance (hereinafter referred to as the antiviral function-exhibiting composition) is preferably 1.5 to 3.5 μm in a dry state in either the coating method or the transfer method. When the coating thickness is less than the lower limit, it is difficult to exert the antiviral performance. When the coating thickness exceeds the upper limit, white spots are likely to be formed in appearance. The coating thickness of the coating liquid containing the functional composition containing (o) an antiallergenic substance (hereinafter referred to as the antiallergenic function-exhibiting composition) is preferably 2.0 to 8.0 μm in a dry state in either the coating method or the transfer method. When the coating thickness is less than the lower limit, it is difficult to exert anti-allergen performance. When the coating thickness exceeds the upper limit, it is easy to form white spots.

In addition, the pH value of the coating liquid containing the functional composition is preferably 3 or more in either the coating method or the transfer method. When the pH value is less than 3, the lattice structure of the (A) component is destroyed, and whitening spots are likely to occur on the surface of the decorative board. The pH value of the coating liquid is the pH value measured in the coating liquid with the solid concentration (the concentration of the above solids contained in the functional composition in the coating liquid) adjusted to 20 mass%. In addition, the pH value is obtained based on the operation of the glass electrode method in accordance with JIS Z8802:2011 "pH Determination Method".

In addition, the coating thickness of the coating liquid containing a composition without a functional display substance is preferably 2.0~8.0μm in a dry state in either the coating method or the transfer method. When the coating thickness is less than the lower limit, the adhesion of fingerprints becomes conspicuous, and when the coating thickness exceeds the upper limit, it is easy to form white spots in appearance. In addition, the pH value of the coating liquid is the same as that of the case containing a functional display substance, preferably 3 or more. The pH value measurement method is also the same as that of the case containing a functional display substance.

The core material may be a thermosetting resin impregnated core paper. The thermosetting resin impregnated core paper is obtained by impregnating an organic fiber substrate such as kraft paper or bleached kraft paper with a resin liquid and drying it. The resin liquid is mainly composed of a thermosetting resin such as a phenolic resin or a melamine-formaldehyde resin.

In addition to the above-mentioned thermosetting resin impregnated core paper, prepregs can also be used. Prepregs are non-woven fabrics, woven fabrics, etc. formed of inorganic fibers such as glass fiber, rock wool, carbon fiber, ceramic fiber, etc. as the base material, impregnated with slurry containing inorganic fillers and adhesives and dried. This can give non-flammability. In particular, glass fiber non-woven fabrics with excellent heat resistance and fire resistance and excellent slurry impregnation are preferred.

Inorganic fillers include endothermic metal hydroxides such as aluminum hydroxide and magnesium hydroxide. Inorganic substances other than endothermic metal hydroxides include calcium carbonate, talc, fly ash, etc., and more than one of them can be used. Endothermic metal hydroxides contain crystal water, which is decomposed at high temperatures and releases crystal water by absorbing heat, thereby having an advantage in non-flammability. It is preferred to use aluminum hydroxide or magnesium hydroxide.

When the endothermic metal hydroxide and inorganic substances other than the endothermic metal hydroxide are used together, it is preferable that the amount of the endothermic metal hydroxide is 2 to 15 parts by mass relative to 1 part by mass of the inorganic substances other than the endothermic metal hydroxide, because a smooth and good surface appearance can be obtained. In addition, the amount of the endothermic metal hydroxide is 2 parts by mass or more relative to 1 part by mass of the inorganic substances other than the endothermic metal hydroxide, thereby making the non-flammability excellent. In addition, the amount of the endothermic metal hydroxide is 15 parts by mass or less relative to 1 part by mass of the inorganic substances other than the endothermic metal hydroxide, thereby making it difficult for the metal hydroxide in the slurry to settle, and as a result, making it easy to control the slurry impregnation amount. Furthermore, the amount of endothermic metal hydroxide is less than 15 parts by mass relative to 1 part by mass of inorganic substances other than endothermic metal hydroxide, thereby reducing the wear of the tool used for cutting the decorative plate.

Examples of adhesives include thermosetting resins such as amino formaldehyde resins, phenolic resins, and mixed resins thereof. The mixing ratio of the adhesive component to the solid content of the inorganic filler material is preferably 5~20:95~80 by mass. When the adhesive component is high, the non-flammability performance is easily reduced, and when the adhesive component is low, the adhesion between the prepregs is easily deteriorated.

The impregnation rate (%) of the slurry to the inorganic fiber substrate is preferably in the range of 500~3000% using the calculation method shown in the above mathematical formula 1. When the impregnation rate exceeds the upper limit, the solid matter will fall off and become difficult to operate. When the impregnation rate is less than the lower limit, the layers are prone to peeling.

