Indian Patents. 268873:TRANSFER SHEET, MELAMINE DECORATIVE BOARD, AND METHOD FOR PRODUCING MELAMINE DECORATIVE BOARD

Title of Invention	TRANSFER SHEET, MELAMINE DECORATIVE BOARD, AND METHOD FOR PRODUCING MELAMINE DECORATIVE BOARD
Abstract	Disclosed is a composition containing a siloxane grafted polymer obtained by combining an organosilica sol, a fluororesin or acrylic resin, and a siloxane, and/or a room temperature glass coating agent. Also disclosed is a melamine decorative board having a surface provided with a low-refractive-index layer which is composed of a cured product of the composition.

Full Text	DESCRIPTION COMPOSITION, TRANSFER SHEET, MELAMINE DECORATIVE BOARD, AND METHOD FOR PRODUCING MELAMINE DECORATIVE BOARD TECHNICAL FIELD [0001] This invention relates to a composition, a transfer sheet, a melamine decorative board, and a method for producing the melamine decorative board. BACKGROUND ART [0002] A melamine decorative board is used as a horizontal surface for a counter, a desk, and others because of its excellent properties in surface hardness, heat resistance, abrasion resistance and the like. The melamine decorative board is generally obtained by stacking a melamine resin impregnated pattern paper and a phenol resin impregnated core paper, and then applying heat and pressure to the stacked papers with a flat plate pressing machine (see Patent Documents 1 -3). The melamine resin impregnated pattern paper is obtained by impregnating a pattern base paper for decorative board with a resin liquid composed primarily of melamine-formaldehyde resin and drying the impregnated pattern base paper. The phenol resin impregnated core paper is obtained by- impregnating a kraft paper with a resin liquid composed primarily of phenol-formaldehyde resin and drying the impregnated kraft paper. Patent Document 1 : Unexamined Japanese Patent Publication No. H06-199528 Patent Document 2: Unexamined Japanese Patent Publication No. 2005-199495 Patent Document 3: Unexamined Japanese Patent Publication No. 2005-146272 DISCLOSURE OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION [0003] The melamine decorative board has excellent surface hardness, heat resistance, abrasion resistance and the like by virtue of characteristics of the resin used therein. On the other hand, the melamine decorative board is disadvantageous in that a greasy dirt such as a sebum membrane of a fingerprint (hereinafter referred to as a fingerprint) adhering onto a surface of the melamine decorative board is easily noticeable. A further disadvantage is that a pattern on a printed paper cannot be clearly exhibited due to reflection of lights and white blur on a melamine resin layer. [0004] The present invention was made in order to overcome such conventional disadvantages. It is an object of the present invention to provide a composition which can be used in producing a melamine decorative board on which a fingerprint and the like is less noticeable and a pattern on a printed paper can be clearly exhibited; a transfer sheet which can be used in producing the melamine decorative board; the melamine decorative board; and a method for producing the melamine decorative board. MEANS TO SOLVE THE PROBLEMS [0005] A composition of the present invention includes (a) an organosilica sol; and (b1) a siloxane graft-type polymer obtained by compositing fluorine resin or acrylic resin with siloxane and/or (b2) a cold glass coating agent. [0006] In other words, there are three different types of the composition in the present invention, that is, a composition including the component (a) and the component (bl), a composition including the component (a) and the component (b2), and a composition including the component (a), the component (b1), and the component (b2). [0007] The composition of the present invention can be used, for example, for forming a low refractive index layer composed of a cured product of the composition of the present invention on a surface of a melamine decorative board. In the melamine decorative board having the low refractive index layer, which is composed of the cured product of the composition of the present invention, formed on the surface thereof, a fingerprint adhering on the surface is less noticeable. This is because the low refractive index layer has a lower refractive index than that of a melamine resin layer and, therefore, a refractive index difference between an adhering fingerprint and the low refractive index layer is smaller than that between an adhering fingerprint and the melamine resin layer. Furthermore, the low refractive index layer has a low reflectivity and a low refractive index, thereby reducing reflection of lights and white blur. As a result, a pattern on a printed paper used for the melamine decorative board can be clearly exhibited to provide the melamine decorative board with high design quality. [0008] In the decorative board of the present invention, since the low refractive index layer composed of the cured product of the above-described composition is formed on the surface, the fingerprint adhering on the surface is less noticeable, and the pattern on the printed paper is clearly exhibited, whereby the high design quality is realized. The low refractive index layer preferably has a refractive index of 1.5 or less. By setting the refractive index to 1.5 or less, the fingerprint becomes still less noticeable and the pattern on the printed paper is exhibited more clearly. [0009] A transfer sheet of the present invention includes a base material and the above-described composition disposed on the base material. The transfer sheet can be used for forming the low refractive index layer on the surface of the melamine decorative board. The transfer sheet makes it easy to form the low refractive index layer. [0010] A method for producing the melamine decorative board of the present invention includes steps of stacking the above-described transfer sheet, a melamine resin impregnated paper, and a core material, applying heat and pressure thereto, and removing the base material of the transfer sheet. According to the method, the melamine decorative board having the low refractive index layer on the surface thereof can be easily produced. While applying heat and pressure, temperature is preferably in a range of 110-180°C, and pressure is preferably in a range of 5-10 MPa. BRIEF DESCRIPTION OF THE DRAWINGS [0011] FIG. 1 is an explanatory view showing a method for producing a melamine decorative board. FIG. 2 is a sectional side view showing a structure of the melamine decorative board. FIG. 3 is a photograph showing clarity on a surface of the melamine decorative board. A right half corresponds to a melamine decorative board of Embodiment 1, and a left half corresponds to a melamine decorative board of Comparative example 1. FIG. 4 is a photograph showing to what degree a fingerprint adheres onto the surface of the melamine decorative board. A right half corresponds to the melamine decorative board of Embodiment 1, and a left half corresponds to the melamine decorative board of Comparative example 1. EXPLANATION OF REFERENCE NUMERALS [0012] 1, 11...transfer sheet, 1a...OPP film, 1b...dried film, 2...melamine resin impregnated overlay paper , 3...melamine resin impregnated decorative paper, 4...phenol resin impregnated core paper, 5...melamine decorative board, 6...low refractive index layer BEST MODE FOR CARRYING OUT THE INVENTION [0013] Hereinafter, the present invention will be described in detail. A siloxane graft-type polymer (a component (b1)) used in a composition of the present invention is obtained by compositing fluorine resin or acrylic resin with siloxane. Specifically, the siloxane graft-type polymer can be obtained by copolymerizing following components: (A) 2-70% by weight of organic solvent-soluble fluorine resin having radical polymerizable unsaturated bond via urethane bond, (B) 4-40% by weight of polysiloxane which is radical polymerizable at one end shown by a following formula 1 (wherein R1 represents a hydrogen atom or a hydrocarbon group having 1-10 carbon atoms; R2, R3, R4, R5, and R6, which may be mutually same or different, represent a hydrogen atom or a hydrocarbon group having 1-10 carbon atoms,' and n represents an integer of 2 or more), and/or polysiloxane which is radical polymerizable at one end shown by a following formula 2 (wherein R7 represents a hydrogen atom or a hydrocarbon group having 1-10 carbon atoms; R8, R9, R10, R11, and R12, which may be mutually same or different, represent a hydrogen atom or a hydrocarbon group having 1-10 carbon atoms; p represents an integer of 0-10; and q represents an integer of 2 or more), and (C) 15-94% by weight of radical polymerizable monomer which is unreactive to the component (A) under radical polymerization reaction condition, except polymerization reaction with a double bond. [0014] [Formula 1] [0015] [Formula 2] Another example of the siloxane graft-type polymer obtained by compositing fluorine resin or acrylic resin with siloxane includes a polymer which is obtained by copolymerizing following components: (A) 2-70% by weight of organic solvent-soluble fluorine resin having radical polymerizable unsaturated bond via urethane bond, (B) 5-55% by weight of polysiloxane which is radical polymerizable at one end shown by the above formula 1, and/or poly siloxane which is radical polymerizable at one end shown by the above formula 2, (C) 5-55% by weight of monomer having an alkoxysilyl group, (D) 15-50% by weight of monomer having a hydroxyl group, and (E) 0-73% by weight of monomer having a functional group which is unreactive to the above components (A)-(D) except radical polymerization. [0016] Still another example of the siloxane graft-type polymer obtained by compositing fluorine resin or acrylic resin with siloxane includes a polymer in which an acrylic-type (co)polymer containing a curable group, having radical polymerizable unsaturated bond via urethane bond and also being soluble in organic solvent, is used in place of the component (A) in each of the above-described siloxane graft-type polymers. [0017] Commercially available siloxane graft-type polymer obtained by compositing fluorine resin or acrylic resin with siloxane includes ZX-007C, ZX-001, ZX-022, ZX-022H, ZX-028R, ZX-036 (all are manufactured by Fuji Kasei Kogyo Co., Ltd.) and the like. [0018] A cold glass coating agent (a component (b2)) used in the composition of the present invention includes one which is obtained by ionizing alcohol-soluble organosilicon compound in a solution composed of water and organic solvent, and adding thereto halogen and boron as catalysts. [0019] A role of B3+ ion is to inhibit a decrease in an amount of SiO2 due to generation and volatilization of SiF6 by reacting with F- ion. B3+ ion reacts with F- ion to generate BF4- complex ion, and B in the BF4- complex ion is replaced extremely easily by Si in Si(OR)n to obtain SiF-n + 1 complex ion. Hydrolysis and dehydrating condensation represented by the formulae below are accelerated, and as a result, metal-oxide glass is obtained at an ambient temperature range. Residual B3+ ion is vaporized and disappears as B(OCH3)3 by the presence of methanol (CH3 +), and F- ion is vaporized and disappears as HF by catalytic reaction with OH" group or others contained in the base material and the like. Here, R represents an alkyl group, M represents a metal, and X represents halogen. [0020] An example of a compound releasing boron ion B3+ includes, for example, trialkoxyboran B(OR)3, among which triethoxyboran B(OEt)3 is preferable. Concentration of B3+ ion in a reaction solution is preferably in a range of l.0-10.0 mol/liter. Halogen ion is preferably F , Cl-, or a mixture of F- and Cl-. A compound used as halogen ion source may be any one which produces F- ion or Cl- ion in the reaction solution. As F- ion source, for example, ammonium hydrogen fluoride NH4F.HF, sodium fluoride NaF, and the like are preferable. As Cl- ion source, for example, ammonium chloride NH4Cl and the like are preferable. [0021] Commercially available cold glass coating agent includes Siragusital A6200, Siragusital B4373(BN) (both are manufactured by Bokuto Kasei Kogyo Co., Ltd.), and the like. [0022] An organosilica sol used in the composition of the present invention includes, for example, a colloidal solution including colloidal silicas with a particle diameter of 1-40 nm (more preferably with a diameter of 7-30 nm) stably dispersed in organic solution. A silica concentration is preferably in a range of 1-50% by weight, more preferably 40% by weight or less to inhibit gelation. [0023] Commercially available organosilica sol includes IPA-ST, IPA-ST-ZL, methanol silica sol, NPC-ST-30, EG-ST, DMAC-ST and the like manufactured by Nissan Chemical Industries, Ltd.; OSCAL manufactured by Shokubai Kasei Kogyo Co., Ltd.; Quartron (registered trademark) manufactured by Fuse Chemical Co., Ltd.; Highlink (registered trademark) OG Silica Organosol manufactured by Clariant Japan K.K.; and the like. [0024] In the composition of the present invention, it is preferable to use an organosilica sol obtained by substituting an aqueous silica sol using a hydrophilic solvent such as alcohol and the like. In the organosilica sol derived from the aqueous silica sol, an amount of hydroxyl groups on a surface of the silica becomes sufficient. Therefore, when the low refractive index layer of the melamine decorative board is formed using the composition of the present invention, adhesion between the low refractive index layer and the melamine layer is promoted, and surface durability of the melamine decorative board is thereby improved. When the organosilica sol is dispersed in a hydrophobic solvent, a surface of the organosilica sol is hydrophobized in order to stabilize the organosilica sol. In such an organosilica sol, the silica does not have a sufficient amount of hydroxyl groups on the surface thereof, and adhesion between the low refractive index layer and the melamine layer is likely to be inferior. [0025] Here, the hydrophilic (polar) solvent refers to a solvent having an affinity with water. An example thereof is a hydrophilic organic solvent including, in a molecule thereof, a hydrophilic group such as a hydroxyl group, a carboxyl group, a carbonyl group and the like. The hydrophilic (polar) solvent includes a protic polar solvent and an aprotic polar solvent. Specific examples of the protic polar solvent include alcohol-based solvent such as methyl alcohol, ethyl alcohol, isopropyl alcohol, ethylene dialcohol, propanol and the like; and cellosolve-based solvent such as methyl cellosolve, ethyl cellosolve, butyl cellosolve, n-propyl cellosolve and the like. Specific examples of the aprotic polar solvent include acetone, dimethyl sulfoxide (DMSO), N,N-dimethyl formamide (DMF), pyridine and the like. [0026] In the composition of the present invention, it is preferable to set a mixing ratio between the component (a) and the component (b1) so that an amount of the component (a) is 4-18 parts by weight (in solid equivalent) per part by weight of the component (bl) (in solid equivalent). By setting the amount of the component (a) to 4 or more parts by weight, the amount of hydroxyl groups on the surface of the silica becomes sufficient. Thus, the adhesion between the low refractive index layer and the melamine layer is promoted, and the surface durability of the melamine