JP3288296B2 - Cosmetic inorganic fiber interior material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a flame-retardant decorative inorganic fiber interior material used for ceiling materials and wall materials of buildings.

[0002]

2. Description of the Related Art Conventionally, a decorative inorganic fiber interior material composed of an inorganic fiber board such as glass wool and a decorative layer has a structure in which the inorganic fiber board has excellent sound absorbing properties, heat insulation properties and light weight, and the decorative layer has a decorative surface of the inorganic fiber board. It is widely used as an interior material for ceilings and walls of general houses, offices, shops, etc. because of its good properties.

In recent years, there has been an increasing demand for flame retardancy of interior materials, and in order to improve the flame retardancy of the surface of the inorganic fiber board, a decorative inorganic fiber interior material having a decorative layer based on glass cloth or glass fiber non-woven fabric has been proposed. Has been proposed. For example, Japanese Utility Model Publication No. 5-40161 discloses a decorative sheet (in the present invention, referred to as a decorative layer) in which an ink containing a large amount of a flame retardant and an extender pigment is printed on a glass fiber nonwoven fabric.
A decorative ceiling material bonded to glass wool via a flame-retardant adhesive is disclosed.

[0004]

However, in the above-mentioned prior art, when the pH of the decorative layer exceeds 7.5, the uncured or phenol-modified phenolic resin, which is a binder of the inorganic fiberboard, is made of an inorganic material. When remaining in the fiberboard, when the residue volatilizes and comes into contact with the decorative layer, or when the phenolic antioxidant of the adhesive comes into contact with the decorative layer, the residue and the antioxidant are There was a problem that color was formed on the decorative layer to deteriorate the hue of the decorative layer.

[0005] This is because even if the pattern and shape of the decorative layer are good, the design of the decorative inorganic fiber interior material is deteriorated, and the decorative layer is partially or entirely discolored with the passage of time. Therefore, there is a problem that the hue is deteriorated, the hue varies in the product, and the aesthetic appearance in the room is deteriorated when installed in the interior of the decorative inorganic fiber interior material room.

[0006] In particular, when a light-colored decorative layer such as white, which is generally widely used, is used, the hue-deteriorated portion is conspicuous, and the quality of the product is further reduced due to hue variation. It also reduced the aesthetics of the room.

Accordingly, an object of the present invention is to provide a decorative inorganic fiber interior material capable of maintaining high flame retardancy when applied to a building and ensuring high design stability over a long period of time. .

[0008]

Means for Solving the Problems In order to achieve the above object, the present invention relates to a decorative inorganic fiber interior material in which a decorative layer comprising a glass fiber nonwoven fabric and a decorative coating material is formed on the surface of an inorganic fiber plate. And a decorative inorganic fiber interior material, wherein the decorative layer has a pH of 7.5 or less.

According to the present invention, by controlling the pH of the decorative layer to 7.5 or less, the uncured phenol resin, the phenol-modified residue, and the phenol-based binder, Since the coloring of the antioxidant caused by contact with the decorative layer can be effectively prevented, it is possible to obtain a decorative inorganic interior material having a long-term stable high design without causing hue deterioration due to coloring.

In a preferred embodiment of the present invention, the decorative coating material contains at least one selected from clay, kaolin, and titanium oxide. By using the inorganic pigment as described above, the pH of the decorative layer can be easily adjusted to 7.5 or less.

Further, it is preferable that the decorative coating material contains at least one selected from ammonium polyphosphate and antimony trioxide. By incorporating these acidic additives, the pH can be adjusted to 7.5 or less even when calcium carbonate is added as an inorganic pigment and aluminum hydroxide is added as a flame retardant. In addition, ammonium polyphosphate and antimony trioxide also contribute to maintaining the flame retardancy of the decorative layer.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION The decorative inorganic fiber interior material of the present invention comprises an inorganic fiber board and a decorative layer, and the decorative layer is one of the paper and paperboard pH test methods specified in JIS P8133. Measurement by cold water extraction method (hereinafter, p
H is based on this measuring method), and is characterized by a pH of 7.5 or less.

In the present invention, the inorganic fiber board is obtained by heating and pressing inorganic fibers such as glass wool and rock wool using a binder such as a phenol resin.

The density of the inorganic fiberboard is usually 32
~ 150 kg / m ³ is preferable, and more preferably 40 ~
It is 120 kg / m ³ . If the density is less than 32 kg / m ³ , the rigidity of the inorganic fiberboard becomes insufficient, and
If it exceeds 50 kg / m ³ , the cost is undesirably increased.