Other core materials may include calcium silicate, plywood, medium density fiberboard, plastic plywood, etc. The core material is not particularly limited. The support material (backup) is arranged on the back of the core material and laminated and hot-pressed to suppress the bending caused by the shrinkage of the melamine decorative board. The support material may be, for example, melamine impregnated paper or phenol impregnated paper using a cellulose substrate as the base material. The cellulose substrate may include α-cellulose paper, titanium paper, kraft paper, bleached kraft paper, etc.

(Examples) The present invention is described below by using examples, experimental examples and comparative examples, but the present invention is not limited to the examples shown below.

[Implementation Example 1]

1. Manufacture of a composition comprising component (A), component (B) and component (C)

The obtained composition includes 100 parts by weight (solid content conversion) of tetraethyl orthosilicate hydrolyzate (trade name "HAS-1", manufactured by Colcoat Co., Ltd.) as (A) hydrolysis condensate of silane oxide; "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, SiO ₂ 30 mass%), 600 mass parts (solid content conversion) as (B) an organosilicon sol dispersed in a hydrophilic solvent; and "DISPERBYK-2009" (a solution of an acrylate copolymer, acrylate copolymer 44 mass%, 1-methoxy-2-propyl acetate, ethylene glycol monobutyl ether) (trade name, manufactured by BYK Co., Ltd.) 13.2 mass parts (solid content conversion) as (C) an acrylic polymer having a hydrophilic group and a hydrophobic group.

2. Manufacture of deodorizing functional compositions

100 parts by weight of the solid content of the composition comprising components (A), (B) and (C) prepared in 1. above was mixed with 40 parts by weight of a deodorizing substance (m) comprising 74% by weight of zinc oxide and 26% of amino-modified silica and having an average particle size of 350 nm, and stirred at 8100 rpm for 10 minutes using a homogenizer to obtain a deodorizing function-exhibiting composition (M).

3. Manufacturing transfer films

A coating liquid containing a deodorizing functional composition (M) was applied to a plastic film so that the film thickness after drying was 4.5 μm, and a transfer sheet (M) was obtained. In addition, the coating liquid was prepared so that the solid content concentration, i.e., the concentration of the solid content contained in the functional composition in the coating liquid, was 20% by mass. In addition, the pH value of the coating liquid was 5.8. The pH value of the coating liquid was measured using a glass electrode pH meter (product name: LAQUA model F-71, manufactured by Horiba, Ltd.). The same applies to other embodiments, experimental examples, and comparative examples.

4. Manufacture of melamine resin impregnated pattern paper (M)

A resin liquid (AA) containing melamine-formaldehyde resin as a main component is impregnated into a decorative paper for a brown decorative board having a basis weight of 100 g/ ^m2 to obtain a melamine resin impregnated pattern paper (M). The impregnation rate of the melamine resin impregnated pattern paper (M) defined by mathematical formula 1 is 140%. In addition, a wood grain pattern having a conduit portion is printed on the surface of the decorative paper.

5. Manufacturing prepreg

A glass fiber substrate with a basis weight of 50 g/ ^m2 is impregnated with a slurry so that the impregnation rate based on Mathematical Formula 1 is 1200%. The slurry includes melamine-formaldehyde resin and phenolic resin as binder components; and inorganic fillers such as aluminum hydroxide and calcium carbonate as inorganic fillers. After drying, a prepreg is obtained. The mass ratio of the solid content of the binder component and the inorganic filler in the slurry is 8:92.

6. Support materials

A resin solution containing melamine-formaldehyde resin as a main component is impregnated into a decorative paper for a decorative board having a basis weight of 80 g/ ^m2 so that the impregnation rate shown in Mathematical Formula 1 is 150%, and a supporting material is obtained after drying.

7. Manufacturing decorative panels

From bottom to top, 1 sheet of support material, 5 sheets of prepreg, 1 sheet of melamine resin impregnated pattern paper (M), and 1 sheet of transfer sheet (M) are sequentially laminated. The laminate is hot-pressed at 140°C, 100kg/ ^cm2 , and 90 minutes using a flat trimming plate. After removing the plastic film, a melamine decorative board is obtained.

[Example 2] The same method as in Example 1 is used except that 60 parts by weight of (m) deodorizing substance is added.

[Example 3] The same method as in Example 1 is used except that 30 parts by weight of (m) deodorizing substance is added.

[Example 4] The same method as in Example 1 was used except that 9.3 parts by weight of "DISPER BYK-2009" as component (C) was added.

[Example 5] The same method as in Example 1 was used except that 16.8 parts by weight of "DISPER BYK-2009" as component (C) was added.

[Example 6] The same method as in Example 1 is used except that 400 parts by weight of "NPC-ST-30" of component (B) is added.

[Example 7] The same method as in Example 1 is used except that 900 parts by weight of "NPC-ST-30" of component (B) is added.

[Example 8] The same method as in Example 1 is used except that the average particle size of the deodorizing substance (m) is set to 200 nm.

