JP3056925B2 - Inorganic decorative board with excellent impact resistance - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonflammable and highly impact-resistant inorganic decorative board used for walls of buildings and structures in the field of civil engineering and construction.

[0002]

2. Description of the Related Art An inorganic base material obtained by mixing aluminum hydroxide and a thermosetting resin, a surface layer obtained by impregnating a printing paper or cloth for a pattern with a thermosetting resin,
The inorganic decorative plate having a basic structure and a laminate formed by thermocompression bonding of both is well known and widely used.

[0003] In this decorative plate, the surface layer is made of a transparent resin to express a pattern such as a color pattern of printed paper or cloth, and the aluminum hydroxide powder aggregate in the inorganic base material has heat resistance and nonflammability. , And has noncombustibility as a whole. And other inorganic powders and clays are blended in the inorganic base material to improve mechanical properties and impart moldability,
There is also a tile sheet obtained by embossing and forming a tile plate at the time of hot pressing with a shielding paper interposed between an inorganic base material and a surface layer (for example, Japanese Patent Publication No. 56-31260).

[0004] The above-mentioned conventional inorganic decorative board is excellent in that it is inexpensive, has good workability, and is nonflammable, while having moldability and design properties similar to those of a synthetic resin decorative board. However, not only when the inorganic decorative panel is used as a wall member in a building, but also when used as a road peripheral member outside the building, it may be damaged by an impact of an object, and fragments thereof may be scattered. The drawback was that large impact loads were still fragile.

[0005] When this inorganic decorative panel is used as a decorative panel on the inner wall of a tunnel, it is incombustible or naturally extinguished in preparation for a tunnel fire, and has an impact resistance in the event of an automobile crash. Also, it is necessary to provide a scattering protection function.

SUMMARY OF THE INVENTION In view of the above problems, the present invention aims to improve the nonflammability and heat resistance and to provide a scattering protection function, and the inorganic decorative plate can be used not only as a wall member in a building but also as a road peripheral member. Are provided for use.

[0007]

The inorganic decorative board of the present invention comprises an inorganic base obtained by mixing an inorganic substance having water of crystallization such as aluminum hydroxide powder as a main aggregate and a thermosetting resin as a binder. A material layer, a surface decorative layer that is disposed on the front side of the inorganic base layer, and is formed by impregnating a thermosetting resin in colored paper or cloth; and a front side and a back side of the inorganic base layer. A carbon-based, polyimide-based, or aramid-based tough fiber layer disposed on one or both of them is integrally laminated by thermocompression bonding.

The inorganic decorative board preferably has a backing layer formed by impregnating a thermosetting resin on paper or cloth on the back side of the inorganic base layer, and the tough fiber layer is provided on the backing layer. What is thermocompression-bonded is adopted.

[0009]

The basic constitution of the inorganic decorative board according to the present invention comprises an inorganic base layer, a surface decorative layer and a tough fiber layer. The inorganic base layer forms and maintains the shape of the decorative board as a whole and is nonflammable. To be determined, the thermosetting resin as a binder solidifies inorganic substances such as aluminum hydroxide particles to form a strong substrate. In addition, inorganic substances having water of crystallization such as aluminum hydroxide as the main aggregate release water of crystallization at 300 to 550 ° C to suppress combustion, and after decomposition, become alumina and act as a heat-resistant material, and are exposed to high temperatures. However, the entire inorganic base material layer is made nonflammable.

The surface decorative layer determines the aesthetic appearance of the surface of the decorative plate, and is formed by impregnating a thermosetting resin into paper or cloth colored in a desired color pattern. Is laminated by thermocompression bonding on the surface side of the surface, so that the surface of the decorative board has a color pattern.