decorative board is thereby improved. Further, by setting the amount of the component (a) to 18 or less parts by weight, the amount of the component (bl) does not become too small. As a result, on a surface of the melamine decorative board, a fingerprint becomes still less noticeable, and a pattern on a printed paper becomes still clearer. [0027] In the composition of the present invention, it is preferable to set a mixing ratio between the component (a) and the component (b2) so that an amount of the component (a) is 4-18 parts by weight (in solid equivalent) per part by weight of the component (b2) (in solid equivalent). By setting the amount of the component (a) to 4 or more parts by weight, the amount of hydroxyl groups on the surface of the silica becomes sufficient. Thus, the adhesion between the low refractive index layer and the melamine layer is promoted, and surface durability of the melamine decorative board is thereby improved. Further, by setting the amount of the component (a) to 18 or less parts by weight, the amount of the component (b2) does not become too small. As a result, on the surface of the melamine decorative board, the fingerprint becomes still less noticeable, and the pattern on the printed paper becomes still clearer. [0028] Examples of base material used as a transfer sheet of the present invention include a plastic film and a metallic foil. As a plastic film, for example, a polyester film, a polyethylene film, a polypropylene film, a cellophane, a diacetylcellulose film, a triacetylcellulose film, an acetylcellulose butyrate film, a polyvinyl chloride film, a polyvinylidene chloride film, a polyvinyl alcohol film, an ethylene vinyl alcohol film, a polystyrene film, a polycarbonate film, a polymethylpentene film, a polysulfone film, a polyether ketone film, a polyether sulfone film, a polyetherimide film, a polyimide film, a fluororesin film, a nylon film, an acrylic film and the like can be used. [0029] As a metallic foil, for example, a gold foil, a silver foil, a copper foil, a zinc foil, an indium foil, an aluminum foil, a tin foil, an iron foil (including a stainless steel (SUS) foil), a titanium foil and the like can be used. [0030] The transfer sheet of the present invention can be produced, for example, by applying the composition to the base material. As an applying method, known methods, for example, a spray coat method, a gravure coat method, a bar coat method, a knife coat method, a roll coat method, a blade coat method, a die coat method, a curtain coat method, a reverse coat method, a comma coat method and the like can be employed. The transfer sheet obtained through such methods is stacked on a melamine resin impregnated paper (e.g., a melamine resin impregnated pattern paper and a melamine resin impregnated overlay paper) so that a composition-applied surface comes in contact with the melamine resin impregnated paper. Then, heat and pressure are applied to the stacked transfer sheet and the melamine resin impregnated paper together with a core material. [0031] A thickness (after dried) of the low refractive index layer formed using the composition of the present invention is preferably in a range of 0.5-15 pm when the composition is composed of the component (a) and the component (b1). By setting the thickness within this range, a refractive index of the low refractive index layer easily becomes 1.5 or less. By setting the film thickness to 0.5 pm or more, the fingerprint becomes still less noticeable, and the pattern on the printed paper becomes still clearer on the surface of the melamine decorative board. Further, by setting the film thickness to 15 pm or less, whitening of the low refractive layer is less likely to occur, and an appearance of the melamine decorative board becomes excellent. [0032] The thickness (after dried) of the low refractive index layer formed using the composition of the present invention is preferably in a range of 0.5-15 um when the composition is composed of the component (a) and the component (b2). By setting the thickness within this range, the refractive index of the low refractive index layer easily becomes 1.5 or less. By setting the film thickness to 0.5 µm or more, the fingerprint becomes still less noticeable, and the pattern on the printed paper becomes still clearer on the surface of the melamine decorative board. Further, by setting the film thickness to 15 um or less, whitening of the low refractive layer is less likely to occur, and the appearance of the melamine decorative board becomes excellent. [0033] In the melamine decorative board of the present invention and a method for producing the melamine decorative board of the present invention, the melamine resin impregnated paper (the melamine resin impregnated pattern paper) may be used. The melamine resin impregnated paper is obtained, for example, by impregnating a decorative paper for use in a decorative board with a resin liquid composed primarily of melamine-formaldehyde resin and drying the impregnated decorative paper. A basis weight of the decorative paper for use in a decorative board is preferably, for example, in a range of about 80-140 g/m2. A degree of impregnation of the resin liquid, which is defined by a following mathematical formula 1, is preferably in a range of 70-160%, for example. [0034] [Mathematical formula 1] In the melamine decorative board of the present invention and the method for producing the melamine decorative board of the present invention, in order to improve abrasion resistance on the surface of the melamine decorative board, the melamine resin impregnated overlay paper may be stacked as an uppermost layer (excluding the low refractive index layer) and heat and pressure may be applied to the stacked body. The melamine resin impregnated overlay paper is obtained, for example, by impregnating an overlay base paper having a basis weight of about 20-60 g/m2 with a resin liquid composed primarily of melamine-formaldehyde resin at a degree of impregnation of 200-400%, and drying the impregnated overlay base paper. [003 5] In the melamine decorative board of the present invention and the method for producing the melamine decorative board of the present invention, a core material may be used. The core material is obtained, for example, by impregnating a kraft paper with a resin liquid composed primarily of phenol-formaldehyde resin and drying the impregnated kraft paper. A basis weight of the kraft paper is preferably, for example, in a range of about 150-300 g/m2. A degree of impregnation of the resin liquid, which is defined by the above mathematical formula 1, is preferably in a range of 30-80%, for example. [0036] The present invention will hereinafter be described by Embodiments. Experimental Examples, and Comparative Examples, which do not limit the present invention in any way. Embodiment I [0037] 1. Production of a composition One part by weight (in solid equivalent) of a siloxane graft-type polymer was mixe with 10 parts by weight (in solid equivalent) of an organosilica sol. As the siioxane graft-type polymer, ZX-022H (hydroxyl value: 120, acid value: 0, solvent species: xylene/butyl acetate/isopropanol, manufactured by Fuji Kasei Kogyo Co., Ltd.) obtained by compositing fluorine resin with siloxane was used. As the organosilica sol, IPA-ST (isopropanol dispersion silica sol, average particle diameter: 10-20 nm, SiO2: 30% by weight, manufactured by Nissan Chemical Industries, Ltd.) was used. IPA-ST is an organosilica sol in which a hydrophilic solvent (isopropanol) is used. [0038] The above mixture was diluted with isopropanol so that a total solid content became 20% by weight, and a composition was obtained. [0039] 2. Production of a transfer sheet The above composition was uniformly applied to an OPP film having a thickness of 30 µm by a bar coat method so that an after-dried film thickness of the composition became 3 µm. The OPP film was dried to obtain a transfer sheet 1. In the transfer sheet 1, a layer composed of dried product of the above composition was formed on the OPP film. [0040] 3. Production of a melamine decorative board An overlay paper having a basis weight of 40 g/m2 for use in a decorative board was impregnated with a resin liquid composed primarily of melamine-formaldehyde resin. A degree of impregnation of the resin liquid was set to 300% according to a calculating method defined by the above mathematical formula 1. The impregnated overlay paper was dried to obtain a melamine resin impregnated overlay paper 2. [0041] A black decorative paper having a basis weight of 100 g/m2 for use in a decorative board was impregnated with a resin liquid composed primarily of melamine-formaldehyde resin. A degree of impregnation of the resin liquid was set to 100% according to the calculating method defined by the above mathematical formula 1. The impregnated decorative paper was dried to obtain a melamine resin impregnated decorative paper 3. [0042] A kraft paper having a basis weight of 200 g/m2 was impregnated with a resin liquid composed primarily of phenol-formaldehyde resin. A degree of impregnation of the resin liquid was set to 50% according to the calculating method defined by the above mathematical formula 1. The impregnated kraft paper was dried to obtain a phenol resin impregnated core paper 4. [0043] As shown in FIG. 1, five sheets of the phenol resin impregnated core paper 4, a sheet of the melamine resin impregnated decorative paper 3, a sheet of the melamine resin impregnated overlay paper 2, and a sheet of the transfer sheet were stacked in this order. The transfer sheet 1, which includes an OPP film la and a dried film 1b of the composition, was stacked so that the dried film 1b came in contact with the melamine resin impregnated overlay paper 2. Heat and pressure are applied to the stacked body at a temperature of 135°C and a pressure of 8 MPa for 80 minutes. Then, the OPP film la was removed to obtain a melamine decorative board 5 as shown in FIG. 2. A low refractive index layer 6 composed of a cured product of the composition was formed on a surface of the melamine decorative board 5. The low refractive index layer 6 was generated from the dried film lb of the composition. Embodiment 2 [0044] A transfer sheet was produced in the same manner as in Embodiment 1 except that the after-dried film thickness of the composition (a thickness of the low refractive index layer) on the transfer sheet was set to 0.5 µm. Further, a melamine decorative board having the low refractive index layer formed on a surface thereof was produced in the same manner as in Embodiment 1 except that the above transfer sheet was used. Embodiment 3 [0045] A transfer sheet was produced in the same manner as in Embodiment 1 except that the after-dried film thickness of the composition (a thickness of the low refractive index layer) on the transfer sheet was set to 15 µm. Further, a melamine decorative board having the low refractive index layer formed on a surface thereof was produced in the same manner as in Embodiment 1 except that the above transfer sheet was used. Embodiment 4 [0046] A composition was produced in the same manner as in Embodiment 1 except that a mixing ratio between the siloxane graft-type polymer and the organosilica sol was set as follows: the siloxane graft-type polymer : 1 part by weight (in solid equivalent) the organosilica sol: 4 parts by weight (in solid equivalent) [0047] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 5 [0048] A composition was produced in the same manner as in Embodiment 1 except that the mixing ratio between the siloxane graft-type polymer and the organosilica sol was set as follows: the siloxane graft-type polymer: 1 part by weight (in solid equivalent) the organosilica sol: 6 parts by weight (in solid equivalent) [0049] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 6 [0050] A composition was produced in the same manner as in Embodiment 1 except that the mixing ratio between the siloxane graft-type polymer and the organosilica sol was set as follows: the siloxane graft-type polymer: 1 part by weight (in solid equivalent) the organosilica sol: 14 parts by weight (in solid equivalent) [0051] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 7 [0052] A composition was produced in the same manner as in Embodiment 1 except that the mixing ratio between the siloxane graft-type polymer and the organosilica sol was set as follows: the siloxane graft-type polymer-' 1 part by weight (in solid equivalent) the organosilica sol: 18 parts by weight (in solid equivalent) [0053] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 8 [0054] A composition was produced in the same manner as in Embodiment 1 except that, instead of IPA-ST, the same amount of methanol silica sol (methanol dispersion silica sol, average particle diameter: 10-20 nm, SiO2: 30% by weight, manufactured by Nissan Chemical Industries, Ltd.) was used as an organosilica sol. The methanol silica sol is an organosilica sol in which a hydrophilic solvent (methanol) is used. [0055] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 9 [0056] A composition was produced in the same manner as in Embodiment 1 except that, instead of IPA-ST, the same amount of NPOST-30 (average particle diameter: 10-20 nm, n-propyl cellosolve dispersion silica sol, SiO2: 30% by weight, manufactured by Nissan Chemical Industries, Ltd.) was used as an organosilica sol. NPOST-30 is an organosilica sol in which a hydrophilic solvent (n-propyl cellosolve) is used. [0057] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 10 [0058] A composition was produced in the same manner as in Embodiment 1 except that, instead of ZX-022H, the same amount of a siloxane graft-type polymer ZX-007C (hydroxyl value: 58, acid value: 5, solvent species: xylene/butyl acetate, manufactured by Fuji Kasei Kogyo Co., Ltd.) obtained by compositing fluorine resin with siloxane was used as a siloxane graft-type polymer. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 11 [0059] A composition was produced in the same manner as in Embodiment 1 except that, instead of ZX-022H, the same amount of a siloxane graft-type polymer ZX-001 (hydroxyl value: 94, acid value: 0, solvent species: xylene/isobutanol, manufactured by Fuji Kasei Kogyo Co., Ltd.) obtained by compositing fluorine resin with siloxane was used as a siloxane graft-type polymer. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 12 [0060] A composition was produced in the same manner as in Embodiment 1 except that, instead of ZX-022H, the same amount of a siloxane graft-type polymer ZX-022 (hydroxyl value: 120, acid value: 5, solvent species: xylene/ butyl acetate, manufactured by Fuji Kasei Kogyo Co., Ltd.) obtained by compositing fluorine resin with siloxane was used as a siloxane graft-type polymer. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 13 [0061] A composition was produced in the same manner as in Embodiment 1 except that, instead of ZX-022H, the same amount of a siloxane graft-type polymer ZX-028-R (hydroxyl value: 100, acid value: 5, solvent species: butyl acetate, manufactured by Fuji Kasei Kogyo Co., Ltd.) obtained by compositing acrylic resin with siloxane was used as a siloxane graft-type polymer. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 14 [0062] A composition was produced in the same manner as in Embodiment 1 except that, instead of ZX-022H, the same amount of a siloxane graft-type polymer ZX-036 (hydroxy 1 value: 119, solvent species: butyl acetate/2-propanol, manufactured by Fuji Kasei Kogyo Co., Ltd.) obtained by compositing acrylic resin with siloxane was used as a siloxane graft-type polymer. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. Embodiment 15 [0063] 1. Production of a composition One part by weight (in solid equivalent) of a cold glass coating agent was mixed with 10 parts by weight (in solid equivalent) of an organosilica sol. As the cold glass coating agent, one-component coating agent (commercial name: Siragusital A6200 manufactured by Bokuto Kasei Kogyo Co., Ltd.) was used. The cold glass coating agent is obtained by mixing alcohol-soluble organic silicon compound (Si(OR)4) with alcohol and the like (isopropanol), and adding thereto boron ion B3+ and halogen ion F- as catalysts to adjust pH to 4.5-5.0. As the organosilica sol, IPA-ST (isopropanol dispersion silica sol, average particle diameter: 10-20 nm, SiO2: 30% by weight, manufactured by Nissan Chemical Industries, Ltd.) was used. [0064] The above mixture was diluted with isopropanol so that a total solid content became 20% by weight, and a composition was obtained. [0065] 2. Production of a transfer sheet The above composition was applied to an OPP film having a thickness of 30 µm by a bar coat method so that an after-dried film thickness of the composition became 3 µm. The OPP film was dried to obtain a transfer sheet 11. [0066] 3. Production of a melamine decorative board Using the transfer sheet 11, a melamine decorative board having a low refractive index layer formed on a surface thereof was produced in the same manner as in Embodiment 1 (see FIG. l). Embodiment 16 [0067] A transfer sheet was produced in the same manner as in Embodiment 15 except that the after-dried film thickness of the composition (a thickness of the low refractive index layer) on the transfer sheet was set to 0.5 µm. Further, a melamine decorative board having the low refractive index layer formed on a surface thereof was produced in the same manner as in Embodiment 15 except that the above transfer sheet was used. Embodiment 17 [0068] A transfer sheet was produced in the same manner as in Embodiment 15 except that the after-dried film thickness of the composition (a thickness of the low refractive index layer) on the transfer sheet was set to 15 µm. Further, a melamine decorative board having the low refractive index layer formed on a surface thereof was produced in the same manner as in Embodiment 15 except that the above transfer sheet was used. Embodiment 18 [0069] A composition was produced in the same manner as in Embodiment 15 except that a mixing ratio between the cold glass coating agent and the organosilica sol was set as follows: the cold glass coating agent: 1 part by weight (in solid equivalent) the organosilica sol: 4 parts by weight (in solid equivalent) [0070] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. Embodiment 19 [0071] A composition was produced in the same manner as in Embodiment 15 except that the mixing ratio between the cold glass coating agent and the organosilica sol was set as follows: the cold glass coating agent: 1 part by weight (in solid equivalent) the organosilica sol: 6 parts by weight (in solid equivalent) [0072] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. Embodiment 20 [0073] A composition was produced in the same manner as in Embodiment 15 except that the mixing ratio between the cold glass coating agent and the organosilica sol was set as follows: the cold glass coating agent: 1 part by weight (in solid equivalent) the organosilica sol: 14 parts by weight (in solid equivalent) [0074] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. Embodiment 21 [0075] A composition was produced in the same manner as in Embodiment 15 except that the mixing ratio between the cold glass coating agent and the organosilica sol was set as follows: the cold glass coating agent: 1 part by weight (in solid equivalent) the organosilica sol: 18 parts by weight (in solid equivalent) [0076] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. Embodiment 22 [0077] A composition was produced in the same manner as in Embodiment 15 except that, instead of IPA-ST, the same amount of methanol silica sol (methanol dispersion silica sol, manufactured by Nissan Chemical Industries, Ltd.) was used as an organosilica sol. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. Embodiment 23 8] A composition was produced in the same manner as in Embodiment 15 except that, instead of IPA-ST, the same amount of NPC-ST-30 (n-propyl cellosolve dispersion silica sol, manufactured by Nissan Chemical Industries, Ltd.) was used as an organosilica sol. Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. Embodiment 24 9] A composition was produced in the same manner as in Embodiment 15 except that, instead of Siragusital A6200, the same amount of Siragusital B4373(BN) (manufactured by Bokuto Kasei Kogyo Co., Ltd.) was used as a cold glass coating agent. Siragusital B4373(BN) is a two-component coating agent containing alcohol-soluble organic silicon compound (Si(OR)4) as a base compound and boron ion B3+ and halogen ion X- as catalysts. The base compound and the catalysts are mixed at a ratio of 10 parts by weight of the base compound to 1 part by weight of the catalysts, and are used after diluted with a diluting solvent to an arbitrary concentration. [0080] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. (Experimental Example 1) A composition was produced in the same manner as in Embodiment 1 except that the mixing ratio between the siloxane graft-type polymer and the organosilica sol was set as follows: the siloxane graft-type polymer: 1 part by weight (in solid equivalent) the organosilica sol: 3 parts by weight (in solid equivalent) [0081] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. (Experimental Example 2) A composition was produced in the same manner as in Embodiment 1 except that the mixing ratio between the siloxane graft-type polymer and the organosilica sol was set as follows: the siloxane graft-type polymer: 1 part by weight (in solid equivalent) the organosilica sol: 20 parts by weight (in solid equivalent) [0082] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. (Experimental Example 3) A composition was produced in the same manner as in Embodiment 1 except that, instead of IPA-ST, the same amount of nBAC-ST (butyl acetate dispersion silica sol, manufactured by Nissan Chemical Industries, Ltd.) was used as an organosilica sol. nBAOST is an organosilica sol, solvent species of which is hydrophobic. [0083] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 1 except that the above composition was used. (Experimental Example 4) A composition was produced in the same manner as in Embodiment 15 except that the mixing ratio between the cold glass coating agent and the organosilica sol was set as follows: the cold glass coating agent: 1 part by weight (in solid equivalent) the organosilica sol: 3 parts by weight (in solid equivalent) [0084] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. (Experimental Example 5) A composition was produced in the same manner as in Embodiment 15 except that the mixing ratio between the cold glass coating agent and the organosilica sol was set as follows: the cold glass coating agent: 1 part by weight (in solid equivalent) the organosilica sol: 20 parts by weight (in solid equivalent) [0085] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. (Experimental Example 6) A composition was produced in the same manner as in Embodiment 15 except that, instead of IPA-ST, the same amount of nBAC-ST (butyl acetate dispersion silica sol, manufactured by Nissan Chemical Industries, Ltd.) was used as an organosilica sol. nBAC-ST is an organosilica sol, solvent species of which is hydrophobic. [0086] Further, a transfer sheet and a melamine decorative board having a low refractive index layer formed on a surface thereof were produced in the same manner as in Embodiment 15 except that the above composition was used. (Comparative Example 1) Five sheets of the phenol resin impregnated core paper, a sheet of the melamine resin impregnated decorative paper, and a sheet of the melamine resin impregnated overlay paper were stacked, and heat and pressure are applied thereto at a temperature of 135°C and a pressure of 8 MPa for 80 minutes to obtain a melamine decorative board. Each of the phenol resin impregnated core paper, the melamine resin impregnated decorative paper, and the melamine resin impregnated overlay paper is the same as that in Embodiment 1. [0087] Then, the melamine decorative boards produced in Embodiments 1-24, Experimental Examples 1-6, and Comparative Example 1 were evaluated. (Evaluation method) (i) Evaluation of anti-fingerprint property using an actual fingerprint An actual fingerprint was attached on a surface of each melamine decorative board, and it was visually evaluated how noticeable the fingerprint was. Evaluation criteria are as follows- [0088] o: The fingerprint is not noticeable [0089] ?: The fingerprint is slightly noticeable [0090] x: The fingerprint is noticeable [0091] (ii) Clarity Clarity of the decorative paper of the melamine decorative board was visually observed under oblique light. Evaluation criteria are as follows: [0092] o: The decorative paper can be clearly observed [0093] ?: Reflection of lights and white blur are slightly observed (iii) Surface durability (1) A surface of each melamine decorative board was wiped back and forth 100 times by dry cotton waste under a load of about 300 g/cm2, and change in gloss level on the surface was visually evaluated. Evaluation criteria are as follows: [0094] o: Change in gloss level is not observed [0095] ?: Change in gloss level is slightly observed [0096] x: Change in gloss level is observed (iv) surface durability (2) The surface of each melamine decorative board was wiped back and forth by dry cotton waste under a load of about 1 kg/cm2, and change in gloss level on the surface was visually evaluated. Evaluation criteria are as follows: [0097] 5: Change in gloss level is not observed when or before the surface was wiped back and forth 500 times [0098] 4: Change in gloss level is observed when or before the surface was wiped back and forth 400 times [0099] 3: Change in gloss level is observed when or before the surface was wiped back and forth 300 times [0100] 2: Change in gloss level is observed when or before the surface was wiped back and forth 200 times [0101] 1: Change in gloss level is observed when or before the surface was wiped back and forth 100 times (v) Refractive index A refractive index on the surface of each melamine decorative board was measured with multi-wavelength Abbe refractometer (DR-M2, manufactured by Atago Co., Ltd.). Refractive index was measured at a wavelength of 589 nm. (vi) Surface hardness Surface hardness of each melamine decorative board was measured under a load of 1 kg according to JIS K 5600;1999 (general testing methods for paints). (vii) Abrasion resistance Abrasion resistance of the surface of each melamine decorative board was measured according to JIS K 6902;1998 (testing method for laminated thermosetting high-pressure decorative sheets) (Evaluation results) Tables 1 and 2 show the evaluation results. In Table 1, "(b1):(a)" represents a weight ratio (in solid equivalent) between the siloxane graft-type polymer (b1) and the organosilica sol (a). In Table 2, "(b2):(a)" represents a weight ratio (in solid equivalent) between the cold glass coating agent (b2) and the organosilica sol (a). As shown in Tables 1 and 2, in the melamine decorative boards of Embodiments 1-24, a fingerprint was less noticeable, and a printed pattern had high clarity. Moreover, the melamine decorative boards of Embodiments 1-24 exhibited high surface durability, high surface hardness, and high abrasion resistance. In contrast, in the melamine decorative board of Comparative Example 1, a fingerprint was noticeable, and a printed pattern had low clarity. [0104] FIG. 3 is a photograph showing surface conditions of the melamine decorative boards of Embodiment 1 and Comparative Example 1. A right half of the photograph corresponds to the melamine decorative board of Embodiment 1, and a left half corresponds to the melamine decorative board of Comparative Example 1. As is clear from this photograph, in the melamine decorative board of Embodiment 1, the decorative paper had a high clarity, whereas the melamine decorative board of Comparative Example 1 was whitish and a decorative paper thereof had low clarity. [0105] FIG. 4 is a photograph showing a fingerprint attached on the surface of each melamine decorative boards of Embodiment 1 and Comparative Example 1 when anti-fingerprint property was evaluated using an actual fingerprint. A right half of the photograph corresponds to the melamine decorative board of Embodiment 1, and a left half corresponds to the melamine decorative board of Comparative Example 1. As is clear from this photograph, in the melamine decorative board of Embodiment 1, the fingerprint on the surface thereof was far less noticeable than that on the surface of the melamine decorative board of Comparative Example 1. This is attributed to the fact that the melamine decorative board of Embodiment 1 includes the low refractive index layer 6. [0106] The evaluation result of each of the melamine decorative boards of Experimental Examples 1 and 3 was slightly inferior to that of each of Embodiments 1-24 in surface durability. [0107] The evaluation result of the melamine decorative board of Experimental Example 2 was slightly inferior to that of each of Embodiments 1-24 in anti-finger print property and clarity. [0108] The evaluation result of each of the melamine decorative boards of Experimental Examples 4 and 6 was slightly inferior to that of each of Embodiments 1-24 in surface durability and surface hardness. [0109] The evaluation result of the melamine decorative board of Experimental Example 5 was slightly inferior to that of each of Embodiments 1-24 in anti-fingerprint property and clarity. CLAIMS 1. A composition comprising: (a) an organosilica sol; and (b1) a siloxane graft-type polymer obtained by compositing fluorine resin or acrylic resin with siloxane and/or (b2) a cold glass coating agent. 2. A transfer sheet comprising: a base material; and the composition according to claim 1, the composition being disposed on the base material. 3. A melamine decorative board comprising a low refractive index layer formed on a surface thereof, the low refractive index layer being composed of a cured product of the composition according to claim 1. 4. The melamine decorative board according to claim 3, wherein the low refractive index layer has a refractive index of 1.5 or less. 5. A method for producing a melamine decorative board, the method comprising steps of: stacking the transfer sheet according to claim 2, a melamine resin impregnated paper, and a core material; applying heat and pressure to above stacked body; and removing the base material. Disclosed is a composition containing a siloxane grafted polymer obtained by combining an organosilica sol, a fluororesin or acrylic resin, and a siloxane, and/or a room temperature glass coating agent. Also disclosed is a melamine decorative board having a surface provided with a low-refractive-index layer which is composed of a cured product of the composition.

