JP6759559B2 - Non-combustible decorative board - Google Patents

Description

The present invention relates to a non-combustible decorative board suitable as a wall covering material for walls and ceilings.

Conventionally, a decorative board in which a paper-based or film-based sheet having a pattern formed on a base material is laminated and a transparent resin paint is applied or impregnated on the sheet, or a pattern and a surface protective layer are provided on the base material. A decorative board in which the formed synthetic resin base material layer is laminated is known. Examples of the decorative sheet to be attached to the base material include a decorative sheet having excellent design as described in Patent Document 1.
Here, in recent years, there has been an increasing demand for nonflammable decorative boards used for interiors of houses such as walls and ceilings of buildings in order to ensure safety in the event of a fire or the like. Standards for finishing materials on walls and ceilings such as evacuation routes such as living rooms, corridors, stairs, etc. in order to prevent the spread of fire in buildings such as residential, commercial facilities, station buildings, and public facilities such as airports. Is provided. For example, for finishing materials for walls and ceilings such as evacuation routes such as living rooms, corridors, and stairs, which are used for a certain scale and application, fireproof materials (non-combustible materials, semi-non-combustible materials, and flame-retardant materials) according to the required performance are used. ) Is required by law (Article 129 of the Enforcement Ordinance).

Japanese Unexamined Patent Publication No. 2008-08715

The present invention has been made focusing on the above-mentioned points, and an object of the present invention is to provide a nonflammable decorative board.

In order to solve the problem, in the non-combustible decorative board according to one aspect of the present invention, a sealer layer, an adhesive layer, and a decorative sheet are formed in this order on one surface of a base material, and the decorative sheet is a resin film. A printing ink layer and a surface protective layer are formed in this order on the surface opposite to the substrate, and a back primer layer is provided on the surface of the resin film on the substrate side, and the substrate is glass. It is characterized by being a gypsum plate mixed with fibers.

The nonflammability of the decorative plate of the present invention is based on the cone calorie combustion test based on ISO5660-1, and when the total calorific value with respect to time and the heat generation rate with respect to time of the noncombustible decorative plate are determined, (i) heating is started. The total calorific value for the next 20 minutes is 8 MJ / m ² or less, (ii) for 20 minutes after the start of heating, the maximum heat generation rate continues for 10 seconds or more and does not exceed 200 kW / m ² , and (iii) after the start of heating. It is nonflammable for 20 minutes, satisfying that there are no cracks or holes that penetrate to the back surface, which is harmful to fire protection.

According to one aspect of the present invention, the base material is a gypsum plate mixed with glass fibers, that is, a gypsum plate with glass fibers as a core material, so that the base material is mainly composed of an inorganic material. It is possible to give the decorative board a predetermined fire resistance and nonflammability, and even if a substrate having such nonflammability is used, a sealer layer is provided on the substrate to adhere the decorative sheet. The adhesion performance is improved.
Here, when the glass fiber non-woven fabric is embedded at least on both sides of the gypsum plate, the impact resistance of the base material can be improved.

It is sectional drawing explaining the non-combustible decorative board which concerns on embodiment based on this invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
Here, the drawings are schematic, and the relationship between the thickness and the plane dimension, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiments shown below exemplify a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention describes the materials, shapes, structures, etc. of the constituent parts as follows. It is not something that is specific to something. The technical idea of the present invention may be modified in various ways within the technical scope specified by the claims stated in the claims.
In the non-combustible decorative plate 10 of the present embodiment, as shown in FIG. 1, a decorative sheet 2 is attached to the surface of the base material 1 via a sealer layer 6 and an adhesive layer 5.

<Cosmetic sheet 2>
In the decorative sheet 2, the printing ink layer 2B and the surface protective layer 2A are formed in this order on the surface of the resin film 2C (the surface opposite to the base material 1). Further, a back surface primer layer 2D is provided on the back surface of the resin film 2C (the surface on the base material 1 side).

"Resin film 2C"
The resin film 2C contains, for example, 70.0 parts by mass or more and 95.5 parts by mass or less of the polyester resin in terms of mass ratio. A known additive may be added to the resin film 2C. For example, it contains 4.5 parts by mass or more and 30.0 parts by mass or less of an inorganic pigment.
The thickness of the resin film 2C is, for example, 0.05 mm or more and 0.07 mm or less, and the mass is, for example, 60.0 g / m ^{2 to} 100.0 g / m ² (organic mass 58.2 g / m ^{2 to} 71. 6 g / m ² ).
As the resin film 2C, a resin film made of polybutylene terephthalate is preferable. Since the resin film made of polybutylene terephthalate has excellent heat resistance, the nonflammability is further improved.

