JP4726401B2 - Manufacturing method of non-combustible decorative board - Google Patents

Description

[0001]
[Industrial application fields]
The present invention relates to a method for manufacturing a non-combustible decorative board.
[0002]
[Patent Document 1]
Japanese Patent Application Laid-Open No. 64-56540 [Patent Document 2]
Japanese Patent Laid-Open No. 03-208632 [Patent Document 3]
JP 2000-104366 A [Patent Document 4]
Japanese Patent Laid-Open No. 53-94578
[Prior art]
Conventionally, a decorative board imparted with fireproofing and nonflammability is known, and a prepreg in which an inorganic fiber nonwoven fabric is impregnated with a binder component and a slurry is used for a core layer, and a decorative layer and a surface layer as necessary And was hot-press molded under conditions of a temperature of 120 to 140 ° C. and a pressure of 60 to 70 kg / cm ² , and resin-impregnated decorative paper was used for the decorative layer.
[0004]
[Problems to be solved by the invention]
However, because of high-pressure molding, the decorative surface is not finished cleanly due to the influence of the inorganic fiber nonwoven fabric base, and even if you try to increase the thickness by increasing the number of prepregs laminated, the organic resin content increases and it is impossible to ensure nonflammability, the specific gravity There were problems such as high product weight.
[0005]
[Means for Solving the Problems]
The present invention has been studied in view of such a situation, and an object of the present invention is to obtain a decorative board having nonflammability and less warping, and is characterized by the following.
[0006]
That is, the invention described in claim 1 is a glass fiber nonwoven fabric in which a slurry comprising a phenol resin as an organic resin component, a melamine-formaldehyde resin, and aluminum hydroxide as an inorganic filler is represented by the formula 1. (%) is a core layer made of impregnated prepreg so that 3-50%, the coated paper was laminated with an adhesive material as the surface layer, the specific gravity after the heat molding is 1.4 to 1.8 Thus, the present invention provides a method for producing a non-combustible decorative board , which is hot- press molded under a pressure of 15 to 40 kg / cm ² .
The invention described in claim 2 is the method for manufacturing a non-combustible decorative board according to claim 1, characterized in that a balance paper is arranged on the back side.
Hereinafter, the present invention will be described in detail.
[0007]
Examples of the inorganic fiber base material used for the core layer of the incombustible decorative board of the present invention include non-woven fabrics and woven fabrics of inorganic fibers such as glass fiber, rock wool, and carbon fiber. The basis weight of the inorganic fiber base material is 10 The range of ˜200 g / m ² is preferable, and it is particularly preferable to use glass fibers that are excellent in heat resistance and flame resistance and excellent in impregnation of slurry.
[0008]
Specific examples of the organic resin component as the binder include phenol resins, amino-formaldehyde resins, urethane resins, and epoxy resins, and two or more of them may be used in combination.
[0009]
Phenol resins are obtained by reacting phenols and aldehydes at a ratio of 1 to 3 moles of aldehydes with 1 mole of phenolic hydroxyl group under a basic catalyst or an acidic catalyst. Phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, bisphenol F, and the like. Examples of aldehydes include formaldehyde, paraformaldehyde, glyoxal, and trioxal.
In addition, those modified with a modifying agent that promotes plasticization such as paratoluene sulfonamide, tung oil, phosphoric esters, glycols, etc. can be applied as necessary, and basic catalysts include alkali metals such as sodium and potassium, And oxides and hydroxides of alkaline earth metals such as magnesium and calcium, amines such as triethylamine and triethanolamine, and ammonia. Examples of acidic catalysts include paratoluenesulfonic acid and hydrochloric acid.
[0010]
Amino-formaldehyde resins include initial condensates obtained by reacting amino compounds such as melamine, urea, benzoguanamine and acetoguanamine with formaldehyde, etherification with lower alcohols such as methyl alcohol and butyl alcohol, and paratoluene. Those modified with a reactive modifier that promotes plasticization such as sulfonamide can be applied, and among them, a melamine-formaldehyde resin excellent in durability is preferable.
[0011]
Examples of the urethane resin include prepolymers, adducts, block isocyanates, and the like made from compounds having an isocyanate group such as tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate.
[0012]
Epoxy resins include bisphenol A type epoxy resins having at least two epoxy groups in one molecule, phenol novolac type epoxy resins having two or more epoxy groups in one molecule, orthocresol novolac type epoxy resins, bisphenols. Examples thereof include F-type epoxy resins, alicyclic epoxy resins, trifunctional or higher polyfunctional epoxy resins and brominated products thereof, and mixtures thereof, and ordinary epoxy resins used for laminates can be used.
[0013]
Examples of the inorganic filler include aluminum hydroxide, magnesium hydroxide, calcium carbonate, silica and the like. The basis weight of the inorganic fiber nonwoven fabric is preferably in the range of 10 to ²⁰⁰ g / m2.
Among inorganic fillers, those with an average particle size in the range of 0.5 to 200 μm can be impregnated into inorganic fiber nonwoven fabrics, and those containing crystal water such as aluminum hydroxide and magnesium hydroxide decompose at high temperatures. It is optimal in terms of nonflammability because it absorbs heat and binds water.
[0014]
The content of the organic resin component in the prepreg may be 3 to 50% according to the calculation method shown in Formula 1. If the upper limit is exceeded, the nonflammability becomes worse, and if the lower limit is exceeded, the strength and adhesion tend to be poor. .
[Formula 1]
[0015]