Full Text

DESCRIPTION
COMPOSITION, TRANSFER SHEET, MELAMINE
DECORATIVE BOARD, AND METHOD FOR PRODUCING
MELAMINE DECORATIVE BOARD
TECHNICAL FIELD
[0001] This invention relates to a composition, a
transfer sheet, a melamine decorative board, and a
method for producing the melamine decorative
board.
BACKGROUND ART
[0002] A melamine decorative board is used as a
horizontal surface for a counter, a desk, and others
because of its excellent properties in surface
hardness, heat resistance, abrasion resistance and
the like. The melamine decorative board is
generally obtained by stacking a melamine resin
impregnated pattern paper and a phenol resin
impregnated core paper, and then applying heat and
pressure to the stacked papers with a flat plate
pressing machine (see Patent Documents 1 -3). The
melamine resin impregnated pattern paper is
obtained by impregnating a pattern base paper for
decorative board with a resin liquid composed
primarily of melamine-formaldehyde resin and
drying the impregnated pattern base paper. The
phenol resin impregnated core paper is obtained by-
impregnating a kraft paper with a resin liquid
composed primarily of phenol-formaldehyde resin
and drying the impregnated kraft paper.
Patent Document 1 : Unexamined Japanese Patent
Publication No. H06-199528
Patent Document 2: Unexamined Japanese Patent
Publication No. 2005-199495
Patent Document 3: Unexamined Japanese Patent
Publication No. 2005-146272
DISCLOSURE OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
[0003] The melamine decorative board has excellent
surface hardness, heat resistance, abrasion
resistance and the like by virtue of characteristics
of the resin used therein. On the other hand, the
melamine decorative board is disadvantageous in
that a greasy dirt such as a sebum membrane of a
fingerprint (hereinafter referred to as a fingerprint)
adhering onto a surface of the melamine decorative
board is easily noticeable. A further disadvantage

is that a pattern on a printed paper cannot be
clearly exhibited due to reflection of lights and
white blur on a melamine resin layer.
[0004] The present invention was made in order to
overcome such conventional disadvantages. It is an
object of the present invention to provide a
composition which can be used in producing a
melamine decorative board on which a fingerprint
and the like is less noticeable and a pattern on a
printed paper can be clearly exhibited; a transfer
sheet which can be used in producing the melamine
decorative board; the melamine decorative board;
and a method for producing the melamine decorative
board.
MEANS TO SOLVE THE PROBLEMS
[0005] A composition of the present invention includes
(a) an organosilica sol; and (b1) a siloxane
graft-type polymer obtained by compositing fluorine
resin or acrylic resin with siloxane and/or (b2) a
cold glass coating agent.
[0006] In other words, there are three different types
of the composition in the present invention, that is,
a composition including the component (a) and the
component (bl), a composition including the

component (a) and the component (b2), and a
composition including the component (a), the
component (b1), and the component (b2).
[0007] The composition of the present invention can be
used, for example, for forming a low refractive index
layer composed of a cured product of the composition
of the present invention on a surface of a melamine
decorative board. In the melamine decorative
board having the low refractive index layer, which is
composed of the cured product of the composition of
the present invention, formed on the surface thereof,
a fingerprint adhering on the surface is less
noticeable. This is because the low refractive
index layer has a lower refractive index than that of
a melamine resin layer and, therefore, a refractive
index difference between an adhering fingerprint
and the low refractive index layer is smaller than
that between an adhering fingerprint and the
melamine resin layer. Furthermore, the low
refractive index layer has a low reflectivity and a
low refractive index, thereby reducing reflection of
lights and white blur. As a result, a pattern on a
printed paper used for the melamine decorative
board can be clearly exhibited to provide the
melamine decorative board with high design quality.