[Example 9] The same method as in Example 1 is used except that the average particle size of the deodorizing substance (m) is set to 1000 nm.

[Example 10] The same method as in Example 1 is used except that the coating liquid containing the deodorizing functional composition (M) is applied so that the film thickness after drying is 2.0 μm.

[Example 11] The same method as in Example 1 is used except that the coating liquid containing the deodorizing functional composition (M) is applied so that the film thickness after drying is 6.5 μm.

[Example 12] The same method is used as in Example 1 except that a deodorizing substance (m) containing 45% by mass of zinc oxide and 55% of amino-modified silicon dioxide is used.

[Example 13] The same method is used as in Example 1 except that a deodorizing substance (m) containing 85% by mass of zinc oxide and 15% of amino-modified silica is used.

[Implementation Example 14]

1. Manufacture of antiviral functional components

For 100 parts by weight of the solid content of the composition comprising components (A), (B) and (C) of Example 1, 50 parts by weight of (n) antiviral substance of triazine-imidazole-thiazole series organic synthetic antiviral substance with an average particle size of 1000 nm was added, and the mixture was stirred at 8100 rpm for 10 minutes using a homogenizer to obtain an antiviral function-exhibiting composition (N).

2. Manufacturing transfer films

A coating liquid containing an antiviral function-displaying composition (N) was applied to a plastic film so that the film thickness after drying was 2.2 μm, thereby obtaining a transfer sheet (N). The pH value of the coating liquid was 8.3.

3. Manufacturing decorative panels

The same method is used except that the transfer sheet (N) mentioned above is used instead of the transfer sheet (M) in Example 1.

[Example 15] The same method is used as in Example 14 except that 26.4 parts by weight of "DISPER BYK-2009" of component (C) and 35 parts by weight of antiviral substance (n) are added.

[Example 16] The same method as in Example 14 is used except that 26.4 parts by weight of "DISPER BYK-2009" of component (C) and 75 parts by weight of antiviral substance (n) are added.

[Example 17] The same method as in Example 14 was used except that 9.3 parts by weight of "DISPER BYK-2009" as component (C) was added.

[Example 18] The same method as in Example 14 was used except that 16.8 parts by weight of "DISPER BYK-2009" as component (C) was added.

[Example 19] The same method as in Example 14 is used except that 26.4 parts by weight of "DISPER BYK-2009" of component (C) is added and the coating liquid containing the antiviral function-developing composition (N) is applied so that the film thickness after drying is 3.5 μm.

[Example 20] The same method as in Example 19 is used except that the coating liquid containing the antiviral function-displaying composition is applied so that the film thickness after drying is 1.5 μm.

[Example 21] The same method as in Example 19 is used except that the average particle size of the (n) antiviral substance is set to 3000 nm, and the coating liquid containing the antiviral function-exhibiting composition is applied so that the film thickness after drying is 2.2 μm.

[Example 22] The same method as Example 21 is used except that the average particle size of (n) the antiviral substance is set to 500 nm.

[Example 23]

1. Manufacture of anti-allergenic functional components

For 100 parts by weight of the solid content of the composition comprising components (A), (B) and (C) of Example 1, 10 parts by weight of an organic synthetic antiallergenic substance ("Allerbuster BV" manufactured by Sekisui Material Solutions Co., Ltd.) was prepared as the antiallergenic substance (o), which has an average particle size of 2000 nm and is a composite of a sodium salt of an acidic anionic modified linear alkane and styrene particles. The mixture was stirred at 8100 rpm for 10 minutes using a homogenizer to obtain an antiallergenic function-exhibiting composition (O).

2. Manufacturing transfer films

A coating liquid containing an anti-allergenic function-displaying composition (O) is applied to a plastic film so that the film thickness after drying is 4.0 μm, thereby obtaining a transfer sheet (O). The pH value of the coating liquid is 6.8.

4. Manufacturing decorative panels

The same method is used except that the transfer sheet (O) mentioned above is used instead of the transfer sheet (M) in Example 1.

[Example 24] The same method is used as in Example 23 except that (o) the anti-allergenic substance is prepared in 3 parts by weight.

[Example 25] The same method is used as in Example 23 except that (o) the anti-allergenic substance is formulated in 50 parts by weight.

[Example 26] The same method is used as in Example 23 except that an organic synthetic antiallergenic substance having an average particle size of 5000nm and being a composite of a sodium salt of an acidic anionic modified linear alkane and styrene particles ("Allerbuster BV" manufactured by Sekisui Material Solutions Co., Ltd.) is used as (o) antiallergenic substance.

[Example 27] The same method as in Example 23 was used except that an organic synthetic antiallergenic substance having an average particle size of 1000 nm and being a composite of a sodium salt of an acidic anionic group-modified linear alkane and styrene particles ("Allerbuster BV" manufactured by Sekisui Material Solutions Co., Ltd.) was used as the (o) antiallergenic substance.