The tough fiber layer is a carbon fiber, a polyimide fiber or an aramid fiber, and is high in strength and thermally stable, and is made of a thermosetting resin mixed in each layer to form a surface side of the inorganic base material layer. Or because it is integrally laminated on the back side, even if a crack occurs in the thickness direction of the inorganic base material layer due to mechanical shock or thermal shock (expansion due to rapid heating),
Adhere and fix the crack pieces without scattering or peeling, furthermore, prevent the propagation of the cracks of the substrate layer in the surface area direction, prevent the cracks from spreading, and significantly reduce the impact of the inorganic decorative plate improves.

The tough fiber layer is not laminated on the surface of the surface decorative layer, but except for this point, it can be laminated on either the front side or the back side of the inorganic base material or on both sides. The above function can be exhibited, and the layer may be indirectly laminated to the inorganic base material via an adhesive layer or another layer (for example, a backing layer), and the function of preventing crack propagation is exhibited.

The backing layer is formed by impregnating paper or cloth with a thermosetting resin, similarly to the surface decorative layer, and is integrally laminated by thermocompression bonding on the back side of the inorganic base material layer opposite to the surface decorative layer. Therefore, the backing layer and the surface decorative layer prevent the decorative plate from warping and deforming during the cooling process after the thermocompression molding and during the subsequent holding and use.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the inorganic decorative board of the present invention will be described below.

1 (A), 1 (B) and 1 (C) are schematic cross-sectional views showing the basic structure of a decorative plate according to the present invention. FIG. 1 (A) shows the surface of the inorganic base material layer 1. Surface cosmetic layer 2 on the side,
The decorative board in which the tough fiber layer 3 is laminated and integrated on the other back side is shown. In FIG. 1B, a tough fiber layer 3 is sandwiched between an inorganic base material layer 1 and a surface decorative layer 2 on the surface side of the inorganic base material layer 1 to be integrally laminated. FIG. 3 (C) shows a structure in which the surface decorative layer 2 and the tough fiber layer 3 are integrated on the front side of the inorganic material 1 and the tough fiber layer 3 is integrated on the other back side.

The materials and formulations for forming the inorganic base material layer 1 of this decorative board are shown below. (Main Aggregate) Aluminum hydroxide (Al ₂ O ₃ · 3H ₂ O,
Alternatively, an inorganic substance having water of crystallization, such as Al (OH) ₃ ), magnesium hydroxide or calcium silicate, is used. These inorganic substances are contained in the inorganic substrate 1 in an amount of 50 to 97%.
If it is less than 50%, the non-combustibility is insufficient, and if it exceeds 97%, the molding becomes defective even with the molding ability of the resin, and the strength as a decorative board decreases. Preferably, it is set to 70 to 90%.

(Binder) The thermosetting resin as a binder is composed of 3-12% of a condensable resin such as a melamine resin, an urea resin, a phenol resin, a xylene resin, or a formalin resin with respect to the inorganic base material layer 1. Of the compounding amount. Melamine resin is the best in terms of flame retardancy. If the amount is less than 3%, the bonding strength will be insufficient, and if it exceeds 12%, it will not be nonflammable even if a large amount of aluminum hydroxide is used.
Optimum loading is in the range of 4-10%.

(Auxiliary Aggregate) In addition to the above-mentioned main aggregate, an auxiliary aggregate can be added to the inorganic base material layer 1.
As the auxiliary aggregate, one or more kinds of fine powders such as silica sand, calcite, calcium carbonate, calcium silicate and the like are blended in order to improve the mechanical strength of the formed inorganic base material layer 1. Also, in order to impart fluidity during hot pressing, one or more clay fine powders such as zeolite, kaolin, bentonite and the like are blended. When added, the total amount of these auxiliary aggregates is added to the inorganic base material layer 1 in an amount of 40% or less.
Preferably it is in the range of 5 to 30%. 40% auxiliary aggregate
If it exceeds, the incombustibility due to aluminum hydroxide is impaired.

(Reinforcing fiber) In order to improve the mechanical strength of the formed inorganic base material, short fibers of inorganic fibers such as glass fiber, ceramic fiber and stainless steel wire, or carbon fiber,
Short fibers of organic fibers, such as aramid fibers and imide fibers, are used in the amount of 0.
2 to 10% can be added.