[0008] In the decorative board of the present invention,
since the low refractive index layer composed of the
cured product of the above-described composition is
formed on the surface, the fingerprint adhering on
the surface is less noticeable, and the pattern on the
printed paper is clearly exhibited, whereby the high
design quality is realized. The low refractive index
layer preferably has a refractive index of 1.5 or less.
By setting the refractive index to 1.5 or less, the
fingerprint becomes still less noticeable and the
pattern on the printed paper is exhibited more
clearly.
[0009] A transfer sheet of the present invention
includes a base material and the above-described
composition disposed on the base material. The
transfer sheet can be used for forming the low
refractive index layer on the surface of the
melamine decorative board. The transfer sheet
makes it easy to form the low refractive index layer.
[0010] A method for producing the melamine decorative
board of the present invention includes steps of
stacking the above-described transfer sheet, a
melamine resin impregnated paper, and a core
material, applying heat and pressure thereto, and
removing the base material of the transfer sheet.

According to the method, the melamine decorative
board having the low refractive index layer on the
surface thereof can be easily produced. While
applying heat and pressure, temperature is
preferably in a range of 110-180°C, and pressure is
preferably in a range of 5-10 MPa.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is an explanatory view showing a method
for producing a melamine decorative board.
FIG. 2 is a sectional side view showing a
structure of the melamine decorative board.
FIG. 3 is a photograph showing clarity on a
surface of the melamine decorative board. A right
half corresponds to a melamine decorative board of
Embodiment 1, and a left half corresponds to a
melamine decorative board of Comparative example
1.
FIG. 4 is a photograph showing to what degree a
fingerprint adheres onto the surface of the melamine
decorative board. A right half corresponds to the
melamine decorative board of Embodiment 1, and a
left half corresponds to the melamine decorative
board of Comparative example 1.

EXPLANATION OF REFERENCE NUMERALS
[0012] 1, 11...transfer sheet, 1a...OPP film, 1b...dried
film, 2...melamine resin impregnated overlay paper ,
3...melamine resin impregnated decorative paper,
4...phenol resin impregnated core paper,
5...melamine decorative board, 6...low refractive
index layer
BEST MODE FOR CARRYING OUT THE INVENTION
[0013] Hereinafter, the present invention will be
described in detail. A siloxane graft-type polymer
(a component (b1)) used in a composition of the
present invention is obtained by compositing
fluorine resin or acrylic resin with siloxane.
Specifically, the siloxane graft-type polymer can be
obtained by copolymerizing following components:
(A) 2-70% by weight of organic solvent-soluble
fluorine resin having radical polymerizable
unsaturated bond via urethane bond, (B) 4-40% by
weight of polysiloxane which is radical
polymerizable at one end shown by a following
formula 1 (wherein R1 represents a hydrogen atom or
a hydrocarbon group having 1-10 carbon atoms; R2,
R3, R4, R5, and R6, which may be mutually same or
different, represent a hydrogen atom or a

hydrocarbon group having 1-10 carbon atoms,' and n
represents an integer of 2 or more), and/or
polysiloxane which is radical polymerizable at one
end shown by a following formula 2 (wherein R7
represents a hydrogen atom or a hydrocarbon group
having 1-10 carbon atoms; R8, R9, R10, R11, and R12,
which may be mutually same or different, represent
a hydrogen atom or a hydrocarbon group having 1-10
carbon atoms; p represents an integer of 0-10; and q
represents an integer of 2 or more), and (C) 15-94%
by weight of radical polymerizable monomer which is
unreactive to the component (A) under radical
polymerization reaction condition, except
polymerization reaction with a double bond.
[0014] [Formula 1]

[0015] [Formula 2]

Another example of the siloxane graft-type
polymer obtained by compositing fluorine resin or
acrylic resin with siloxane includes a polymer which
is obtained by copolymerizing following components:
(A) 2-70% by weight of organic solvent-soluble
fluorine resin having radical polymerizable
unsaturated bond via urethane bond, (B) 5-55% by
weight of polysiloxane which is radical
polymerizable at one end shown by the above
formula 1, and/or poly siloxane which is radical
polymerizable at one end shown by the above
formula 2, (C) 5-55% by weight of monomer having
an alkoxysilyl group, (D) 15-50% by weight of
monomer having a hydroxyl group, and (E) 0-73% by
weight of monomer having a functional group which
is unreactive to the above components (A)-(D) except
radical polymerization.
[0016] Still another example of the siloxane graft-type
polymer obtained by compositing fluorine resin or
acrylic resin with siloxane includes a polymer in
which an acrylic-type (co)polymer containing a
curable group, having radical polymerizable
unsaturated bond via urethane bond and also being
soluble in organic solvent, is used in place of the
component (A) in each of the above-described
siloxane graft-type polymers.
[0017] Commercially available siloxane graft-type
polymer obtained by compositing fluorine resin or
acrylic resin with siloxane includes ZX-007C,
ZX-001, ZX-022, ZX-022H, ZX-028R, ZX-036 (all are
manufactured by Fuji Kasei Kogyo Co., Ltd.) and the
like.
[0018] A cold glass coating agent (a component (b2))
used in the composition of the present invention
includes one which is obtained by ionizing
alcohol-soluble organosilicon compound in a
solution composed of water and organic solvent, and
adding thereto halogen and boron as catalysts.
[0019] A role of B3+ ion is to inhibit a decrease in an
amount of SiO2 due to generation and volatilization
of SiF6 by reacting with F- ion. B3+ ion reacts with
F- ion to generate BF4- complex ion, and B in the
BF4- complex ion is replaced extremely easily by Si
in Si(OR)n to obtain SiF-n + 1 complex ion.
Hydrolysis and dehydrating condensation
represented by the formulae below are accelerated,
and as a result, metal-oxide glass is obtained at an
ambient temperature range. Residual B3+ ion is
vaporized and disappears as B(OCH3)3 by the
presence of methanol (CH3 +), and F- ion is vaporized
and disappears as HF by catalytic reaction with OH"
group or others contained in the base material and
the like. Here, R represents an alkyl group, M
represents a metal, and X represents halogen.
[0020]
An example of a compound releasing boron ion
B3+ includes, for example, trialkoxyboran B(OR)3,
among which triethoxyboran B(OEt)3 is preferable.
Concentration of B3+ ion in a reaction solution is
preferably in a range of l.0-10.0 mol/liter. Halogen
ion is preferably F , Cl-, or a mixture of F- and Cl-.
A compound used as halogen ion source may be any
one which produces F- ion or Cl- ion in the reaction
solution. As F- ion source, for example, ammonium
hydrogen fluoride NH4F.HF, sodium fluoride NaF,
and the like are preferable. As Cl- ion source, for
example, ammonium chloride NH4Cl and the like are
preferable.
[0021] Commercially available cold glass coating agent
includes Siragusital A6200, Siragusital B4373(BN)
(both are manufactured by Bokuto Kasei Kogyo Co.,
Ltd.), and the like.
[0022] An organosilica sol used in the composition of
the present invention includes, for example, a
colloidal solution including colloidal silicas with a
particle diameter of 1-40 nm (more preferably with a
diameter of 7-30 nm) stably dispersed in organic
solution. A silica concentration is preferably in a
range of 1-50% by weight, more preferably 40% by
weight or less to inhibit gelation.
[0023] Commercially available organosilica sol
includes IPA-ST, IPA-ST-ZL, methanol silica sol,
NPC-ST-30, EG-ST, DMAC-ST and the like
manufactured by Nissan Chemical Industries, Ltd.;
OSCAL manufactured by Shokubai Kasei Kogyo Co.,
Ltd.; Quartron (registered trademark)
manufactured by Fuse Chemical Co., Ltd.; Highlink
(registered trademark) OG Silica Organosol
manufactured by Clariant Japan K.K.; and the like.
[0024] In the composition of the present invention, it is
preferable to use an organosilica sol obtained by
substituting an aqueous silica sol using a
hydrophilic solvent such as alcohol and the like. In
the organosilica sol derived from the aqueous silica
sol, an amount of hydroxyl groups on a surface of the
silica becomes sufficient. Therefore, when the low
refractive index layer of the melamine decorative
board is formed using the composition of the present
invention, adhesion between the low refractive
index layer and the melamine layer is promoted, and
surface durability of the melamine decorative board
is thereby improved. When the organosilica sol is
dispersed in a hydrophobic solvent, a surface of the
organosilica sol is hydrophobized in order to
stabilize the organosilica sol. In such an
organosilica sol, the silica does not have a sufficient
amount of hydroxyl groups on the surface thereof,
and adhesion between the low refractive index layer
and the melamine layer is likely to be inferior.
[0025] Here, the hydrophilic (polar) solvent refers to a
solvent having an affinity with water. An example
thereof is a hydrophilic organic solvent including, in
a molecule thereof, a hydrophilic group such as a
hydroxyl group, a carboxyl group, a carbonyl group
and the like. The hydrophilic (polar) solvent
includes a protic polar solvent and an aprotic polar
solvent. Specific examples of the protic polar
solvent include alcohol-based solvent such as methyl
alcohol, ethyl alcohol, isopropyl alcohol, ethylene
dialcohol, propanol and the like; and
cellosolve-based solvent such as methyl cellosolve,
ethyl cellosolve, butyl cellosolve, n-propyl
cellosolve and the like. Specific examples of the
aprotic polar solvent include acetone, dimethyl
sulfoxide (DMSO), N,N-dimethyl formamide (DMF),
pyridine and the like.
[0026] In the composition of the present invention, it is
preferable to set a mixing ratio between the
component (a) and the component (b1) so that an
amount of the component (a) is 4-18 parts by weight
(in solid equivalent) per part by weight of the
component (bl) (in solid equivalent). By setting
the amount of the component (a) to 4 or more parts
by weight, the amount of hydroxyl groups on the
surface of the silica becomes sufficient. Thus, the
adhesion between the low refractive index layer and
the melamine layer is promoted, and the surface
durability of the melamine decorative board is
thereby improved. Further, by setting the amount
of the component (a) to 18 or less parts by weight,
the amount of the component (bl) does not become
too small. As a result, on a surface of the melamine
decorative board, a fingerprint becomes still less
noticeable, and a pattern on a printed paper becomes
still clearer.
[0027] In the composition of the present invention, it is
preferable to set a mixing ratio between the
component (a) and the component (b2) so that an
amount of the component (a) is 4-18 parts by weight
(in solid equivalent) per part by weight of the
component (b2) (in solid equivalent). By setting
the amount of the component (a) to 4 or more parts
by weight, the amount of hydroxyl groups on the
surface of the silica becomes sufficient. Thus, the
adhesion between the low refractive index layer and
the melamine layer is promoted, and surface
durability of the melamine decorative board is
thereby improved. Further, by setting the amount
of the component (a) to 18 or less parts by weight,
the amount of the component (b2) does not become
too small. As a result, on the surface of the
melamine decorative board, the fingerprint becomes
still less noticeable, and the pattern on the printed
paper becomes still clearer.
[0028] Examples of base material used as a transfer
sheet of the present invention include a plastic film
and a metallic foil. As a plastic film, for example, a
polyester film, a polyethylene film, a polypropylene
film, a cellophane, a diacetylcellulose film, a
triacetylcellulose film, an acetylcellulose butyrate
film, a polyvinyl chloride film, a polyvinylidene
chloride film, a polyvinyl alcohol film, an ethylene
vinyl alcohol film, a polystyrene film, a
polycarbonate film, a polymethylpentene film, a
polysulfone film, a polyether ketone film, a
polyether sulfone film, a polyetherimide film, a
polyimide film, a fluororesin film, a nylon film, an
acrylic film and the like can be used.
[0029] As a metallic foil, for example, a gold foil, a
silver foil, a copper foil, a zinc foil, an indium foil,
an aluminum foil, a tin foil, an iron foil (including a
stainless steel (SUS) foil), a titanium foil and the
like can be used.
[0030] The transfer sheet of the present invention can
be produced, for example, by applying the
composition to the base material. As an applying
method, known methods, for example, a spray coat
method, a gravure coat method, a bar coat method, a
knife coat method, a roll coat method, a blade coat
method, a die coat method, a curtain coat method, a
reverse coat method, a comma coat method and the
like can be employed. The transfer sheet obtained
through such methods is stacked on a melamine
resin impregnated paper (e.g., a melamine resin
impregnated pattern paper and a melamine resin
impregnated overlay paper) so that a
composition-applied surface comes in contact with
the melamine resin impregnated paper. Then, heat
and pressure are applied to the stacked transfer
sheet and the melamine resin impregnated paper
together with a core material.
[0031] A thickness (after dried) of the low refractive
index layer formed using the composition of the
present invention is preferably in a range of 0.5-15
pm when the composition is composed of the
component (a) and the component (b1). By setting
the thickness within this range, a refractive index of
the low refractive index layer easily becomes 1.5 or
less. By setting the film thickness to 0.5 pm or
more, the fingerprint becomes still less noticeable,
and the pattern on the printed paper becomes still
clearer on the surface of the melamine decorative
board. Further, by setting the film thickness to 15
pm or less, whitening of the low refractive layer is
less likely to occur, and an appearance of the
melamine decorative board becomes excellent.
[0032] The thickness (after dried) of the low refractive
index layer formed using the composition of the
present invention is preferably in a range of 0.5-15
um when the composition is composed of the
component (a) and the component (b2). By setting
the thickness within this range, the refractive index
of the low refractive index layer easily becomes 1.5
or less. By setting the film thickness to 0.5 µm or
more, the fingerprint becomes still less noticeable,
and the pattern on the printed paper becomes still
clearer on the surface of the melamine decorative
board. Further, by setting the film thickness to 15
um or less, whitening of the low refractive layer is
less likely to occur, and the appearance of the
melamine decorative board becomes excellent.
[0033] In the melamine decorative board of the present
invention and a method for producing the melamine
decorative board of the present invention, the
melamine resin impregnated paper (the melamine
resin impregnated pattern paper) may be used. The
melamine resin impregnated paper is obtained, for
example, by impregnating a decorative paper for use
in a decorative board with a resin liquid composed
primarily of melamine-formaldehyde resin and
drying the impregnated decorative paper. A basis
weight of the decorative paper for use in a
decorative board is preferably, for example, in a
range of about 80-140 g/m2. A degree of
impregnation of the resin liquid, which is defined by
a following mathematical formula 1, is preferably in
a range of 70-160%, for example.
[0034] [Mathematical formula 1]