Further, the thickness of the inorganic fiberboard is 10 to 10
0 mm is preferred, and more preferably 20 to 50 mm. If the thickness is less than 10 mm, the rigidity of the interior material becomes insufficient, causing deflection or swelling after construction, and the thickness is 100 m.
If it exceeds m, the cost increases and it is economically disadvantageous.

In the present invention, the decorative layer is a decorative layer having a pH of 7.5 or less composed of an inexpensive glass fiber nonwoven fabric for improving the design and a decorative coating material for improving the design and flame retardancy. In addition to having flammability, the design property of the surface of the decorative inorganic fiber interior material is ensured for a long time.

The glass fiber non-woven fabric is obtained by a usual paper making method or the like.
150 g / m ² is preferred, and more preferably 40 to 11
0 g / m ² . If the basis weight is less than 25 g / m ² , the handleability at the time of work is deteriorated due to insufficient strength of the glass fiber non-woven fabric, and if the basis weight exceeds 150 g / m ² , the cost is increased and it is economically disadvantageous.

Further, the glass fiber nonwoven fabric may be subjected to a hiding treatment in order to hide the hue of the inorganic fiber plate. The glass fiber nonwoven fabric subjected to the concealment treatment may be used in a papermaking process or in another process, in a resin binder such as an acrylic resin emulsion, a vinyl acetate resin emulsion, or a vinyl chloride resin emulsion, preferably clay, kaolin, titanium oxide, or the like. A mixed liquid containing an inorganic material, a processing stabilizing aid, a flame retardant, and the like is coated on a glass fiber nonwoven fabric and dried. At this time, the content of the organic substance in the glass fiber nonwoven fabric subjected to the concealment treatment after drying is preferably 20% by weight or less in order to improve the flame retardancy of the decorative layer.

When the concealment treatment is performed, the pH of the nonwoven glass fiber nonwoven fabric is set to 7.7 in advance in consideration of the fact that the pH of the decorative layer is finally reduced to 7.5 or less.
The treatment is preferably performed so as to be 5 or less, more preferably the pH is controlled to be 7.0 or less. For this reason, it is preferable to use clay, kaolin, titanium oxide or the like as the inorganic material for the concealing process.

The decorative coating material of the present invention comprises a blend of a resin, an inorganic pigment, an organic pigment, a viscosity modifier and the like, and further blends a foaming agent within a range that does not affect the flame retardancy or the pH of the decorative layer. This is preferable because a three-dimensional effect can be imparted and the design can be further improved.

Here, the resin is mainly used to permanently maintain the strength of the decorative layer. Examples of such a resin include vinyl acetate resin, acrylic resin, vinyl chloride resin, and the like. Coalescence, the cosmetic coating material,
This resin is used as an emulsion, an aqueous solution or a solvent. Among them, it is preferable to use an emulsion system from the viewpoint of handling properties and working environment.

The content of the resin in the decorative coating material is as follows:
It is preferably from 5 to 30% by weight, more preferably from 10 to 20% by weight, of the solid content of the decorative coating material. When the content is less than 5% by weight, the film strength as a decorative coating film is weak, and when the content is more than 30% by weight, the flame retardancy is inferior.

The inorganic pigment is mainly used as a pigment which is generally widely used and effective for obtaining a light-colored decorative layer such as white color. The inorganic pigment is used not only for coloring the decorative layer, but also for adjusting the pH of the decorative layer to 7.5 or less or imparting flame retardancy. Examples of such an inorganic pigment include clay, kaolin, titanium oxide, calcium carbonate, silica, and alumina.
In order to make the decorative layer neutral or acidic, it is preferable to use at least one selected from clay, kaolin, and titanium oxide. It is preferable that the inorganic pigment composed of clay, kaolin and titanium oxide is contained in an amount of 60 to 95% of the applied amount of the decorative coating material described later after drying. Thereby, the pH of the decorative layer is 7.
It is not more than 5 and maintains a stable pH.

Furthermore, the decorative coating material of the present invention preferably contains an acidic additive in addition to the inorganic pigment described above. The acidic additive has a relatively high acidity, and is added to the decorative layer to neutralize the inorganic pigment contained in the decorative layer and more effectively adjust the pH to 7.5 or less. Things. For example, even when the cosmetic layer contains an alkaline pigment such as calcium carbonate which is widely used as an inorganic pigment or aluminum hydroxide which is widely used as a flame retardant, the pH is 7.5. It can be: Examples of such acidic additives include hydrated silicates, guanidine polyphosphate, ammonium polyphosphate, antimony trioxide, antimony pentoxide, and the like. Among them, in order to maintain the flame retardancy of the decorative layer, , Especially for the makeup layer,
It is preferable that at least one acidic additive of ammonium polyphosphate and antimony trioxide is contained. These acidic additives are economically disadvantageous if the content is large because of their high price, but the content of the acidic additive is sufficiently described below even if the content is small, so that the content will be described later. 3.0 with respect to the applied amount of the cosmetic coating material after drying
% By weight or less, more preferably 0.1% by weight or less.
2 to 1.0% by weight.