"Printing ink layer 2B"
The printing ink layer 2B is formed on the resin film 2C in order to improve the design of the decorative plate 10.
The printing ink layer 2B can be provided by using a known printing method. Since the resin film 2C can be prepared in a wound state, printing for forming a printing ink layer can be performed with a roll-to-roll printing apparatus. The printing method is not particularly limited, but a gravure printing method can be used, for example, in consideration of productivity and the quality of the pattern.
A pattern can be added by the printing ink layer 2B. As the pattern, any pattern may be adopted in consideration of the design as a wall covering material.

The printing ink is not particularly limited, but an ink compatible with the printing method can be appropriately selected. In particular, it is preferable to select it in consideration of adhesion to the resin film 2C, printability, and weather resistance as a wall covering material.
For the printing ink layer 2B, for example, an ink containing 78 parts by mass or more and 100 parts by mass or less of the urethane resin and 0 parts by mass or more and 22 parts by mass or more of the inorganic pigment is used in terms of mass ratio. The mass of the printing ink layer 2B is, for example, 6.73 g / m ² (solid content) or less (organic mass 5.25 g / m ² or less).

"Surface protection layer 2A"
The surface protective layer 2A is provided so as to cover the printing ink layer 2B. The surface protective layer 2A may be a single layer, or a plurality of layers may be stacked to form a surface protective layer. In this embodiment, the case where the surface protection layer 2A is a single layer is illustrated.
The surface protective layer 2A is made of a curable resin layer such as a thermosetting type or an electromagnetic radiation curing type. When the surface protective layer 2A is provided, coating and curing of the coating film can be performed using a known coating device, a heat drying device, and an ionizing radiation device such as ultraviolet irradiation, depending on the type of the curable resin as the material. ..

The surface protective layer 2A has an important role of determining the superiority or inferiority of the bending workability, scratch resistance and cleanability. The surface protective layer 2A contains a curable resin as a main component. That is, it is preferable that the resin component is substantially composed of a curable resin. Substantial means, for example, 80 parts by mass or more when the whole resin is 100 parts by mass. The surface protective layer 2A may contain a weather resistant agent, a plasticizer, a stabilizer, a filler, a dispersant, a dye, a colorant such as a pigment, a solvent, or the like, if necessary.

The surface protective layer 2A of the present embodiment contains an ultraviolet curable resin as a main component. In addition, silica or other matting agent may be added in order to adjust the 60-degree mirror surface gloss to a desired gloss.
The surface protective layer 2A may further contain a thermosetting resin. However, even in this case, the content ratio of the curable resin is 50% or more of the total amount of the ionizing radiation curable resin.
Here, it is important to make a selection in consideration of cleanability. As a result of diligent studies on this point, we were able to find the following findings.

That is, by using a mixture of the ultraviolet curable resin and the thermosetting resin as the main component of the surface protective layer 2A, the scratch resistance is improved and the surface protective layer 2A is less likely to be whitened or cracked during bending. I got the knowledge that it will be.
Here, the ionizing radiation curable resin is not particularly limited, and a prepolymer (including an oligomer) containing a radically polymerizable double bond in the molecule capable of polymerizing and cross-linking by irradiation with ionizing radiation such as ultraviolet rays and electron beams and / Alternatively, a transparent resin containing a monomer as a main component can be used. These prepolymers or monomers can be used alone or in admixture. The curing reaction is usually a cross-linking curing reaction.

For example, the surface protective layer 2A is composed of 80 parts by mass or more and 86 parts by mass or less of an acrylic curable resin and 14 parts by mass or more and 20 parts by mass or less of an inorganic additive.
The surface protective layer 2A has, for example, a thickness of 0.04 mm or less and a mass of 16.3 g / m ² (solid content) or less (organic mass of 13.0 g / m ² or less).

Here, unevenness may be formed on the surface of the surface protective layer 2A in order to impart a given design property. Usually, an uneven pattern is formed by embossing. The embossing method is not particularly limited. A known single-wafer type or rotary type embossing machine is used for embossing. Examples of the uneven shape include wood grain conduit groove, stone plate surface unevenness (granite cleavage surface, etc.), cloth surface texturer, satin finish, sand grain, hairline, and many-line groove.