In the melamine decorative board of the present
invention and the method for producing the
melamine decorative board of the present invention,
in order to improve abrasion resistance on the
surface of the melamine decorative board, the
melamine resin impregnated overlay paper may be
stacked as an uppermost layer (excluding the low
refractive index layer) and heat and pressure may be
applied to the stacked body. The melamine resin
impregnated overlay paper is obtained, for example,
by impregnating an overlay base paper having a
basis weight of about 20-60 g/m2 with a resin liquid
composed primarily of melamine-formaldehyde resin
at a degree of impregnation of 200-400%, and drying
the impregnated overlay base paper.
[003 5] In the melamine decorative board of the present
invention and the method for producing the
melamine decorative board of the present invention,
a core material may be used. The core material is
obtained, for example, by impregnating a kraft
paper with a resin liquid composed primarily of
phenol-formaldehyde resin and drying the
impregnated kraft paper. A basis weight of the
kraft paper is preferably, for example, in a range of
about 150-300 g/m2. A degree of impregnation of
the resin liquid, which is defined by the above
mathematical formula 1, is preferably in a range of
30-80%, for example.
[0036] The present invention will hereinafter be described by
Embodiments. Experimental Examples, and Comparative Examples,
which do not limit the present invention in any way.
Embodiment I
[0037] 1. Production of a composition
One part by weight (in solid equivalent) of a
siloxane graft-type polymer was mixe with 10 parts
by weight (in solid equivalent) of an organosilica sol.
As the siioxane graft-type polymer, ZX-022H
(hydroxyl value: 120, acid value: 0, solvent species:
xylene/butyl acetate/isopropanol, manufactured by
Fuji Kasei Kogyo Co., Ltd.) obtained by compositing
fluorine resin with siloxane was used. As the
organosilica sol, IPA-ST (isopropanol dispersion
silica sol, average particle diameter: 10-20 nm,
SiO2: 30% by weight, manufactured by Nissan
Chemical Industries, Ltd.) was used. IPA-ST is an
organosilica sol in which a hydrophilic solvent
(isopropanol) is used.
[0038] The above mixture was diluted with isopropanol
so that a total solid content became 20% by weight,
and a composition was obtained.
[0039] 2. Production of a transfer sheet
The above composition was uniformly applied to
an OPP film having a thickness of 30 µm by a bar
coat method so that an after-dried film thickness of
the composition became 3 µm. The OPP film was
dried to obtain a transfer sheet 1. In the transfer
sheet 1, a layer composed of dried product of the
above composition was formed on the OPP film.
[0040] 3. Production of a melamine decorative board
An overlay paper having a basis weight of 40
g/m2 for use in a decorative board was impregnated
with a resin liquid composed primarily of
melamine-formaldehyde resin. A degree of
impregnation of the resin liquid was set to 300%
according to a calculating method defined by the
above mathematical formula 1. The impregnated
overlay paper was dried to obtain a melamine resin
impregnated overlay paper 2.
[0041] A black decorative paper having a basis weight
of 100 g/m2 for use in a decorative board was
impregnated with a resin liquid composed primarily
of melamine-formaldehyde resin. A degree of
impregnation of the resin liquid was set to 100%
according to the calculating method defined by the
above mathematical formula 1. The impregnated
decorative paper was dried to obtain a melamine
resin impregnated decorative paper 3.
[0042] A kraft paper having a basis weight of 200 g/m2
was impregnated with a resin liquid composed
primarily of phenol-formaldehyde resin. A degree
of impregnation of the resin liquid was set to 50%
according to the calculating method defined by the
above mathematical formula 1. The impregnated
kraft paper was dried to obtain a phenol resin
impregnated core paper 4.
[0043] As shown in FIG. 1, five sheets of the phenol
resin impregnated core paper 4, a sheet of the
melamine resin impregnated decorative paper 3, a
sheet of the melamine resin impregnated overlay
paper 2, and a sheet of the transfer sheet were
stacked in this order. The transfer sheet 1, which
includes an OPP film la and a dried film 1b of the
composition, was stacked so that the dried film 1b
came in contact with the melamine resin
impregnated overlay paper 2. Heat and pressure
are applied to the stacked body at a temperature of
135°C and a pressure of 8 MPa for 80 minutes.
Then, the OPP film la was removed to obtain a
melamine decorative board 5 as shown in FIG. 2. A
low refractive index layer 6 composed of a cured
product of the composition was formed on a surface
of the melamine decorative board 5. The low
refractive index layer 6 was generated from the
dried film lb of the composition.
Embodiment 2
[0044] A transfer sheet was produced in the same
manner as in Embodiment 1 except that the
after-dried film thickness of the composition (a
thickness of the low refractive index layer) on the
transfer sheet was set to 0.5 µm. Further, a
melamine decorative board having the low refractive
index layer formed on a surface thereof was
produced in the same manner as in Embodiment 1
except that the above transfer sheet was used.
Embodiment 3
[0045] A transfer sheet was produced in the same
manner as in Embodiment 1 except that the
after-dried film thickness of the composition (a
thickness of the low refractive index layer) on the
transfer sheet was set to 15 µm. Further, a
melamine decorative board having the low refractive
index layer formed on a surface thereof was
produced in the same manner as in Embodiment 1
except that the above transfer sheet was used.
Embodiment 4
[0046] A composition was produced in the same manner
as in Embodiment 1 except that a mixing ratio
between the siloxane graft-type polymer and the
organosilica sol was set as follows:
the siloxane graft-type polymer : 1 part by
weight (in solid equivalent)
the organosilica sol: 4 parts by weight (in solid
equivalent)
[0047] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 5
[0048] A composition was produced in the same manner
as in Embodiment 1 except that the mixing ratio
between the siloxane graft-type polymer and the
organosilica sol was set as follows:
the siloxane graft-type polymer: 1 part by
weight (in solid equivalent)
the organosilica sol: 6 parts by weight (in solid
equivalent)
[0049] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 6
[0050] A composition was produced in the same manner
as in Embodiment 1 except that the mixing ratio
between the siloxane graft-type polymer and the
organosilica sol was set as follows:
the siloxane graft-type polymer: 1 part by
weight (in solid equivalent)
the organosilica sol: 14 parts by weight (in solid
equivalent)
[0051] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 7
[0052] A composition was produced in the same manner
as in Embodiment 1 except that the mixing ratio
between the siloxane graft-type polymer and the
organosilica sol was set as follows:
the siloxane graft-type polymer-' 1 part by
weight (in solid equivalent)
the organosilica sol: 18 parts by weight (in solid
equivalent)
[0053] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 8
[0054] A composition was produced in the same manner
as in Embodiment 1 except that, instead of IPA-ST,
the same amount of methanol silica sol (methanol
dispersion silica sol, average particle diameter:
10-20 nm, SiO2: 30% by weight, manufactured by
Nissan Chemical Industries, Ltd.) was used as an
organosilica sol. The methanol silica sol is an
organosilica sol in which a hydrophilic solvent
(methanol) is used.
[0055] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 9
[0056] A composition was produced in the same manner
as in Embodiment 1 except that, instead of IPA-ST,
the same amount of NPOST-30 (average particle
diameter: 10-20 nm, n-propyl cellosolve dispersion
silica sol, SiO2: 30% by weight, manufactured by
Nissan Chemical Industries, Ltd.) was used as an
organosilica sol. NPOST-30 is an organosilica sol
in which a hydrophilic solvent (n-propyl cellosolve)
is used.
[0057] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 10
[0058] A composition was produced in the same manner
as in Embodiment 1 except that, instead of ZX-022H,
the same amount of a siloxane graft-type polymer
ZX-007C (hydroxyl value: 58, acid value: 5, solvent
species: xylene/butyl acetate, manufactured by Fuji
Kasei Kogyo Co., Ltd.) obtained by compositing
fluorine resin with siloxane was used as a siloxane
graft-type polymer. Further, a transfer sheet and a
melamine decorative board having a low refractive
index layer formed on a surface thereof were
produced in the same manner as in Embodiment 1
except that the above composition was used.
Embodiment 11
[0059] A composition was produced in the same manner
as in Embodiment 1 except that, instead of ZX-022H,
the same amount of a siloxane graft-type polymer
ZX-001 (hydroxyl value: 94, acid value: 0, solvent
species: xylene/isobutanol, manufactured by Fuji
Kasei Kogyo Co., Ltd.) obtained by compositing
fluorine resin with siloxane was used as a siloxane
graft-type polymer. Further, a transfer sheet and a
melamine decorative board having a low refractive
index layer formed on a surface thereof were
produced in the same manner as in Embodiment 1
except that the above composition was used.
Embodiment 12
[0060] A composition was produced in the same manner
as in Embodiment 1 except that, instead of ZX-022H,
the same amount of a siloxane graft-type polymer
ZX-022 (hydroxyl value: 120, acid value: 5, solvent
species: xylene/ butyl acetate, manufactured by Fuji
Kasei Kogyo Co., Ltd.) obtained by compositing
fluorine resin with siloxane was used as a siloxane
graft-type polymer. Further, a transfer sheet and a
melamine decorative board having a low refractive
index layer formed on a surface thereof were
produced in the same manner as in Embodiment 1
except that the above composition was used.
Embodiment 13
[0061] A composition was produced in the same manner
as in Embodiment 1 except that, instead of ZX-022H,
the same amount of a siloxane graft-type polymer
ZX-028-R (hydroxyl value: 100, acid value: 5,
solvent species: butyl acetate, manufactured by Fuji
Kasei Kogyo Co., Ltd.) obtained by compositing
acrylic resin with siloxane was used as a siloxane
graft-type polymer. Further, a transfer sheet and a
melamine decorative board having a low refractive
index layer formed on a surface thereof were
produced in the same manner as in Embodiment 1
except that the above composition was used.
Embodiment 14
[0062] A composition was produced in the same manner
as in Embodiment 1 except that, instead of ZX-022H,
the same amount of a siloxane graft-type polymer
ZX-036 (hydroxy 1 value: 119, solvent species: butyl
acetate/2-propanol, manufactured by Fuji Kasei
Kogyo Co., Ltd.) obtained by compositing acrylic
resin with siloxane was used as a siloxane graft-type
polymer. Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
Embodiment 15
[0063] 1. Production of a composition
One part by weight (in solid equivalent) of a
cold glass coating agent was mixed with 10 parts by
weight (in solid equivalent) of an organosilica sol.
As the cold glass coating agent, one-component
coating agent (commercial name: Siragusital A6200
manufactured by Bokuto Kasei Kogyo Co., Ltd.) was
used. The cold glass coating agent is obtained by
mixing alcohol-soluble organic silicon compound
(Si(OR)4) with alcohol and the like (isopropanol),
and adding thereto boron ion B3+ and halogen ion F-
as catalysts to adjust pH to 4.5-5.0. As the
organosilica sol, IPA-ST (isopropanol dispersion
silica sol, average particle diameter: 10-20 nm,
SiO2: 30% by weight, manufactured by Nissan
Chemical Industries, Ltd.) was used.
[0064] The above mixture was diluted with isopropanol
so that a total solid content became 20% by weight,
and a composition was obtained.
[0065] 2. Production of a transfer sheet
The above composition was applied to an OPP
film having a thickness of 30 µm by a bar coat
method so that an after-dried film thickness of the
composition became 3 µm. The OPP film was dried
to obtain a transfer sheet 11.
[0066] 3. Production of a melamine decorative board
Using the transfer sheet 11, a melamine
decorative board having a low refractive index layer
formed on a surface thereof was produced in the
same manner as in Embodiment 1 (see FIG. l).
Embodiment 16
[0067] A transfer sheet was produced in the same
manner as in Embodiment 15 except that the
after-dried film thickness of the composition (a
thickness of the low refractive index layer) on the
transfer sheet was set to 0.5 µm. Further, a
melamine decorative board having the low refractive