[Example 28] The same method is used as in Example 23 except that the coating liquid containing the antiallergenic composition is applied so that the film thickness after drying is 2.0 μm.

[Example 29] The same method is used as in Example 23 except that the coating liquid containing the antiallergenic composition is applied so that the film thickness after drying is 8.0 μm.

[Example 30] The same method is used as in Example 23 except that 900 parts by weight of "NPC-ST-30" of component (B) is added.

[Example 31] The same method is used as in Example 23 except that 300 parts by weight of "NPC-ST-30" of component (B) is added.

[Example 32]

1. Manufacturing thermosetting resin impregnated core paper

Decorative paper for brown decorative board with a basis weight of 200 g/ ^m2 is impregnated with a resin liquid containing phenolic resin as a main component so that the impregnation rate defined by mathematical formula 1 is 50%. After drying, a phenolic resin impregnated core paper is obtained as a thermosetting resin impregnated core paper.

2. Manufacturing decorative panels

Five phenol resin impregnated core papers, one melamine resin impregnated pattern paper (M) the same as in Example 1, and one transfer sheet (M) were sequentially laminated from bottom to top. The laminated material was hot-pressed at 140°C, 100 kg/ ^cm2 , and 90 minutes using a flat trimming plate. After the plastic film was removed, a melamine decorative board was obtained.

[Example 33] is implemented in the same manner as in Example 2 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 34] is implemented in the same manner as in Example 3 except that phenolic resin-impregnated core paper is used instead of prepreg and no supporting material is used.

[Example 35] The same method as in Example 32 is used except that the average particle size of the deodorizing substance (m) is set to 200 nm.

[Example 36] The same method as in Example 32 is used except that the average particle size of the deodorizing substance (m) is set to 1000 nm.

[Example 37] The same method as in Example 32 is used except that the coating liquid containing the deodorizing functional composition is applied so that the film thickness after drying is 2.5 μm.

[Example 38] The same method as in Example 32 is used except that the coating liquid containing the deodorizing functional composition is applied so that the film thickness after drying is 6.5 μm.

[Example 39] is implemented in the same manner as in Example 14 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 40] is implemented in the same manner as in Example 15 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 41] is implemented in the same manner as in Example 16 except that phenolic resin-impregnated core paper is used instead of prepreg and no supporting material is used.

[Example 42] is implemented in the same manner as in Example 19 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 43] is implemented in the same manner as in Example 20 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 44] The same method as in Example 39 is used except that the average particle size of (n) the antiviral substance is set to 3000 nm.

[Example 45] The same method as in Example 39 is used except that the average particle size of (n) the antiviral substance is set to 500 nm.

[Example 46] is implemented in the same manner as in Example 23 except that phenolic resin-impregnated core paper is used instead of prepreg and no supporting material is used.

[Example 47] The same method as in Example 24 is used except that the phenol resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 48] is implemented in the same manner as in Example 25 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 49] is implemented in the same manner as in Example 26 except that phenolic resin-impregnated core paper is used instead of prepreg and no supporting material is used.

[Example 50] is implemented in the same manner as in Example 27 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 51] is implemented in the same manner as in Example 28 except that a phenolic resin-impregnated core paper is used instead of the prepreg and no supporting material is used.

[Example 52] is implemented in the same manner as in Example 29 except that phenolic resin-impregnated core paper is used instead of prepreg and no supporting material is used.

[Example 53] The same method as in Example 1 is used except that zeolite is used as (m) the deodorizing substance.

[Example 54] The same method as Example 1 is used except that copper oxide is used as (m) the deodorizing substance.

[Example 55] The same method as in Example 1 is used except that zirconium oxide is used as (m) the deodorizing substance.

[Example 56] is implemented in the same manner as in Example 14 except that amino-modified polyvinyl alcohol particles are used as (n) antiviral substances.

[Example 57] is implemented in the same manner as Example 14 except that amino-modified acrylic ester particles are used as (n) antiviral substances.

[Example 58] The same method is used except that in Example 23, acidic anion-modified polyvinyl alcohol is used instead of the sodium salt of acidic anion-modified linear alkane as (o) the anion-modified organic compound of the antiallergenic substance.

[Example 59] The same method is used as in Example 23 except that silver oxide particles are used instead of styrene particles as the carrier of (o) the anti-allergenic substance.

[Example 60] The same method is used as in Example 1 except that the composition comprising components (A), (B) and (C) obtained in Example 1 is used instead of the deodorizing function-exhibiting composition (M).

[Example 61] The same method as in Example 1 is used except that the following melamine resin impregnated pattern paper (Mt) is used and the following manufacturing method is used.