"Backside primer layer 2D"
A back surface primer layer 2D is formed on the back surface of the resin film 2C for the purpose of improving the adhesiveness with the base material 1.
As the material of the back surface primer layer 2D, various polymer materials such as urethane-based, polyester-based, acrylic-based, and epoxy-based are used, and urethane-based coating agents containing a polyol component and polyisocyanate are preferable.

As the polyol component in the urethane coating agent, a polyester-based polyol is preferable, and examples of the polyester-based polyol include a polyester-based polyol obtained by reacting a polyvalent carboxylic acid or the like with glycols. Examples of the polyisocyanate include 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylenedi isocyanate, p-phenylenedi isocyanate, 4,4'-diphenylmethane diisocyanate, hexamethylene diisocyanate, xylylene diisocyanate, isophorone diisocyanate and the like. Is exemplified.

The thickness of the back surface primer layer 2D may be appropriately set, but is preferably 0.01 to 10 μm, more preferably 0.05 to 5 μm. If the thickness is less than 0.01 μm, the bondability will be insufficient, and if it exceeds 10 μm, the productivity will decrease.
The back surface primer layer 2D of the present embodiment is configured to contain, for example, 62 parts by mass of urethane resin and 38 parts by mass of inorganic pigment in terms of mass ratio.
The backside primer layer 2D has, for example, a mass of 1.3 g / m ² (solid content) or less (organic mass of 0.8 g / m ² or less).

<Adhesive layer 5>
Examples of the adhesive constituting the adhesive layer 5 include thermoplastic resin-based adhesives, thermosetting resin-based adhesives, rubber (elastomer) -based adhesives, and the like. As these, known ones or commercially available products can be appropriately selected and used. Examples of the thermoplastic resin-based adhesive include polyvinyl acetate resin, polyvinyl alcohol, polyvinyl acetal (polyvinyl formal, polyvinyl butyral, etc.), cyanoacrylate, polyvinyl alkyl ether, polyvinyl chloride, polyamide, polymethyl methacrylate, and nitrocellulose. , Cellulose acetate, thermoplastic epoxy, polystyrene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer and the like, and examples of the heat-curable resin-based adhesive include urea resin and melamine resin. , Phenolic resin, resorcinol resin, furan resin, epoxy resin, unsaturated polyester resin, polyurethane resin, polyimide resin, polyamideimide, polybenzimidazole, polybenzothiazole and the like. As rubber-based adhesives, natural rubber, recycled rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, butyl rubber, polysulfide rubber, silicone rubber, polyurethane rubber, stereo rubber (synthetic natural rubber), ethylene propylene rubber, block Copolymer rubber (SBS, SIS, SEBS, etc.) and the like can be mentioned.
The adhesive layer 5 of the present embodiment may be composed of 95.7 parts by mass of an ethylene-vinyl acetate copolymer resin and 4.3 parts by mass of an organic curing agent (isocyanate type) in terms of mass ratio. In this case, the mass of the adhesive layer is, for example, 11.9 to 17.8 g / m ² (solid content).

<Sealer layer 6>
The sealer layer 6 is provided on the surface of the base material 1 in order to improve the adhesiveness between the base material 1 and the decorative sheet 2. The sealer layer 6 of the present embodiment has, for example, 66.6 parts by mass of an epoxy resin / 33.4 parts by mass of a curing agent, or 65 parts by mass of a modified alicyclic polyamine / 20 parts by mass of a modified aliphatic polyamine in terms of mass ratio. It is composed of 15 parts by mass of polythiol. The mass of the sealer layer 6 is, for example, 18.0 g / m ² (solid content) or less.

<Base material 1>
The base material 1 has, for example, a thickness of 5 mm or more and 7 mm or less, and a mass of 5.0 kg / m or more and 7.0 kg / m or less.
The base material 1 is mainly composed of dihydrate gypsum, and glass fibers are mixed with the gypsum. That is, the base material 1 is made of a gypsum plate having a glass fiber as a core material. The base material of the present embodiment functionally comprises a base material main body 1B and double-sided portions 1A and 1C located on both sides of the base material main body 1B, respectively.

