JP6476993B2 - Incombustible decorative board - Google Patents

Description

  The present invention relates to a decorative board used for interiors of buildings, various furniture, fittings, ceilings, or interior materials in the vicinity of a bathroom or kitchen, etc., and has design characteristics and various surface resistances while having non-combustibility. It relates to a non-combustible decorative board provided with

In recent years, there has been an increasing demand for nonflammability for decorative panels used for interiors of houses such as walls and ceilings of buildings in order to ensure safety when a fire or the like occurs. As a decorative board having such noncombustibility, a decorative board in which a paper-based sheet on which a pattern is formed is laminated on a noncombustible base material and a transparent resin paint is applied or impregnated thereon, or a noncombustible base A decorative board is known in which a synthetic resin base material layer on which a pattern and a surface protective layer are formed is laminated on a material.
Moreover, as a decorative sheet affixed on a base material, there exists a decorative sheet as described in Patent Document 1, for example. When this decorative sheet is used, a decorative board excellent in design can be provided.

  Conventionally, a decorative sheet with physical irregularities, such as a surface layer of a decorative resin base layer made of a synthetic resin base layer, with concave portions provided by embossing, or a convex portion provided with raised printing, has been laminated. A decorative board is known. However, the embossing method has a limit on the depth of the recesses, and in the case of build-up printing, the surface is inferior in various resistances such as stain resistance, and is excellent in various resistances such as surface contamination resistance, and unevenness synchronized with the pattern on the surface. It was not possible to obtain a non-combustible decorative board excellent in design and touch feeling.

JP2013-123863A

  The present invention has been made paying attention to the above-mentioned problems, is excellent in various resistances such as surface contamination resistance, and has non-combustibility excellent in design and touch feeling having unevenness in synchronism with the pattern on the surface. It aims to provide a non-combustible decorative board.

  In order to solve the problem, one aspect of the present invention is a non-combustible decorative board in which a decorative sheet is provided on the surface of a non-combustible base material, and the decorative sheet includes at least a pattern layer on a synthetic resin base material layer. A transparent gloss adjusting layer is formed in this order, and a convex portion made of an ionizing radiation curable resin is formed on the surface of the transparent gloss adjusting layer in synchronization with the pattern of the pattern pattern layer. The thickness of the material layer is 40 μm or more and 80 μm or less, the height of the projection is 5 μm or more and 60 μm or less, and the area occupied by the pattern to be synchronized is 5% or more and 80% or less. 20 mass parts or more and 30 mass parts or less of granular particles with a particle size of 3 micrometers or more and 10 micrometers or less are contained with respect to 100 mass parts of curable resin.

  According to the present invention, by specifying the configuration of the decorative sheet as described above, it has non-flammability and is excellent in various resistances such as surface contamination resistance, and has a surface with unevenness synchronized with the pattern. It is possible to provide a non-combustible decorative board that is excellent in properties and touch. That is, according to the present invention, it is possible to provide a non-combustible decorative board that has both design properties, various surface resistances, and non-combustibility.

It is sectional drawing for demonstrating the nonflammable decorative board which concerns on embodiment based on this invention.

Hereinafter, embodiments according to the present invention will be described with reference to the drawings.
Here, the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiment described below exemplifies a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention is that the material, shape, structure, etc. of the component parts are as follows. It is not something specific. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

As shown in FIG. 1, the incombustible decorative board of the present embodiment is configured by providing a decorative sheet on the surface of the incombustible base material 7. The decorative sheet has at least a pattern layer 2 and a transparent gloss adjusting layer 3 formed in this order on a synthetic resin base material layer 1 made of a polyester-based resin and the like. Convex portions 4 made of ionizing radiation curable resin are formed in synchronism with the pattern of the pattern layer 2.
Furthermore, it is preferable to provide a transparent antifouling resin layer 5 having a layer thickness of 0.5 μm or more and 1.5 μm or less in a region other than the region where the convex portion 4 is formed on the surface of the transparent gloss adjusting layer 3.
Moreover, it is preferable to provide the moisture-proof sheet layer (not shown) which consists of an inorganic oxide vapor deposition film etc. in the back surface of the nonflammable base material 7.