Next, the surface decorative layer 2 is formed by adding a resin such as a melamine resin, a urea resin, a diallyl phthalate resin, or a guanamine resin to a colored paper or cloth 21 (including nonwoven fabric) such as cellulose pulp paper or inorganic noncombustible paper. 22 impregnated. 70 g / m ^{2 of} paper or cloth 21
As described above, a resin impregnated with 100 to 300 g / m ² is used, and the resin impregnation amount is 5 to 20 parts of the resin with respect to 10 parts of the paper cloth in a weight ratio per unit area of the paper cloth. Impregnated resin 22
Melamine resin is most suitable in terms of flame retardancy and a transparent and deep pattern can be obtained.

The coloring of the pulp paper or the noncombustible paper is performed by printing a desired color or pattern on these papers and then impregnating the resin. Alternatively, the color may be printed on the surface of the resin after the impregnation.

The inorganic noncombustible paper is composed mainly of an inorganic substance containing water such as magnesium silicate, aluminum hydroxide, magnesium hydroxide or aluminum silicate.
It is made of paper containing 5 wt% and has excellent heat resistance and nonflammability, high bending strength and good workability. Other components include 5 to 20% by weight of glass fiber for reinforcement and 0 to 10% by weight of an organic component as a binder. This non-combustible paper is most excellent in combination with a melamine resin.

The tough fiber layer 3 is made of a woven or non-woven fabric of long fibers of aramid resin fiber, polyimide resin fiber or carbon fiber. As the aramid resin fiber, a meta type (such as polymetaphenylene isophthalamide) and a para type (such as polyparaphenylene terephthalamide) are used. In particular, para-type araside resin fiber has high strength, heat resistance,
It has excellent dimensional stability and fatigue resistance, has a breaking strength three times that of glass fiber, and significantly improves the impact resistance of the inorganic decorative board. These woven or nonwoven fabrics are 20 to 60 g / m ^2.
It is good. A nonwoven fabric obtained by mixing 30% or less of polyethylene terephthalate fiber, polyester fiber, or polyvinyl acetate fiber with these aramid resin fibers or polyimide resin fibers can also be used.

In the molding of the decorative board, the fibrous nonwoven fabric of the tough fiber layer 3, the aluminum hydroxide powder aggregate serving as the inorganic base material layer 1, and the binder resin are interposed between a pair of pressable upper and lower press molds. The mixed mixture and the above-mentioned resin-impregnated paper to be the surface decorative layer 2 are placed and stacked, and both press dies are pressurized, and the press dies are heated and held at a temperature higher than the melting temperature of the resin. After cooling, a decorative plate having a three-layer structure composed of the bonded tough fiber layer 3, the inorganic base material layer 1, and the surface decorative layer 2 (FIG. 1)
(A)) is obtained. By changing the arrangement order of the surface decorative layer 2, the inorganic base material layer 1, and the tough fiber layer 3 and pressing similarly, decorative panels having the structures shown in FIGS. 1B and 1C can be obtained. From the viewpoint of moldability and workability, it is preferable to use a mixture obtained by mixing the aluminum hydroxide powder aggregate and the binder resin which are to be the inorganic base material layer 1 in advance into a single plate.

Even if the tough fiber layer 3 itself does not contain a thermosetting resin, the thermosetting resin of the inorganic base material 1 melts and oozes out, and the tough fiber layer 3 and the inorganic base material 1 are firmly bonded. It is fixed. An adhesive layer 4 is interposed between the surface decorative layer 2 and the inorganic base material layer 1 and between the inorganic base material layer 1 and the tough fiber layer 3 to facilitate the adhesion between the three layers. (See FIG. 2A). The adhesive layer 4 is obtained by impregnating 10 to 100 g / m ² of thin paper of cellulose pulp paper with a thermosetting resin such as a phenol resin, a melamine resin or a urea resin in an amount of 10 to 30 parts based on 10 parts of the thin paper. Things. Phenolic resins are preferably used for good adhesion.