The base material body 1B contains, for example, 0.5 parts by mass of an organic additive (starch, paraffin, silicone, etc.) and 0.1 to 0.5 parts by mass of glass fiber with respect to 100 parts by mass of dihydrate. It is composed.
The double-sided portions 1A and 1C are each formed by embedding a glass fiber non-woven fabric in dilute water. At the embedding position of the glass fiber non-woven fabric, the glass fiber non-woven fabric is 80 parts by mass or more in terms of the total mass ratio. Further, in order to improve the adhesiveness, an acrylic resin binder may be contained.
The mass of the glass fiber non-woven fabric is, for example, about 45 to 55 g / m ² .

<Action and others>
In the non-combustible decorative board 10 having the above configuration, the base material 1 contains gypsum as a main component and further has a glass fiber non-woven fabric, so that the decorative board 10 can be made nonflammable, and further, such non-combustibility Even if a substrate having the same material is used, the adhesion performance is improved by providing the sealer layer 6 on the substrate and adhering the decorative sheet 2 to the substrate.

Here, the nonflammability referred to in the present embodiment is based on the cone calorie combustion test based on ISO5660-1, and when the total calorific value with respect to time and the heat generation rate with respect to time of the noncombustible decorative plate 10 are obtained, (i) The total calorific value for 20 minutes after the start of heating is 8 MJ / m ² or less, (ii) the maximum heat generation rate does not exceed 200 kW / m ² continuously for 10 seconds or more for 20 minutes after the start of heating, and (iii) heating. It is nonflammable for 20 minutes after the start, satisfying that there are no cracks or holes penetrating to the back surface, which is harmful for fire protection.
Further, when a polybutylene terephthalate resin film is used as the resin film 2C of the decorative sheet 2, the heat resistance is improved and the nonflammability is further improved.

Next, an example will be described for the non-combustible decorative plate 10 based on the present invention.
<Example 1>
The non-combustible decorative board 10 of Example 1 was prepared with the following configuration.
・ Cosmetic sheet 2
A polybutylene terephthalate resin film was used as the resin film 2C.

The composition of this resin film 2C is composed of polyester resin 95.5 / inorganic pigment 4.5 by mass. The thickness of the resin film 2C was 0.06 mm, and the mass was 75.0 g / m ² (organic mass 71.6 g / m ² ).
A printing ink layer 2B was provided on the surface of the resin film 2C by printing. The composition of the ink used for printing was composed of urethane resin 85 / inorganic pigment 15 by mass. The printing ink layer 2B has a mass of 6.73 g / m ² (solid content) (organic mass of 5.25 g / m ² ).

A surface protective layer 2A is provided on the printing ink layer 2B. The surface protective layer 2A is composed of an acrylic ultraviolet curable resin 80 / inorganic additive 20 in terms of mass ratio. The surface protective layer 2A has a thickness of 0.04 mm and a mass of 16.3 g / m ² (solid content) (solid content). The organic mass is 13.0 g / m ² ).
Further, a back surface primer layer 2D was formed on the back surface of the resin film 2C.
The composition of the back surface primer layer 2D was composed of urethane resin 62 / inorganic pigment 38 in terms of mass ratio. The mass of the back surface primer layer 2D was 1.3 g / m ² (solid content) (organic mass 0.8 g / m ² or less).

・ Adhesive layer 5
The composition of the adhesive layer 5 was an ethylene-vinyl acetate copolymer resin 95.7 / organic curing agent (isocyanate) 4.3 in terms of mass ratio. The mass of the adhesive layer 5 was 16.2 g / m ² (solid content).
・ Sealer layer 6
The composition of the sealer layer 6 was 18.0 g / m ² (solid content) thereof, which was composed of 66.6 parts by mass of the epoxy resin and 33.4 parts by mass of the curing agent in terms of mass ratio.

The base material 1 has a thickness of 6.0 mm and a mass of 6.0 kg / m ² .
The total amount of gypsum of the base material 1 was 5.9 kg / m2 in mass.
The base material body 1B has the following configuration.
(2) Water soap 99.0 parts by mass Organic additive 0.5 parts by mass Glass fiber 0.5 parts by mass Both sides 1A and 1C are composed of glass fiber non-woven fabric embedded in gypsum, but 80 parts by mass. Is a glass fiber non-woven fabric. In addition, an acrylic resin binder is mixed in to improve the adhesiveness.