(Non-combustible substrate 7)
The nonflammable substrate 7 is made of an inorganic substrate, for example. What is necessary is just to use a well-known thing for the inorganic type base material according to a use. Examples of the incombustible base material 7 include calcium silicate board, rock wool, volcanic glassy multilayer board (conforming to JIS A5440 “incombustible volcanic glassy multilayer board”), asbestos slate board, plaster board, gypsum board. Examples thereof include gypsum board base materials such as die light and tiger glass rock [Yoshino Gypsum Co., Ltd .: trade name], and plates such as cement, ceramics, glass, and metal. The thickness is usually 2 to 15 mm, although it depends on the material, and is preferably 2 mm or more and 9 mm or less from the viewpoint of exothermic property and handling property. In addition, these inorganic base materials may be subjected to surface treatment such as sealer coating or sanding in order to enhance adhesion with other layers.

(Decorative sheet)
<Synthetic resin base material layer 1>
As the synthetic resin base material layer 1, a conventionally known material can be used as long as the pattern layer 2 can be provided by printing or the like and has processability as a decorative sheet.
The synthetic resin substrate layer 1 is preferably a polyester resin sheet, a polyolefin resin sheet, or the like. In particular, from the viewpoint of providing incombustibility, it is more preferable to use a polyester resin sheet having a low calorific value during combustion.
Various additives such as conventionally known fillers, foaming agents, flame retardants, lubricants, antioxidants, ultraviolet absorbers, light stabilizers, and the like are added to the synthetic resin base layer 1 according to conventional methods as necessary. be able to. The thickness of the synthetic resin base material layer 1 is preferably about 40 to 100 μm, although it depends on the use and selection of materials, and more preferably 40 to 80 μm in consideration of the calorific value at the time of combustion.

<Pattern pattern layer 2>
The pattern pattern layer 2 is provided for imparting design properties by a pattern to the incombustible decorative board. The pattern layer 2 uses a printing ink or paint obtained by dissolving or dispersing a colorant such as a dye or a pigment together with an appropriate binder resin in an appropriate diluent solvent, for example, a gravure printing method or an offset printing method. And various coating methods such as a gravure coating method or a roll coating method.
As the binder resin, for example, urethane resin, acrylic resin, vinyl chloroacetate resin, polyimide resin, nitrified cotton, or a mixture thereof is often used, but it is not limited thereto. The type of the pattern is arbitrary as desired, for example, a wood grain pattern, a stone pattern, a cloth pattern, an abstract pattern, a geometric pattern, a character or a symbol, a combination thereof, etc., and may be a solid color.
In order to improve the concealing property of the decorative sheet, a concealing layer made of an opaque printing ink or paint containing a large amount of an opaque pigment such as titanium dioxide or iron oxide may be provided on the back side of the pattern layer 2.

<Transparent gloss adjustment layer 3>
The transparent gloss adjusting layer 3 is for adjusting the gloss of the surface. The transparent gloss adjusting layer 3 is a resin component (binder resin) from the viewpoint of versatility of adhesion to various transparent thermoplastic resin layers, deformation followability when bending a decorative sheet into a conduit groove, and scratch resistance. ) And select a two-component curable urethane resin, and apply a composition to which a gloss adjusting agent (also called matting agent or matting agent) is added or not added depending on the desired gloss. can get.
When making the surface highly glossy, no gloss adjusting agent is added. In addition, when the glossiness is low, a gloss adjusting agent is added. Examples of the gloss adjusting agent include inorganic substances such as silica, alumina (α-alumina, etc.), calcium carbonate, barium sulfate, kaolinite, aluminosilicate, and organic (resin) fine particles such as polycarbonate, nylon, and urethane resin.
The average particle size of the gloss adjusting agent is preferably about 1 to 10 μm, and the addition amount is appropriately selected according to the desired gloss, but is usually about 30% by mass at maximum.