A prepreg based on an inorganic fiber is obtained by impregnating an inorganic fiber base material with a slurry comprising an organic resin component and an inorganic filler, and the inorganic fiber base material, the organic resin component, and the inorganic filler are the same as described above. It is not necessary to use the same type.
The slurry content (%) in the prepreg is calculated by the formula 2 and is preferably in the range of 500 to 3000%. If the upper limit is exceeded, the solid content will drop off and it will be difficult to handle. It becomes easy to do.
[Formula 2]
[0016]
An adhesive is interposed on at least one side of the core layer made of the prepreg in order to improve the adhesion to the coated paper described later.
The main component of the adhesive is 18-40 g / m ² of decorative paper surface paper and a thermosetting resin such as amino-formaldehyde resin, diallyl phthalate resin, unsaturated polyester resin, or a mixture thereof. Examples thereof include a resin-impregnated sheet obtained by impregnating and drying an impregnation rate of 80 to 300% represented by the formula 3 and a resin resin coated with a synthetic resin adhesive such as a vinyl acetate resin adhesive.
[Formula 3]
[0017]
On the adhesive coated paper is laminated as a facing layer. Coated paper is made by applying synthetic resin such as urethane resin, amino alkyd resin, acrylate resin, etc. to the surface of 40-80 g / m ² decorative paper. It may be hot-pressed using a press such as a press or a continuous press, but the pressure is lower than that for obtaining a normal decorative board so that the specific gravity is 1.4 to 1.8, specifically, molded in a range of 15~40 k g / cm ^2. If the specific gravity is less than the lower limit, insufficient strength or adhesiveness tends to be inferior. Moreover, when it exceeds an upper limit, nonflammability will become inferior easily.
[0018]
In addition, it is desirable to place a balance paper on the bottom layer to suppress warping due to curing shrinkage. As the balance paper, a similar resin-impregnated sheet or a synthetic resin adhesive such as vinyl acetate resin adhesive is applied to the paper. The thing which was done is mentioned.
[0019]
【Example】
Hereinafter, although an Example and a comparative example are given and demonstrated in detail, this invention is shown more concretely and is not specifically limited.
Example 1
A slurry in which 4 parts of melamine-formaldehyde resin and 91 parts of aluminum hydroxide are blended with 5 parts of phenol resin in a glass fiber nonwoven fabric of prepreg 50 g / m ^{2 so that} the solid content ratio shown in Formula 2 is 2000%. To obtain a prepreg.
A melamine resin-impregnated sheet was obtained by impregnating a surface paper having an adhesive sheet basis weight of 22 g / m ² with a melamine-formaldehyde resin so that the impregnation ratio represented by Formula 3 was 250%.
In order from the bottom of the non-combustible decorative board, 1 sheet of melamine resin impregnated sheet, 4 sheets of prepreg, 1 sheet of melamine resin impregnated sheet, 1 sheet of coated paper coated with 15 g / m ² of modified acrylate resin on 65 g / m ² printing paper It laminated | stacked and it hot-press-molded at 140 degreeC and 35 kg / cm < ² > for 60 minutes using the flat finish plate, and obtained the nonflammable decorative board of Example 1. FIG.
[0020]
Example 2
In order from the bottom, one sheet of 35 g / m ² paper coated with vinyl acetate resin and four prepregs similar to those in Example 1 are laminated, and the same coating as in Example 1 is applied via a vinyl acetate resin adhesive. One sheet of paper was laminated and hot-press molded at 140 ° C. and 35 kg / cm ² for 60 minutes using a flat finish plate to obtain a non-combustible decorative board of Example 2.
[0021]
Comparative Example 1 (when the molding pressure is less than the lower limit)
In Example 1, except that the molding pressure was 10 k g / cm ² is carried out analogously to obtain the decorative board of Comparative Example 1.
[0022]
Comparative Example 2 (when the molding pressure exceeds the upper limit)
In Example 1, except that the molding pressure was 70 k g / cm ² is carried out analogously to obtain the decorative board of Comparative Example 1.
[0023]
The evaluation results are shown in Table 1.
[Table 1]
[0024]
The test method was as follows.
Nonflammability: According to Article 4, Item 9 of the Building Standards Law, “4.9.2 Exothermic test and evaluation method”. (20-minute test with a cone calorimeter based on ISO 5660) Strength: A 500 g iron ball was dropped from above 20 cm of the sample.
Adhesiveness: Insert a crosscut into the decorative layer with a cutter knife to a depth that reaches the core layer, affix the cellophane tape, and peel off rapidly. X.
[0025]
【The invention's effect】
In the present invention, the inorganic fiber base material is impregnated with a slurry composed of an organic resin component and an inorganic filler and dried, and the coated paper is coated with a resin-impregnated surface paper, and the pressure is 15 to 40 kg / cm ^2. Low-pressure molding, layered integration, and specific gravity of 1.4-1.8 can provide a non-combustible cosmetic material with the desired molded product thickness, light weight, sufficient strength, and non-flammability. It was.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view illustrating a configuration of a non-combustible decorative board according to a first embodiment.
[Explanation of symbols]
2 Prepreg 3 Resin impregnated sheet 4 Coated paper 6 Non-combustible decorative board

Claims (2)

A glass fiber non-woven fabric is made of a slurry composed of a phenol resin as an organic resin , a melamine-formaldehyde resin, and aluminum hydroxide as an inorganic filler so that the content (%) represented by Formula 1 is 3 to 50%. a core layer made of impregnated prepreg, the coated paper was laminated with an adhesive material as the surface layer, as the specific gravity after the heat molding is 1.4 to 1.8, the pressure 15~40kg / cm ^A method for producing a non-combustible decorative board , which is hot-press molded under the condition of ² .
[Formula 1]
2. The method for producing a non-combustible decorative board according to claim 1, wherein balance paper is disposed on the back side.