<Manufacturing of melamine resin impregnated pattern paper (Mt)>

A resin liquid (AA) containing melamine-formaldehyde resin as the main component was impregnated into a decorative paper for a brown decorative board having a basis weight of 100 g/ ^m2 so that the impregnation rate defined by Mathematical Formula 1 was 140%. Furthermore, a coating liquid containing the deodorizing function-exhibiting composition (M) of Example 1 was applied to the decorative paper so that the film thickness after drying was 4.5 μm, thereby obtaining a melamine resin-impregnated pattern paper (Mt). In addition, a wood grain pattern having a conduit portion was printed on the surface of the decorative paper.

<Manufacturing decorative panels>

From bottom to top, 1 sheet of support material, 5 sheets of prepreg, and 1 sheet of melamine resin impregnated pattern paper (Mt) were sequentially laminated, and the laminated material was hot-pressed at 140°C, 100 kg/cm ² , and 90 minutes using a flat trimming plate to obtain a melamine decorative board.

[Example 62] The same method as in Example 14 is used except that the following melamine resin impregnated pattern paper (Nt) is used and the following manufacturing method is used.

<Manufacturing of melamine resin impregnated patterned paper (Nt)>

Decorative paper for brown decorative board with a basis weight of 100 g/ ^m2 was impregnated with a resin liquid (AA) containing melamine-formaldehyde resin as the main component so that the impregnation rate defined by Mathematical Formula 1 was 140%, thereby obtaining impregnated paper. Furthermore, a coating liquid containing the antiviral function-exhibiting 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, thereby obtaining melamine resin impregnated pattern paper (Nt). In addition, a wood grain pattern having a conduit portion was printed on the surface of the decorative paper.

<Manufacturing decorative panels>

One sheet of supporting material, five sheets of prepreg, and one sheet of melamine resin impregnated pattern paper (Nt) were sequentially laminated from bottom to top, and the laminated material was hot-pressed at 140°C, 100 kg/cm ² , and 90 minutes using a flat trimming plate to obtain a melamine decorative board.

[Example 63] The same method is used as in Example 23 except that the following melamine resin impregnated pattern paper (Ot) is used and the following manufacturing method is used.

<Manufacturing of melamine resin impregnated pattern paper (Ot)>

Decorative paper for brown decorative board with a basis weight of 100 g/ ^m2 was impregnated with a resin liquid (AA) containing melamine-formaldehyde resin as the main component so that the impregnation rate defined by Mathematical Formula 1 was 140%, thereby obtaining impregnated paper. Furthermore, a coating liquid containing the antiallergenic function-exhibiting 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, thereby obtaining melamine resin impregnated pattern paper (Ot). In addition, a wood grain pattern having a conduit portion was printed on the surface of the decorative paper.

<Manufacturing decorative panels>

From bottom to top, 1 sheet of support material, 5 sheets of prepreg, and 1 sheet of melamine resin impregnated pattern paper (Ot) were sequentially laminated, and the laminated material was hot-pressed at 140°C, 100 kg/cm ² , and 90 minutes using a flat trimming board to obtain a melamine decorative board.

[Comparative Example 1] The same method is used except that a silicone graft polymer (trade name "ZX-036", hydroxyl value 119, solvent type: butyl acetate/2-propanol, manufactured by Fuji Chemical Industries, Ltd.) composed of acrylic resin and silicone is used to replace (A) the hydrolyzed condensate of silane oxide.

[Comparative Example 2] The same method is used as in Example 1 except that a hydrophobic silica sol (trade name "sylophobic", manufactured by Fuji Silysia Chemical Co., Ltd.) is used instead of (B) the organic silica sol dispersed in a hydrophilic solvent.

[Comparative Example 3] The same method was used as in Example 1 except that 100 parts by weight of an acrylic polymer containing a methacrylic functional group (trade name "RA-3705MB", manufactured by Negami Industrial Co., Ltd.) was used as (x) a reactive (meth) acrylic polymer to replace (C) an acrylic polymer having a hydrophilic group and a hydrophobic group, and 0.4 parts by weight of 1,6-bis(tertiary butylperoxycarbonyloxy)hexane (trade name "Kayalene6-70", manufactured by AKZO Chemical Co., Ltd.) was added as a thermal polymerization initiator.

[Comparative Example 4] is implemented in the same manner as in Comparative Example 3 except that the function-exhibiting substance is not included.

[Comparative Example 5~Comparative Example 9] are implemented in the same manner except that the conditions in Comparative Example 3 are changed to those shown in Table 4-1 and Table 4-2.

[Example 64 to Example 78] are implemented in the same manner except that the conditions in Example 1 are changed to those shown in Table 5-1 and Table 5-2. In addition, in Example 64 to Example 78, the same deodorant as in Example 1 is used as the (m) deodorant, the same antiviral substance as in Example 14 is used as the (n) antiviral, and the same antiallergenic substance as in Example 23 is used as the (o) antiallergenic.