The two-component curable urethane resin is a urethane resin mainly composed of polyol and isocyanate as a crosslinking agent (curing agent). As the polyol, one having two or more hydroxyl groups in the molecule, for example, polyethylene glycol, polypropylene glycol, acrylic polyol, polyester polyol, polyether polyol, polycarbonate polyol, polyurethane polyol and the like are used. As the isocyanate, a polyvalent isocyanate having two or more isocyanate groups in the molecule is used. For example, aromatic isocyanates such as 2,4-tolylene diisocyanate, xylene diisocyanate, 4,4'-diphenylmethane diisocyanate, or 1,6-hexamethylene diisocyanate, isophorone diisocyanate, hydrogenated tolylene diisocyanate, hydrogenated diphenylmethane diisocyanate, etc. Aliphatic (or alicyclic) isocyanates are used. Alternatively, adducts or multimers of the above various isocyanates can be used. For example, there are tolylene diisocyanate adducts, tolylene diisocyanate trimers, and the like. Of the above-mentioned isocyanates, aliphatic (or alicyclic) isocyanates are preferred in that they can be well weathered and heat-resistant yellowed. Specifically, for example, 1,6-hexamethylene diisocyanate can be used.
It is preferable from a design point of view that the glossiness of the mat portion is about 3 to 5 in terms of the reflection gloss coefficient by adding the above glossiness adjusting agents.

<Convex part 4>
The convex part 4 is comprised from ionizing radiation curable resin. The convex portion 4 has a height of 5 μm or more and 60 μm or less, and the area occupied by the pattern to be synchronized is defined as 5% or more and 80% or less.
The convex part 4 contains 20 mass parts or more and 30 mass parts or less of granular particles having a particle diameter of 3 μm or more and 10 μm or less with respect to 100 mass parts of the ionizing radiation curable resin.
Ionizing radiation curable resins include those having energy quanta capable of crosslinking and polymerizing molecules in electromagnetic waves or charged particle beams, that is, resin compositions that are crosslinked and cured by irradiation with ultraviolet rays or electron beams. Point to. Specifically, it can be appropriately selected from polymerizable monomers and polymerizable oligomers or prepolymers conventionally used as ionizing radiation or ultraviolet curable resin compositions.

  Typically, a (meth) acrylate monomer having a radical polymerizable unsaturated group in the molecule is suitable as the polymerizable monomer, and among them, a polyfunctional (meth) acrylate is preferable. Here, “(meth) acrylate” means “acrylate or methacrylate”. The polyfunctional (meth) acrylate is not particularly limited as long as it is a (meth) acrylate having two or more ethylenically unsaturated bonds in the molecule. Specifically, ethylene glycol di (meth) acrylate, propylene glycol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol di (meta) ) Acrylate, polyethylene glycol di (meth) acrylate, hydroxypivalate neopentyl glycol di (meth) acrylate, dicyclopentanyl di (meth) acrylate, caprolactone modified dicyclopentenyl di (meth) acrylate, ethylene oxide modified diphosphate ( (Meth) acrylate, allylated cyclohexyl di (meth) acrylate, isocyanurate di (meth) acrylate, trimethylolpropane tri (meth) acrylate, ethylene oxide modified trimethylo Propane tri (meth) acrylate, dipentaerythritol tri (meth) acrylate, propionic acid modified dipentaerythritol tri (meth) acrylate, pentaerythritol tri (meth) acrylate, propylene oxide modified trimethylolpropane tri (meth) acrylate, tris ( Acryloxyethyl) isocyanurate, propionic acid modified dipentaerythritol penta (meth) acrylate, dipentaerythritol hexa (meth) acrylate, ethylene oxide modified dipentaerythritol hexa (meth) acrylate, caprolactone modified dipentaerythritol hexa (meth) acrylate, etc. Is mentioned. These polyfunctional (meth) acrylates may be used singly or in combination of two or more.

  In the present embodiment, together with the polyfunctional (meth) acrylate, a monofunctional (meth) acrylate can be appropriately used in combination as long as the object of the present invention is not impaired for the purpose of reducing the viscosity. . Examples of monofunctional (meth) acrylates include methyl (meth) acrylate, ethyl (meth) acrylate, propyl (meth) acrylate, butyl (meth) acrylate, pentyl (meth) acrylate, hexyl (meth) acrylate, cyclohexyl ( Examples include meth) acrylate, 2-ethylhexyl (meth) acrylate, lauryl (meth) acrylate, stearyl (meth) acrylate, and isobornyl (meth) acrylate. These monofunctional (meth) acrylates may be used alone or in combination of two or more.