index layer formed on a surface thereof was
produced in the same manner as in Embodiment 15
except that the above transfer sheet was used.
Embodiment 17
[0068] A transfer sheet was produced in the same
manner as in Embodiment 15 except that the
after-dried film thickness of the composition (a
thickness of the low refractive index layer) on the
transfer sheet was set to 15 µm. Further, a
melamine decorative board having the low refractive
index layer formed on a surface thereof was
produced in the same manner as in Embodiment 15
except that the above transfer sheet was used.
Embodiment 18
[0069] A composition was produced in the same manner
as in Embodiment 15 except that a mixing ratio
between the cold glass coating agent and the
organosilica sol was set as follows:
the cold glass coating agent: 1 part by weight (in
solid equivalent)
the organosilica sol: 4 parts by weight (in solid
equivalent)
[0070] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the

same manner as in Embodiment 15 except that the
above composition was used.
Embodiment 19
[0071] A composition was produced in the same manner
as in Embodiment 15 except that the mixing ratio
between the cold glass coating agent and the
organosilica sol was set as follows:
the cold glass coating agent: 1 part by weight (in
solid equivalent)
the organosilica sol: 6 parts by weight (in solid
equivalent)
[0072] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
Embodiment 20
[0073] A composition was produced in the same manner
as in Embodiment 15 except that the mixing ratio
between the cold glass coating agent and the
organosilica sol was set as follows:
the cold glass coating agent: 1 part by weight (in
solid equivalent)
the organosilica sol: 14 parts by weight (in solid
equivalent)

[0074] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
Embodiment 21
[0075] A composition was produced in the same manner
as in Embodiment 15 except that the mixing ratio
between the cold glass coating agent and the
organosilica sol was set as follows:
the cold glass coating agent: 1 part by weight (in
solid equivalent)
the organosilica sol: 18 parts by weight (in solid
equivalent)
[0076] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
Embodiment 22
[0077] A composition was produced in the same manner
as in Embodiment 15 except that, instead of IPA-ST,
the same amount of methanol silica sol (methanol
dispersion silica sol, manufactured by Nissan
Chemical Industries, Ltd.) was used as an

organosilica sol. Further, a transfer sheet and a
melamine decorative board having a low refractive
index layer formed on a surface thereof were
produced in the same manner as in Embodiment 15
except that the above composition was used.
Embodiment 23
8] A composition was produced in the same manner
as in Embodiment 15 except that, instead of IPA-ST,
the same amount of NPC-ST-30 (n-propyl cellosolve
dispersion silica sol, manufactured by Nissan
Chemical Industries, Ltd.) was used as an
organosilica sol. Further, a transfer sheet and a
melamine decorative board having a low refractive
index layer formed on a surface thereof were
produced in the same manner as in Embodiment 15
except that the above composition was used.
Embodiment 24
9] A composition was produced in the same manner
as in Embodiment 15 except that, instead of
Siragusital A6200, the same amount of Siragusital
B4373(BN) (manufactured by Bokuto Kasei Kogyo
Co., Ltd.) was used as a cold glass coating agent.
Siragusital B4373(BN) is a two-component coating
agent containing alcohol-soluble organic silicon
compound (Si(OR)4) as a base compound and boron
ion B3+ and halogen ion X- as catalysts. The base
compound and the catalysts are mixed at a ratio of
10 parts by weight of the base compound to 1 part by
weight of the catalysts, and are used after diluted
with a diluting solvent to an arbitrary
concentration.
[0080] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
(Experimental Example 1)
A composition was produced in the same manner
as in Embodiment 1 except that the mixing ratio
between the siloxane graft-type polymer and the
organosilica sol was set as follows:
the siloxane graft-type polymer: 1 part by
weight (in solid equivalent)
the organosilica sol: 3 parts by weight (in solid
equivalent)
[0081] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.