[Example 79 to Example 93] are implemented in the same manner except that the conditions in Example 1 are changed to those shown in Table 6-1 and Table 6-2. In addition, in Example 79 to Example 93, the same deodorant as in Example 1 is used as the (m) deodorant, the same antiviral substance as in Example 14 is used as the (n) antiviral, and the same antiallergenic substance as in Example 23 is used as the (o) antiallergenic.

However, in Example 88, "HAS-6" which is a hydrolyzed condensate of ethyl silicate is used instead of "HAS-1" as the (A) component. In Example 89, "HAS-10" which is a hydrolyzed condensate of ethyl silicate is used instead of "HAS-1" as the (A) component. In Example 90, "IPA-ST" (trade name, manufactured by Nissan Chemical Industries, Ltd., average particle size 10~15nm, isopropyl alcohol dispersed silica sol, SiO2 ₃₀ mass%) is used instead of "NPC-ST-30" as the (B) component. In Example 91, "MEK-AC-2140Z" (trade name, manufactured by Nissan Chemical Industries, Ltd., average particle size 10~15nm, methyl ethyl ketone dispersed silica sol, _SiO2 40% by mass) is used instead of "NPC-ST-30" as the (B) component. In Example 92, "DISPERBYK-2000" (a solution of an acrylate copolymer, 40% by mass of an acrylate copolymer, 1-methoxy-2-propyl acetate, ethylene glycol monobutyl ether) (trade name, manufactured by BYK Co., Ltd.) is used instead of "DISPERBYK-2009" as the (C) component. In Example 93, "DISPERBYK-2008" (a solution of an acrylate copolymer, 60% by mass of an acrylate copolymer, 40% by mass of polypropylene glycol, trade name, manufactured by BYK Co., Ltd.) is used instead of "DISPERBYK-2009" as the (C) component.

[Implementation Example 94]

<Manufacturing of melamine resin impregnated covering paper>

The same resin solution (AA) as in Example 1 was impregnated into a covering paper having a basis weight of 22 g/ ^m2 to obtain a melamine resin impregnated covering paper. The impregnation rate of the melamine resin impregnated covering paper defined by Mathematical Formula 1 was 260%.

<Manufacturing decorative panels>

Prepare the same transfer sheet as in Example 79. Also, obtain the melamine resin impregnated pattern paper in the same manner as in Example 1 except that the impregnation rate defined by Mathematical Formula 1 is 100%.

In addition, the same phenol resin impregnated core paper as in Example 32 was prepared. Five sheets of phenol resin impregnated core paper, one sheet of melamine resin impregnated pattern paper, one sheet of melamine resin impregnated cover paper, and one sheet of transfer sheet were sequentially laminated from bottom to top, and the laminated material was hot-pressed at 140°C, 100 kg/ ^cm2 , and 90 minutes using a flat trimming plate, and the plastic film was removed to obtain a melamine decorative board.

[Example 95] The same method is used as in Example 94 except that the transfer sheet of Example 80 is used.

[Example 96] is implemented in the same manner as Example 94 except that the transfer sheet of Example 81 is used.

[Experimental Example 1 to Experimental Example 6] are implemented in the same manner except that the conditions in Example 1 are changed to those shown in Table 7-1 and Table 7-2.

[Experimental Example 7~Experimental Example 10] are implemented in the same manner except that the conditions in Example 1 are changed to those shown in Table 8-1 and Table 8-2.

[Experimental Example 11 to Experimental Example 22] The same method was used except that the conditions in Example 1 were changed to those shown in Table 9-1 and Table 9-2. In the above-mentioned Examples, Experimental Examples and Comparative Examples, the composition including component (A), component (B) and component (C) and the blending ratio of the functional composition, the particle size and pH value of the functional development material, the coating amount and the type of the core material of the core layer are shown in Table 1-1 to Table 2-2.

In addition, A, B, C, m, n and o in the table are as follows.

A hydrolysis condensation product of silane oxide

B: Organosilicon sol dispersed in hydrophilic solvent

C: Acrylic polymer with hydrophilic and hydrophobic groups

m: Deodorant

n: Antiviral substances

o: Anti-allergenic substances

In addition, the mass values of A, B and C in the table are based on the solid content.

In addition, the values of the amounts of m, n and o are the proportions of the solid content relative to 100 parts by mass of the solid content of the composition.

[Evaluation method] The melamine decorative boards of the above-mentioned embodiments, experimental examples and comparative examples were evaluated from the perspectives of appearance, functionality (deodorization, antiviral or antiallergenic properties), drug resistance and non-flammability using the following method.

(1) Appearance: The appearance of melamine decorative boards was checked based on JIS K 6902:2007 "Test methods 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 and then removed, and the surface was visually observed to evaluate whether the fingerprints were conspicuous. The appearance of the melamine decorative board was evaluated based on the following criteria.