  Next, as the polymerizable oligomer, an oligomer having a radical polymerizable unsaturated group in the molecule, for example, epoxy (meth) acrylate, urethane (meth) acrylate, polyester (meth) acrylate, polyether (meth) acrylate The system etc. are mentioned. Here, the epoxy (meth) acrylate oligomer can be obtained, for example, by reacting (meth) acrylic acid with an oxirane ring of a relatively low molecular weight bisphenol type epoxy resin or novolak type epoxy resin and esterifying it. . Further, a carboxyl-modified epoxy (meth) acrylate oligomer obtained by partially modifying this epoxy (meth) acrylate oligomer with a dibasic carboxylic acid anhydride can also be used. The urethane (meth) acrylate oligomer can be obtained, for example, by esterifying a polyurethane oligomer obtained by reaction of polyether polyol or polyester polyol and polyisocyanate with (meth) acrylic acid. Examples of polyester (meth) acrylate oligomers include esterification of hydroxyl groups of polyester oligomers having hydroxyl groups at both ends obtained by condensation of polycarboxylic acid and polyhydric alcohol with (meth) acrylic acid, It can be obtained by esterifying the terminal hydroxyl group of an oligomer obtained by adding an alkylene oxide to a carboxylic acid with (meth) acrylic acid. The polyether (meth) acrylate oligomer can be obtained by esterifying the hydroxyl group of the polyether polyol with (meth) acrylic acid.

  Furthermore, other polymerizable oligomers include polybutadiene (meth) acrylate oligomers with high hydrophobicity that have (meth) acrylate groups in the side chain of polybutadiene oligomers, and silicone (meth) acrylate oligomers that have polysiloxane bonds in the main chain. In a molecule such as an aminoplast resin (meth) acrylate oligomer modified with an aminoplast resin having many reactive groups in a small molecule, or a novolak epoxy resin, bisphenol epoxy resin, aliphatic vinyl ether, aromatic vinyl ether, etc. There are oligomers having a cationic polymerizable functional group.

The granular particles contained in the convex portion 4 are not particularly limited, and may be an organic type such as a resin or an inorganic type such as glass or silica. In particular, spherical spherical beads are preferred from the viewpoints of touch and stain resistance.
When the content of the granular particles is less than 20 parts by mass, the feeling of touch is not felt so much, and when the content is more than 30 parts by mass, the stain resistance tends to deteriorate.
On the other hand, when the particle size is smaller than 3 μm, the feeling of touch is hardly felt, and when it is larger than 10 μm, the stain resistance tends to be deteriorated.

Moreover, various additives can be mix | blended with the convex part 4 according to a desired physical property. Examples of this additive include a weather resistance improver, an abrasion resistance improver, a polymerization inhibitor, a crosslinking agent, an infrared absorber, an antistatic agent, an adhesion improver, a leveling agent, a thixotropic agent, a coupling agent, A plasticizer, an antifoamer, a filler, a solvent, a coloring agent, etc. are mentioned.
The shape of the convex portion 4 is not particularly limited, and may be a regular shape in which a pattern such as a circle, a rectangle, or a hexagon is regularly arranged in a plan view, or may be an irregular pattern. A regular pattern is preferable because it is excellent in touch, matte, gloss and design. Moreover, a real feeling is acquired by synchronizing the convex part 4 with the pattern pattern layer 2. FIG.

The convex part 4 preferably contains 10 to 50 parts by mass of a reactive silicone resin.
Examples of the reactive silicone resin include materials having a silicon skeleton in the main chain, silicone oil used for a mold release agent, etc., and in particular, the side chain has a silicon skeleton in terms of contamination resistance. UV effect acrylate resins are preferred.
If the content of the reactive silicone resin is less than 10 parts by mass, the stain resistance tends to deteriorate, and if it exceeds 50 parts by mass, problems such as poor adhesion to the substrate due to bleed out of silicon may occur. is there. Or if it is the same as resin used for the transparent stain-resistant resin layer 55 mentioned later, the surface will consist of the same resin, and will become preferable.