<Evaluation>
"Non-combustible test"
The flammability of the non-combustible decorative plate 10 of Example 1 having the above configuration was confirmed by a test method using a corn calorimeter (based on ISO5660-1). The test was performed on three samples.

In all three sample tests, the total calorific value was 4.3 MJ / m ² or less, the average maximum heat generation rate was 77.3 kW / m ² , and all were 200 kW / m for 10 seconds or longer. It never exceeded m ² . In addition, no cracks reaching the back surface occurred for 20 minutes after the start of heating. As described above, it was confirmed that the non-combustible decorative plate 10 based on the present invention satisfies the standard of non-combustible material.

"Peeling test"
When the 180 ° peeling strength was measured with respect to the non-combustible decorative plate 10 of Example 1 having the above configuration in order to confirm the adhesion of the decorative sheet 2, a sufficient peeling strength of 30.1 N / 25 cm was secured. It was confirmed.
Moreover, when the plane tensile strength was also evaluated, it was confirmed that the plane tensile strength was 1.19 N / mm ² .
As described above, it was confirmed that the non-combustible decorative plate 10 of the present invention has sufficient adhesion performance.

1 Base material 1A, 1C Both sides 1B Base material body 2 Decorative sheet 2A Surface protection layer 2B Printing ink layer 2C Resin film 2D Back surface primer layer 5 Adhesive layer 6 Sealer layer 10 Non-combustible decorative plate

Claims (8)

A sealer layer, an adhesive layer, and a decorative sheet are formed on one surface of the base material in this order.
The decorative sheet has a printing ink layer and a surface protective layer formed in this order on the surface of the resin film opposite to the base material, and has a back surface primer layer on the surface of the resin film on the base material side. ,
The base material is a gypsum plate mixed with glass fibers, and has a thickness of 5 mm or more and 7 mm or less and a mass of 5.0 kg / m ² or more and 7.0 kg / m ² or less. Oh it is,
The base material is arranged on both sides of the base material main body containing glass fiber in the range of 0.1 part by mass or more and 0.5 part by mass or less with respect to 100 parts by mass of gypsum, and the base material main body. It has both sides with glass fiber non-woven fabric embedded in plaster.
The content of the glass fiber nonwoven fabric in the duplex unit, non-combustible decorative board, characterized in that relative to the mass of the double-sided unit, Ru der least 80 parts by weight. A sealer layer, an adhesive layer, and a decorative sheet are formed on one surface of the base material in this order.
The decorative sheet has a printing ink layer and a surface protective layer formed in this order on the surface of the resin film opposite to the base material, and has a back surface primer layer on the surface of the resin film on the base material side. ,
The base material is a gypsum plate mixed with glass fibers, and has a thickness of 5 mm or more and 7 mm or less and a mass of 5.0 kg / m ² or more and 7.0 kg / m ² or less. Oh it is,
The sealer layer is a non-combustible decorative board containing a modified alicyclic polyamine and a modified aliphatic polyamine . The base material is a gypsum plate, a pair of glass fiber non-woven fabrics embedded in both the front and back surfaces of the gypsum plate, and a glass fiber embedded in the gypsum plate located between the pair of glass fiber non-woven fabrics. The non-combustible decorative board according to claim 2 , which is characterized by having. The non-combustible decorative board according to claim 1 , wherein the double-sided portion contains an acrylic resin-based binder. The non-combustible decorative plate according to any one of claims 1, 3 and 4, wherein the mass of the glass fiber non-woven fabric is in the range of 45 g / m ² or more and 55 g / m ² or less. .. The non-combustible decorative board according to any one of claims 1 and 3 to 5, wherein the sealer layer contains a modified alicyclic polyamine and a modified aliphatic polyamine. The non-combustible decorative board according to any one of claims 1 to 6, wherein the adhesive layer contains an ethylene-vinyl acetate copolymer resin. In the heat generation test by the cone calorimeter tester conforming to ISO5660-1, (1) the total calorific value (MJ / m ² ) for 20 minutes after the start of heating was 8 MJ / m ² or less, and (2) 20 minutes after the start of heating. The maximum heat generation rate of the above is not to exceed 200 kW / m ² continuously for 10 seconds or more. The non-combustible decorative board according to any one of claims 1 to 7, wherein the non-combustible decorative board is characterized.

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