○: No abnormality (no white spots on the surface, fingerprints are not noticeable)

△1: Slight whitening occurs on the surface, but the wood grain pattern of the decorative layer can be identified. Fingerprints are not noticeable.

△2: No white spots appear on the surface, but fingerprints are more noticeable.

×: White spots are clearly visible on the surface, the wood grain pattern of the decorative layer is not clear and the duct part cannot be identified. Fingerprints are not noticeable.

In addition, fingerprints are less noticeable when white spots appear on the surface.

(2) Deodorization rate (%)

(2-1) Deodorization performance of hydrogen sulfide: A test piece cut into 100 mm × 200 mm was covered with aluminum tape on the back and sides to make the effective area 200 cm ² . After the test piece was placed in a gas sampling bag (Tedlar bag), 3 L of hydrogen sulfide gas was injected into the bag to make the concentration 4 ppm, and the residual concentration of hydrogen sulfide after 24 hours was measured. The total amount of deodorized hydrogen sulfide was calculated from this measured value as the deodorization rate (%) of hydrogen sulfide gas.

(2-2) Ammonia deodorization performance: A test piece cut into 100 mm × 200 mm was covered with aluminum tape on the back and sides to make the effective area 200 cm ² . After the test piece was placed in a gas sampling bag, 3 L of ammonia gas was injected into the bag to make the concentration 100 ppm, and the residual concentration of ammonia after 24 hours was measured. The total amount of ammonia deodorized was calculated from this measured value as the deodorization rate (%).

(3) Antiviral performance bacteriophage test

Test virus: bacteriophage Qβ

Test specification: JIS R 1756:2020 "Precision ceramics-Test method for antiviral properties of visible light responsive photocatalytic materials-Method using bacteriophage Qβ"

Testing time: 24 hours

The test bacteria virus bacteriophage Qβ was contacted and cut into a 50mm×50mm test piece. The test bacteria solution was recovered after 24 hours and the virus infectivity titer was calculated. The antiviral activity value was calculated based on the following formula based on the calculated virus infectivity titer.

Antiviral activity value = log(viral infectivity of unprocessed product)-log(viral infectivity of processed product)

In addition, the unprocessed product is a melamine decorative board without forming a hardened layer of the composition, and the processed product is the melamine decorative board of each embodiment, each experimental example and each comparative example.

(4) Anti-allergen properties

Test bacteria: mite allergen (Der fII), fir tree allergen (Cry jI)

Measurement time: 24 hours

Measurement method: ELISA method

Cut the test piece into 50mm×50mm and use adhesive to make a 40mm×40mm outer frame. Drop the allergen solution prepared to a specific concentration into the outer frame and make the thin piece adhere tightly.

After 24 hours, the solution was recovered and the allergen concentration was measured by ELISA (enzyme immunoassay). The difference between the measured value and the concentration of the unprocessed product was calculated as the allergen reduction rate (%).

(5) Drug resistance

<Medications used>

q: Osvan solution 0.025% solution

r: 5.0% cresol soap solution

s: Sodium hypochlorite 6.0% solution

t: 1% hydrochloric acid aqueous solution

u: 1% sodium hydroxide aqueous solution

<Test method>

After cleaning the test piece, dry it, drop 0.2 ml of test solution on the test piece, leave it for 24 hours, then wash off the test solution with water, observe the changes of the test piece with the naked eye, and evaluate it using the following evaluation method.

<Evaluation method>

○: No change

△: No corrosion but changes in color and gloss

×: There is erosion

(6) Non-flammability

The heat release test was conducted for 20 minutes using a cone calorimeter in accordance with ISO5660. In the evaluation method, the total heat release was 8MJ/ ^m2 or less, the maximum heat release rate was no more than 200kW/ ^m2 for more than 10 seconds, and the test specimen after the test had no damage or cracks that penetrated to the back surface, which was rated as ○. If any of the three conditions was not met, it was rated as ×.

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

[Discussion] As shown in Table 16-1, in Experiment 1, the amount of (m) deodorant was small, and the deodorizing performance was poor. In Experiment 2, the amount of (m) deodorant was large, and slight whitening spots (△1) appeared on the appearance. In Experiment 3, the amount of (n) antiviral was small, and the antiviral performance was poor. In Experiment 4, the amount of (n) antiviral was large, and slight whitening spots (△1) appeared on the appearance. In Experiment 5, the amount of (o) antiallergenic was small, and the antiallergenic performance was poor. In Experiment 6, the amount of (o) antiallergenic was large, and slight whitening spots (△1) appeared on the appearance.