FIG. 2A shows an example in which a backing layer 5 is provided on the back surface side of the inorganic base material layer 1. This backing layer 5
Has the same structure as the surface decorative layer 2 except that it is not colored, and the inorganic base material layer 1 on the opposite side of the surface decorative layer 2
Is fixed at the same time as the surface decorative layer by thermocompression bonding via the adhesive layer 4. Since this backing layer 5 uses the same pulp paper or non-combustible paper used for the surface decorative layer 2 and the impregnated resin, in the cooling process after thermocompression molding, the inorganic base layer 1 and the surface decorative layer 2 The backing layer 5 offsets and prevents warpage deformation when warpage due to a difference in shrinkage occurs.
When this backing layer 5 is used, the tough fiber layer 3 is fixed by seepage of the thermosetting resin from the backing layer 5.

Next, the test results of the decorative board of the present invention are shown below. As an example, a decorative plate having the structure shown in FIG. 2A was molded with the following composition.

(1) Inorganic base material layer: 80% aluminum hydroxide, 7.5% melamine resin solution, 10% calcium carbonate, 2.0% glass fiber, hardener
A 0.5% mixture previously roll-formed into a 4 mm thick sheet.

(2) Decorative layer; noncombustible paper (85% magnesium silicate, 10% glass fiber, 5% organic fiber) 10
A material obtained by impregnating 10 parts by weight of melamine resin into parts by weight.

(3) Backing layer Same as the decorative layer. (4) Fiber layer: Aramid fiber nonwoven fabric (manufactured by Japan Vilene Co., Ltd .; 40 g / m ² ). (5) Adhesive layer; thin paper impregnated with phenolic resin (10 parts by weight of thin paper impregnated with 25 parts of resin).

These materials are arranged as shown in FIG. 3 (A), heated at 150 ° C. × 5 min under a pressure of 100 kg / cm ² by a press mold, hot-pressed, and then cooled in the mold. A decorative board having a thickness of 42 mm, a length of 220 mm, and a width of 220 mm was obtained.

As a comparative example, a decorative board having the same structure was molded with the following composition. The thermocompression molding method is the same as in the example, and is a decorative plate having a thickness of 42 mm. (1) Inorganic base material layer: 70% aluminum hydroxide, 7.5% phenol resin liquid, 15% calcium carbonate,
Glass fiber 2.5% kneaded beforehand 4m thick
Roll formed on m-sheet.

(2) Decorative layer: Thin paper made of cellulose pulp impregnated with a melamine resin (10 parts by weight of thin paper impregnated with 12 parts by weight of resin). (3) Backing layer: Same as the decorative layer. (4) Adhesive layer; thin paper impregnated with phenolic resin (10 parts by weight of thin paper impregnated with 25 parts of resin).

Table 1 summarizes the test results. The decorative plate of the example is particularly excellent in impact resistance, and in the steel ball drop test, the decorative plate of the comparative example dropped and splintered at the same time as the fall, but in the case of the example, the aramid fiber The shape was retained by the non-woven fabric layer, and no fragments were scattered.

[0035]

[Table 1]

FIGS. 2B and 2C show other examples of the constitution of the inorganic decorative plate of the present invention. FIG. 2B shows that the tough fiber layer 3a and the back surface of the backing layer 5 are combined with the decorative layer. Another tough fiber layer 3b is interposed between the base material 2 and the inorganic base material layer 1 as well.
Heavily fortified. For this reason, even if the decorative layer 2 shown in the figure is made of cellulose pulp thin paper impregnated with a thermosetting resin such as melamine resin, a decorative board sufficiently resistant to impact can be obtained. Since the tough fiber layers 3a and 3b are on both sides of the inorganic base material layer 1, the base material layer 1 is free from cracks and cracks, and has excellent impact resistance as a decorative board. Further, since no inorganic substance is mixed in the decorative layer 2, the adhesive force with the inorganic base material layer 1 is further enhanced. FIG. 2C shows an example in which the tough fiber layer 3 is interposed between the backing layer 5 and the inorganic base material layer 1.