<Transparent antifouling resin layer 5>
The transparent stain-resistant resin layer 5 is appropriately provided in a region other than the region where the convex portions 4 are formed on the surface of the transparent gloss adjusting layer 3. The layer thickness of the transparent contamination-resistant resin layer 5 is preferably 0.5 μm or more and 1.5 μm or less. Although it does not specifically limit as resin used for the transparent stain-resistant resin layer 5, A block isocyanate hardening type urethane-type resin is used suitably. If the layer thickness is less than 0.5 μm, a sufficient anti-contamination effect cannot be obtained, and if the layer thickness is more than 1.5 μm, the three-dimensional effect and the design are impaired.
<Adhesive layer 6>
The adhesive layer 6 that bonds the non-flammable substrate 7 and the decorative sheet is not particularly limited as long as it improves the adhesion between the non-flammable substrate 7 and the decorative sheet, and is applicable. Specifically, an adhesive such as urethane resin, acrylic resin, or ethylene vinyl acetate copolymer resin is preferably used.

<Dampproof sheet>
The moisture-proof sheet is not particularly limited, but a moisture-proof sheet having a moisture permeability of 20 g / m ² · 24 hr or less, preferably 7 g / m ² · 24 hr or less is used, and the paper layer is sandwiched with polyolefin resin. Examples include the sheets that have been visited. Moreover, an inorganic oxide vapor deposition film having a lower moisture permeability is more preferably used.
Although the inorganic oxide vapor deposition film which comprises a moisture-proof sheet is not specifically limited, Biaxially-stretched polyethylene terephthalate is used suitably. The thickness may be about 10 to 100 μm in consideration of winding workability, printing suitability, and the like.

The inorganic oxide vapor-deposited film is a film made of an inorganic oxide such as aluminum oxide, silicon oxide, tin oxide, magnesium oxide, or a mixture thereof, and may be any film having moisture resistance. Among these, it is more preferable to use aluminum oxide and silicon oxide in view of resistance in a high temperature and high humidity environment. However, the inorganic oxide film of this embodiment is not limited to the inorganic oxide described above, and any material that meets the above conditions can be used.
Moreover, the composition which added the inorganic oxide represented by silicon oxide, magnesium oxide, and aluminum oxide to polyvinyl alcohol or polyvinyl alcohol may be coated on an inorganic oxide vapor deposition film.

  The non-combustible decorative board as described above has a non-flammable surface, and by limiting the configuration of the decorative sheet as described above, it has various resistances such as surface contamination resistance and has unevenness synchronized with the pattern on the surface. It is possible to provide a non-combustible decorative board excellent in design and touch feeling.

Next, examples according to the present invention will be described.
<Example 1>
A polybutylene terephthalate film having a thickness of 60 μm was used as the synthetic resin substrate layer 1 of the decorative sheet, and a woodgrain pattern was gravure-printed thereon with a urethane resin ink as the pattern layer 2 thereon.
After drying, silica powder is added to the surface as a transparent gloss adjusting layer 3 to adjust the gloss to a low level, and an ultraviolet curable resin containing 20 parts by mass of a reactive silicone resin and an appropriate amount of an ultraviolet initiator is applied after drying. The coating was performed so that the amount was 6 g / m ² . The reflection gloss coefficient was 4.

After the crosslinking and curing of the transparent gloss adjusting layer 3, a blocked isocyanate-curable urethane resin was applied as the transparent contamination-resistant resin layer 5 so that the coating amount after drying was 1 g / m ² .
After drying, the convex part 4 made of ionizing radiation-curing resin is provided by raised printing so that the convex part 4 has a height of 40 μm on a printing plate (pattern area 53%) synchronized with the pattern of the pattern layer 2 , Got a decorative sheet. The ink for forming the convex part 4 is an ink obtained by adding 30 parts by mass of urethane beads having a particle diameter of 5 μm and 20 parts by mass of a reactive silicone additive to 100 parts by mass of an ultraviolet curable resin.