As shown in Table 17-1, in Experimental Example 7, although the functional composition includes components (A), (B), and (C), the amount of component (B) is less than 0.5 parts by mass per 1 part by mass of the solid content of component (A), and the deodorizing performance and drug resistance are poor. In Experimental Example 8, although the functional composition includes components (A), (B), and (C), the amount of component (B) is more than 12 parts by mass per 1 part by mass of the solid content of component (A), and although fingerprints are not obvious in appearance, slight whitening spots (△1) are produced. In Experimental Example 9, although the functional composition includes components (A), (B), and (C), the amount of component (C) is less than 0.005 parts by mass relative to 1 part by mass of the solid content of component (B). Although no whitening spots are produced in appearance, fingerprints are more conspicuous (△2). In Experimental Example 10, although the functional composition includes components (A), (B), and (C), the amount of component (C) is more than 0.3 parts by mass relative to 1 part by mass of the solid content of component (B). Although fingerprints are not conspicuous in appearance, slight whitening spots are produced (△1).

As shown in Table 18-1, in Experimental Example 11, the deodorizing property was poor. In Experimental Example 12, although the fingerprints were not noticeable in appearance, slight whitening spots (△1) were produced. In Experimental Example 13, the antiviral property was poor. In Experimental Example 14, although the fingerprints were not noticeable in appearance, slight whitening spots (△1) were produced. In Experimental Example 15, the deodorizing property was poor. In Experimental Example 16, although the fingerprints were not noticeable in appearance, slight whitening spots (△1) were produced. In Experimental Example 17, the anti-allergenic property was poor. In Experimental Example 18, although the fingerprints were not noticeable in appearance, slight whitening spots (△1) were produced. In Experimental Example 19, the antiviral property was poor. In Experimental Example 20, although the fingerprints were not obvious in appearance, slight whitening spots (△1) were produced. In Experimental Example 21, the anti-allergenicity was poor. In Experimental Example 22, although the fingerprints were not obvious in appearance, slight whitening spots (△1) were produced.

2: Hardening layer of functional composition 3: Melamine resin impregnated pattern paper 4: Prepreg 6: Core layer 7: Support material 11: Melamine decorative board

Claims (14)

A composition comprising: (A) a hydrolysis condensate of silane oxide; (B) 0.5 to 12 parts by weight of an organosilicon sol dispersed in a hydrophilic solvent relative to the weight of component (A); (C) 0.005 to 0.3 parts by weight of an acrylic polymer having a hydrophilic group and a hydrophobic group relative to the weight of component (B); and at least one substance selected from the group consisting of 30 to 60 parts by weight of (m) a deodorant substance relative to 100 parts by weight of the solid matter of the composition, 35 to 75 parts by weight of (n) an antiviral substance relative to 100 parts by weight of the solid matter of the composition, and 3 to 50 parts by weight of (o) an antiallergenic substance relative to 100 parts by weight of the solid matter of the composition. The composition of claim 1, wherein the deodorant (m) is contained in an amount of 30 to 60 parts by weight relative to 100 parts by weight of the solid content of the composition. The composition of claim 1, wherein the (n) antiviral substance is contained in an amount of 35 to 75 parts by weight relative to 100 parts by weight of the solid content of the composition. The composition of claim 1, wherein the (o) antiallergenic substance is contained, and the amount of the (o) antiallergenic substance in the composition is 3 to 50 parts by weight relative to 100 parts by weight of the solid content of the composition. The composition of claim 1, wherein the composition comprises the (m) deodorizing substance, wherein the (m) deodorizing substance is a chemical adsorption type deodorizing substance. The composition of claim 5, wherein the chemical adsorption type deodorizing substance comprises at least one selected from the group consisting of zinc oxide, silicon dioxide, zeolite, copper oxide and zirconium oxide. The composition of claim 1, wherein the (n) antiviral substance is included, and the (n) antiviral substance is at least one selected from the group consisting of triazine-thiazole-imidazole based substances, amino-modified polyvinyl alcohol and amino-modified acrylic polymer. The composition of claim 1, wherein the (o) antiallergenic substance is included, and the (o) antiallergenic substance is a complex of an anion-modified organic compound and a carrier. The composition of claim 8, wherein the anion-modified organic compound is at least one selected from the group consisting of anion-modified linear alkanes and anion-modified polyvinyl alcohols. A composition as claimed in claim 8, wherein the carrier comprises at least one selected from the group consisting of styrene particles and silver oxide particles. The composition of claim 1 is used for melamine decorative panels. A transfer sheet comprising: a sheet-like substrate; and a hardened layer of a composition as described in any one of claims 1 to 11 formed on one side of the sheet-like substrate. A melamine decorative board, comprising in order: a core layer; a decorative layer comprising a hardened material of melamine resin; and a hardened layer of a composition as in any one of claim items 1 to 11. A method for producing a melamine decorative board, the melamine decorative board sequentially comprising a core layer, a decorative layer comprising a cured product of a melamine resin, and a surface layer. The method for producing the melamine decorative board comprises curing a composition as described in any one of claims 1 to 11 to form the surface layer.