The inorganic decorative board as described above is excellent in impact resistance and nonflammability, and thus is preferably used for applications as an interior material for tunnels. FIG. 4 shows a method of attaching the inorganic decorative plate to the inner surface of the tunnel. The pillars 8 are attached to the inner wall 91 of the tunnel 9 at appropriate intervals. The upper and lower edges of the inorganic decorative plate 10 are sandwiched between the C-channel steel members 81 so as to be exchangeably fixed. However, the inorganic decorative plate may be directly screwed or bolted to the support.

The inorganic decorative panel 10 on the inner wall of the tunnel does not scatter fragments even if the traveling automobile is damaged by contact collision. Also, in the event of a fire in the tunnel,
Since it is difficult to burn, there is no danger of spreading the fire. Further, the surface of the decorative board is a decorative layer impregnated with a thermosetting resin, has excellent hardness and contamination properties, and has excellent cleaning recovery ability against wall surface contamination due to waste gas in the tunnel. This greatly reduces maintenance in the tunnel, such as reducing the brightness in the tunnel and reducing the time and effort required to clean the wall. In particular, when a melamine resin is used as the resin impregnated in the decorative layer, the above-mentioned effect becomes remarkable.

The decorative board similar to the inner wall of the tunnel is used as a sidewalk of an underground walkway or a subway and a wall material of the station building.

Furthermore, since this inorganic decorative panel is excellent in water resistance as well as heat resistance and impact resistance, it can be used in bathrooms in buildings,
It is also used as interior materials such as walls and ceilings in kitchens, toilets and other humid rooms.

[0041]

The inorganic decorative board of the present invention is characterized in that the inorganic base layer is made of an inorganic material having crystallization water, such as aluminum hydroxide, as a main aggregate to impart incombustibility and heat resistance to the decorative board, and the tough fiber layer is made of aramid Since it is fiber, polyimide fiber or carbon fiber, it gives impact resistance to the decorative board itself and prevents shards from scattering, so it can be used as a wall member having both non-combustibility and impact resistance, especially interior for tunnel There is an excellent use as a material.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view (A, B, C) and a partially cutaway perspective view (D) of an inorganic decorative board according to an embodiment of the present invention.

FIG. 2 is a schematic sectional view (A, B, C) of an inorganic decorative board according to another embodiment.

FIG. 3 is a cross-sectional view showing an arrangement of each member at the time of press-forming an inorganic decorative board.

FIG. 4 is a schematic view of a tunnel section showing the arrangement of an inorganic decorative board attached to the inner wall of the tunnel (A), and a partial cross section of the tunnel showing the procedure for attaching the inorganic decorative board.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Inorganic base material layer 10 Inorganic decorative board 2 Surface decorative layer 21 Non-combustible paper 3 Tough fiber layer 4 Adhesive layer 5 Backing layer 7 Press type 8 Prop 9 Tunnel

(Equation 1)

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Toshifumi Fukui 2-3-13 Azuchicho, Chuo-ku, Osaka City Inside Takiron Co., Ltd. (56) References JP-A-64-56539 (JP, A) JP-A Sho 59-114050 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (2)

(57) [Claims] 1. An inorganic base material layer obtained by mixing an inorganic material having crystallization water such as aluminum hydroxide powder as a main aggregate and a thermosetting resin as a binder, and a surface side of the inorganic base material layer. A surface decorative layer formed by impregnating a thermosetting resin into colored paper or cloth disposed on a surface, and a carbon-based or polyimide-based layer disposed on one or both of the front side and the back side of the inorganic base layer Or an aramid-based tough fiber layer integrally laminated by thermocompression bonding. 2. A backing layer formed by impregnating paper or cloth with a thermosetting resin is disposed on the back side of the inorganic base material layer.
2. The tough fiber layer is thermocompression bonded to the backing layer.
The inorganic decorative plate as described in the above.