Next, this decorative sheet and a nonflammable base material 7 in which an aluminum foil / thin paper was laminated on a volcanic glassy multilayer board were bonded together via an ethylene vinyl acetate adhesive 15 g / m ^2, and Example 1 was completed. The incombustible decorative board was obtained.
<Example 2>
A non-combustible decorative board was obtained in the same manner as in Example 1 except that the amount of urethane beads having a particle size of 5 μm added to the convex portion 4 made of ionizing radiation curable resin was 20 parts by mass.
<Comparative example 1>
A non-combustible decorative board was obtained in the same manner as in Example 1 except that the amount of urethane beads having a particle size of 5 μm added to the convex portion 4 made of ionizing radiation curable resin was 5 parts by mass.
<Comparative example 2>
A noncombustible decorative board was obtained in the same manner as in Example 1 except that the amount of urethane beads having a particle diameter of 5 μm added to the convex portion 4 made of ionizing radiation curable resin was 40 parts by mass.

<Performance evaluation>
Blind evaluation was performed in order to evaluate touch feeling. As a comparison, a decorative sheet similar to Example 1 was used except that urethane beads were not contained, and whether or not a difference in touch feeling was felt in an invisible state was evaluated as ×.
In order to evaluate the stain resistance, a wiping test was conducted with oily marker black tissue paper. The case where it can be easily wiped off was indicated as “◯”, and the case where unwiping occurred was indicated as “X”.
The results are shown in Table 1.

<Combustion test>
About the incombustible decorative board created in Example 1, the combustion test was done using the cone calorimeter tester based on ISO5660-1. The results are as follows.
That is,
• The total amount of heat generated by the heating start after 20 minutes: 6.5MJ ^{/ m} 2.
・ Maximum heat generation rate for 20 minutes after the start of heating: 0 ^second , exceeding 200 kW / m ² .
-About the base material after the completion of the test for 20 minutes after the start of heating, there are no cracks or holes penetrating to the back surface.
It became.
Thus, the nonflammable decorative sheet based on this invention was obtained as a nonflammable decorative board having a performance capable of obtaining nonflammable certification.

  According to the present invention, it is possible to obtain a non-combustible decorative board having non-flammability and excellent various resistances such as surface contamination resistance, and having excellent design and touch feeling on the surface having unevenness synchronized with the pattern. . In particular, when it is used for a wood grain pattern, it can obtain the same texture as the material using actual wood, leading to reduction of environmental burden as an alternative to wood resources.

DESCRIPTION OF SYMBOLS 1 ... Synthetic resin base material layer 2 ... Pattern pattern layer 3 ... Transparent gloss adjustment layer 4 ... Convex part 5 ... Contamination-resistant resin layer 6 ... Adhesive layer 7 ... Nonflammable base material

Claims (5)

A non-combustible decorative board provided with a decorative sheet on the surface of a non-combustible base material,
In the decorative sheet, at least a pattern layer and a transparent gloss adjustment layer are formed in this order on the synthetic resin base material layer, and the surface of the transparent gloss adjustment layer is synchronized with the pattern pattern of the pattern layer. Protrusions made of ionizing radiation curable resin are formed,
The synthetic resin base material layer has a thickness of 40 μm or more and 80 μm or less,
The convex portion has a height of 5 μm or more and 60 μm or less, and an occupied area of the pattern to be synchronized is 5% or more and 80% or less,
The convex part contains 20 parts by mass or more and 30 parts by mass or less of granular particles having a particle size of 3 μm or more and 10 μm or less with respect to 100 parts by mass of the ionizing radiation curable resin ,
A non-combustible decorative board , wherein a moisture-proof sheet layer is provided on the surface of the non-combustible substrate opposite to the surface provided with the decorative sheet.   The non-combustible decorative board according to claim 1, wherein the convex part contains 10 to 50 parts by mass of a reactive silicone resin with respect to 100 parts by mass of the ionizing radiation curable resin.   The transparent contamination-resistant resin layer having a layer thickness of 0.5 µm or more and 1.5 µm or less is provided in a region other than the region where the convex portion is formed on the surface of the transparent gloss adjusting layer. The noncombustible decorative board described in 2.   The non-combustible decorative board according to any one of claims 1 to 3, wherein the synthetic resin base material layer is made of a polyester-based resin. The non-combustible decorative board according to any one of claims 1 to 4, wherein the moisture-proof sheet layer comprises an inorganic oxide vapor-deposited film.

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