(Experimental Example 2)
A composition was produced in the same manner
as in Embodiment 1 except that the mixing ratio
between the siloxane graft-type polymer and the
organosilica sol was set as follows:
the siloxane graft-type polymer: 1 part by
weight (in solid equivalent)
the organosilica sol: 20 parts by weight (in solid
equivalent)
[0082] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 1 except that the
above composition was used.
(Experimental Example 3)
A composition was produced in the same manner
as in Embodiment 1 except that, instead of IPA-ST,
the same amount of nBAC-ST (butyl acetate
dispersion silica sol, manufactured by Nissan
Chemical Industries, Ltd.) was used as an
organosilica sol. nBAOST is an organosilica sol,
solvent species of which is hydrophobic.
[0083] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the

same manner as in Embodiment 1 except that the
above composition was used.
(Experimental Example 4)
A composition was produced in the same manner
as in Embodiment 15 except that the mixing ratio
between the cold glass coating agent and the
organosilica sol was set as follows:
the cold glass coating agent: 1 part by weight (in
solid equivalent)
the organosilica sol: 3 parts by weight (in solid
equivalent)
[0084] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
(Experimental Example 5)
A composition was produced in the same manner
as in Embodiment 15 except that the mixing ratio
between the cold glass coating agent and the
organosilica sol was set as follows:
the cold glass coating agent: 1 part by weight (in
solid equivalent)
the organosilica sol: 20 parts by weight (in solid
equivalent)

[0085] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
(Experimental Example 6)
A composition was produced in the same manner
as in Embodiment 15 except that, instead of IPA-ST,
the same amount of nBAC-ST (butyl acetate
dispersion silica sol, manufactured by Nissan
Chemical Industries, Ltd.) was used as an
organosilica sol. nBAC-ST is an organosilica sol,
solvent species of which is hydrophobic.
[0086] Further, a transfer sheet and a melamine
decorative board having a low refractive index layer
formed on a surface thereof were produced in the
same manner as in Embodiment 15 except that the
above composition was used.
(Comparative Example 1)
Five sheets of the phenol resin impregnated core
paper, a sheet of the melamine resin impregnated
decorative paper, and a sheet of the melamine resin
impregnated overlay paper were stacked, and heat
and pressure are applied thereto at a temperature of
135°C and a pressure of 8 MPa for 80 minutes to

obtain a melamine decorative board. Each of the
phenol resin impregnated core paper, the melamine
resin impregnated decorative paper, and the
melamine resin impregnated overlay paper is the
same as that in Embodiment 1.
[0087] Then, the melamine decorative boards produced
in Embodiments 1-24, Experimental Examples 1-6,
and Comparative Example 1 were evaluated.
(Evaluation method)
(i) Evaluation of anti-fingerprint property using
an actual fingerprint
An actual fingerprint was attached on a surface
of each melamine decorative board, and it was
visually evaluated how noticeable the fingerprint
was. Evaluation criteria are as follows-
[0088] o: The fingerprint is not noticeable
[0089] ?: The fingerprint is slightly noticeable
[0090] x: The fingerprint is noticeable
[0091] (ii) Clarity
Clarity of the decorative paper of the melamine
decorative board was visually observed under
oblique light. Evaluation criteria are as follows:
[0092] o: The decorative paper can be clearly observed
[0093] ?: Reflection of lights and white blur are
slightly observed

(iii) Surface durability (1)
A surface of each melamine decorative board
was wiped back and forth 100 times by dry cotton
waste under a load of about 300 g/cm2, and change in
gloss level on the surface was visually evaluated.
Evaluation criteria are as follows:
[0094] o: Change in gloss level is not observed
[0095] ?: Change in gloss level is slightly observed
[0096] x: Change in gloss level is observed
(iv) surface durability (2)
The surface of each melamine decorative board
was wiped back and forth by dry cotton waste under
a load of about 1 kg/cm2, and change in gloss level on
the surface was visually evaluated. Evaluation
criteria are as follows:
[0097] 5: Change in gloss level is not observed when or
before the surface was wiped back and forth 500
times
[0098] 4: Change in gloss level is observed when or
before the surface was wiped back and forth 400
times
[0099] 3: Change in gloss level is observed when or
before the surface was wiped back and forth 300
times
[0100] 2: Change in gloss level is observed when or

before the surface was wiped back and forth 200
times
[0101] 1: Change in gloss level is observed when or
before the surface was wiped back and forth 100
times
(v) Refractive index
A refractive index on the surface of each
melamine decorative board was measured with
multi-wavelength Abbe refractometer (DR-M2,
manufactured by Atago Co., Ltd.). Refractive index
was measured at a wavelength of 589 nm.
(vi) Surface hardness
Surface hardness of each melamine decorative
board was measured under a load of 1 kg according to
JIS K 5600;1999 (general testing methods for
paints).
(vii) Abrasion resistance
Abrasion resistance of the surface of each
melamine decorative board was measured according
to JIS K 6902;1998 (testing method for laminated
thermosetting high-pressure decorative sheets)
(Evaluation results)
Tables 1 and 2 show the evaluation results. In
Table 1, "(b1):(a)" represents a weight ratio (in solid
equivalent) between the siloxane graft-type polymer

(b1) and the organosilica sol (a). In Table 2,
"(b2):(a)" represents a weight ratio (in solid
equivalent) between the cold glass coating agent (b2)
and the organosilica sol (a).

As shown in Tables 1 and 2, in the melamine
decorative boards of Embodiments 1-24, a
fingerprint was less noticeable, and a printed
pattern had high clarity. Moreover, the melamine
decorative boards of Embodiments 1-24 exhibited
high surface durability, high surface hardness, and
high abrasion resistance. In contrast, in the
melamine decorative board of Comparative Example
1, a fingerprint was noticeable, and a printed
pattern had low clarity.
[0104] FIG. 3 is a photograph showing surface
conditions of the melamine decorative boards of
Embodiment 1 and Comparative Example 1. A right
half of the photograph corresponds to the melamine
decorative board of Embodiment 1, and a left half
corresponds to the melamine decorative board of
Comparative Example 1. As is clear from this
photograph, in the melamine decorative board of
Embodiment 1, the decorative paper had a high
clarity, whereas the melamine decorative board of
Comparative Example 1 was whitish and a
decorative paper thereof had low clarity.
[0105] FIG. 4 is a photograph showing a fingerprint
attached on the surface of each melamine decorative
boards of Embodiment 1 and Comparative Example 1
when anti-fingerprint property was evaluated using
an actual fingerprint. A right half of the
photograph corresponds to the melamine decorative
board of Embodiment 1, and a left half corresponds
to the melamine decorative board of Comparative
Example 1. As is clear from this photograph, in the
melamine decorative board of Embodiment 1, the
fingerprint on the surface thereof was far less

noticeable than that on the surface of the melamine
decorative board of Comparative Example 1. This
is attributed to the fact that the melamine
decorative board of Embodiment 1 includes the low
refractive index layer 6.
[0106] The evaluation result of each of the melamine
decorative boards of Experimental Examples 1 and 3
was slightly inferior to that of each of Embodiments
1-24 in surface durability.
[0107] The evaluation result of the melamine
decorative board of Experimental Example 2 was
slightly inferior to that of each of Embodiments 1-24
in anti-finger print property and clarity.
[0108] The evaluation result of each of the melamine
decorative boards of Experimental Examples 4 and 6
was slightly inferior to that of each of Embodiments
1-24 in surface durability and surface hardness.
[0109] The evaluation result of the melamine
decorative board of Experimental Example 5 was
slightly inferior to that of each of Embodiments 1-24
in anti-fingerprint property and clarity.

CLAIMS
1. A composition comprising:
(a) an organosilica sol; and
(b1) a siloxane graft-type polymer obtained by
compositing fluorine resin or acrylic resin with siloxane
and/or (b2) a cold glass coating agent.
2. A transfer sheet comprising:
a base material; and
the composition according to claim 1, the
composition being disposed on the base material.
3. A melamine decorative board comprising a low
refractive index layer formed on a surface thereof, the low
refractive index layer being composed of a cured product of
the composition according to claim 1.
4. The melamine decorative board according to claim 3,
wherein the low refractive index layer has a
refractive index of 1.5 or less.
5. A method for producing a melamine decorative board,
the method comprising steps of:
stacking the transfer sheet according to claim 2, a

melamine resin impregnated paper, and a core material;
applying heat and pressure to above stacked body;
and
removing the base material.

Disclosed is a composition containing a siloxane grafted polymer obtained by combining an organosilica sol, a
fluororesin or acrylic resin, and a siloxane, and/or a room temperature glass coating agent. Also disclosed is a melamine decorative
board having a surface provided with a low-refractive-index layer which is composed of a cured product of the composition.

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=rFNnZ30WI7zeFiyui+qyDA==&loc=wDBSZCsAt7zoiVrqcFJsRw==

« Previous Patent

Next Patent »

Patent Number

268873

Indian Patent Application Number

4335/KOLNP/2009

PG Journal Number

39/2015

Publication Date

25-Sep-2015

Grant Date

21-Sep-2015

Date of Filing

15-Dec-2009

Name of Patentee

AICA KOGYO CO., LTD.

Applicant Address

2288 NISHIHORIE, KIYOSU-SHI, AICHI 452-0917 JAPAN

Inventors:

#	Inventor's Name	Inventor's Address
1	YAMAMOTO, TOMOHIRO	C/O AICA KOGYO CO., LTD., 24 AZA-FUKAMI, OAZA-KAMIKAYATSU, JIMOKUJI-CHO, AMA-GUN, AICHI 490-1112 JAPAN
2	TANIMOTO, NAOSHI	C/O AICA KOGYO CO., LTD., 24 AZA-FUKAMI, OAZA-KAMIKAYATSU, JIMOKUJI-CHO, AMA-GUN, AICHI 490-1112 JAPAN
3	ITO, TAKAHARU	C/O AICA KOGYO CO., LTD., 24 AZA-FUKAMI, OAZA-KAMIKAYATSU, JIMOKUJI-CHO, AMA-GUN, AICHI 490-1112 JAPAN
4	HONMA, KATSUMI	C/O AICA KOGYO CO., LTD., 24 AZA-FUKAMI, OAZA-KAMIKAYATSU, JIMOKUJI-CHO, AMA-GUN, AICHI 490-1112 JAPAN

PCT International Classification Number

C08L 55/00;B29C43/18;B32B27/00;B32B33/00

PCT International Application Number

PCT/JP2008/059565

PCT International Filing date

2008-05-23

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	2007-180521	2007-07-10	Japan
2	2007-195470	2007-07-27	Japan