[0025] The decorative inorganic fiber interior material of the present invention is capable of bonding a glass fiber non-woven fabric to an inorganic fiber plate even if a decorative coating material is applied to the glass fiber non-woven fabric to form a decorative layer before bonding to the inorganic fiber plate. After that, a decorative coating material may be applied to form a decorative layer.

In the former case, it can be obtained by patterning or coating a decorative coating material on a glass fiber nonwoven fabric by a known printing method, and drying it if necessary. As a known printing method, silk screen printing is optimal, and in addition, gravure printing, gravure offset printing, intaglio printing, and the like can be adopted.

In the latter case, it is obtained by laminating a glass fiber nonwoven fabric on an inorganic fiber plate, applying a decorative coating material by a known method such as spraying or a roll coater, and drying as necessary.

The applied amount of the decorative coating material is preferably 50 to 350 g / m ² in terms of the weight after drying. If the weight after drying is 50 g / m ² or less, a sufficient design cannot be obtained as a decorative layer, and if it exceeds 350 g / m ² , it is not preferable because it is disadvantageous in terms of flame retardancy and economy.

In order to bond the inorganic fiber plate to the glass fiber nonwoven fabric or the decorative glass fiber nonwoven fabric, an emulsion adhesive, a solvent adhesive, a hot melt adhesive or the like can be used. From the viewpoint, it is preferable to use an adhesive having higher flame retardancy, such as a solution-type chloroprene rubber adhesive and a hot-melt adhesive containing a flame retardant.

The decorative inorganic fiber interior material thus obtained is, for example, as shown in FIG. 1, a glass fiber nonwoven fabric 3 adhered to the surface of an inorganic fiber plate 1 via an adhesive 2, and further on the glass fiber nonwoven fabric 3. The decorative coating material 4 is applied, and the decorative layer 5 is formed by the glass fiber nonwoven fabric 3 and the decorative coating material 4.

[0031]

Example 1 A mixed solution of an acrylic resin emulsion and a clay was coated on a glass fiber nonwoven fabric (organic content: 12%, basis weight: 50 g / m ² ) obtained by a papermaking method, followed by drying and concealment treatment. Glass fiber nonwoven fabric (basis weight 110g /
m ² , organic matter content 15% by weight). Subsequently, a vinyl acetate resin emulsion, clay, and a viscosity modifier are blended,
A decorative coating material having a viscosity of 2,000 centipoise and a solid content of 70% by weight (resin content: 15% by weight) was coated on the concealed glass fiber nonwoven fabric by a screen printing method to apply the decorative coating material in dry weight. After pattern printing to 230 g / m ² , drying treatment was carried out to adjust the pH to 7.0.
Thus, No. 1 decorative layer was obtained.

The obtained decorative layer was bonded to glass wool having a density of 40 kg / m ³ and a thickness of 25 mm via a flame-retardant rubber-based adhesive to obtain a decorative inorganic fiber interior material.

Example 2 A glass fiber nonwoven fabric concealed in the same manner as in Example 1 was prepared, and a vinyl acetate resin emulsion, calcium carbonate,
A viscosity adjuster and ammonium polyphosphate are blended, the viscosity is 2,000 centipoise, the solid content is 70% (resin content is 1
The decorative layer adjusted to 5% by weight is patterned and printed on the concealed glass fiber nonwoven fabric by a screen printing method so that the applied amount of the decorative coating material is 230 g / m ² in dry weight, and then dried. Thus, a decorative layer having a pH of 7.2 was obtained.
Thereafter, it was bonded to glass wool in the same manner as in Example 1 to obtain a decorative inorganic fiber interior material.

Example 3 Glass wool having a density of 80 kg / m ³ and a thickness of 25 mm was
Glass fiber nonwoven fabric (organic content 12%, basis weight 50g /
m ² ) together with a phenolic resin adhesive,
Subsequently, a vinyl acetate emulsion, calcium carbonate, a viscosity modifier, and ammonium polyphosphate were blended, and a viscosity of 150
A cosmetic coating material adjusted to 0 centipoise and a solid content of 65% (resin content 15% by weight) is applied in a dry weight of 300
g / m ² was spray-coated on the glass fiber nonwoven fabric, and then dried to obtain a decorative inorganic fiber interior material having a decorative layer having a pH of 7.0.

Comparative Example 1 A glass fiber nonwoven fabric concealed in the same manner as in Example 1
A decorative coating material prepared by blending a vinyl acetate resin, calcium carbonate, and a viscosity modifier and adjusting the viscosity to 2,000 centipoise and the solid content to 70% (resin content: 15% by weight) was patterned and printed in the same manner as in Example 1. After drying, pH8.
0 was obtained. Thereafter, it was bonded to glass wool in the same manner as in Example 1 to obtain a decorative inorganic fiber interior material.

Comparative Example 2 A glass fiber nonwoven fabric obtained by a papermaking method (with a basis weight of 50 g /
m ² organic matter content, 12%) was coated with a mixture of an acrylic resin emulsion and aluminum hydroxide, then dried and concealed to obtain a glass fiber nonwoven fabric (having a basis weight of 1).
10 g / m ² , organic matter content 15% by weight). Subsequently, pattern printing was performed on the concealed glass fiber nonwoven fabric in the same manner as in Comparative Example 1 to obtain a decorative layer having a pH of 9.0. Thereafter, it was bonded to glass wool in the same manner as in Example 1 to obtain a decorative inorganic fiber interior material.

Test Example 1 The decorative layer was peeled off from the decorative inorganic fiber interior materials obtained in Examples and Comparative Examples, and the pH of the decorative layer was measured.

Test Example 2 The decorative inorganic fiber interior materials obtained in Examples and Comparative Examples were obtained after 90 days at room temperature, and at a temperature of 6
Leave for 24 hours (hr) in an environment of 0 ° C. and 90% humidity,
After returning to room temperature for 60 days, the discoloration state of the surface was measured with a colorimeter.
0.5 or more to less than 1.0 was rated as Δ, and 1.0 or more was rated as ×.
Note that ΔE indicates the difference between the lightness (L) and the chromaticity (a, b) between the standard material and the measurement material, and the lightness and chromaticity of the standard material are L0, a0, and b0, respectively. , And the lightness and chromaticity of the measurement material are L1, a1, and b1, respectively, and are obtained by the square root of the following equation.

[0039]

[Number 1] ^{(L1-L0) 2 + (} a1-a0) 2 + (b1
−b0) ²

[0040]

[Table 1] From the above results, the interior materials of the examples in which the pH of the decorative layer composed of the glass fiber nonwoven fabric and the decorative coating material is 7.5 or less, have a stable design without discoloration of the surface over time.

On the other hand, the interior materials of Comparative Examples in which the pH of the decorative layer was higher than 7.5 had discoloration on the surface over time,
It can be seen that the design is adversely affected.

[0042]

As described above, according to the present invention,
Since the decorative inorganic fiber interior material has a decorative layer having a pH of 7.5 or less based on a glass fiber nonwoven fabric on the surface of the inorganic fiber plate, the phenol resin residue in the inorganic fiber plate and the antioxidant in the adhesive are used. Has a decorative layer that is not affected by hue deterioration without coloring even if they adhere to the decorative layer,
Since a decorative inorganic fiber interior material capable of maintaining a stable high design property over a long period of time can be obtained, the interior aesthetics will not be impaired even when constructed on a building.

Further, the decorative inorganic fiber interior material is made of a decorative layer containing a glass fiber nonwoven fabric and a flame retardant, and thus has high flame retardancy.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of a decorative inorganic fiber interior material according to the present invention.

[Explanation of symbols]

 1: Inorganic fiberboard 2: Adhesive 3: Glass fiber nonwoven fabric 4: Decorative coating material 5: Decorative layer

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-63-154342 (JP, A) JP-A-6-88045 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) C04B 32/02 E04B 1/94 C04B 41/62

Claims (3)

(57) [Claims] 1. A decorative inorganic fiber interior material in which a decorative layer comprising a glass fiber nonwoven fabric and a decorative coating material is formed on the surface of an inorganic fiber plate, wherein the decorative layer has a pH of 7.5 or less. Cosmetic inorganic fiber interior material. 2. The decorative coating material according to claim 1, wherein said decorative coating material contains at least one selected from clay, kaolin and titanium oxide.
A decorative inorganic fiber interior material as described in the above. 3. The decorative inorganic fiber interior material according to claim 1, wherein the decorative coating material contains at least one selected from ammonium polyphosphate and antimony trioxide.