JP6828303B2 - Non-combustible veneer - Google Patents

Description

The present invention relates to a non-combustible decorative board.

Conventionally, as a non-combustible decorative board, for example, there is a technique described in Patent Document 1. In the technique described in Patent Document 1, a non-combustible decorative plate is obtained by laminating a paper base material, a metal foil, a paper base material, a sealer layer, an adhesive layer, and a decorative sheet in this order on a volcanic vitreous multi-layer plate. Is forming. The metal leaf imparts nonflammability to the non-combustible decorative board.

JP-A-2015-54455

However, in the technique described in Patent Document 1, since there is an organic substance such as a sealer layer or a paper base material between the decorative sheet and the metal foil, the amount of heat generated by heating may increase. Further, it is necessary to shorten the curing period by a step of drying the aqueous emulsion adhesive composition to form an adhesive layer and a step of heating and pressurizing a decorative sheet on the formed adhesive layer.
The present invention has focused on the above points, and an object of the present invention is to provide a non-combustible decorative board that suppresses the amount of heat generated by heating and makes it possible to shorten the curing period.

In order to solve the above problems, in one aspect of the present invention, a first adhesive layer, a metal leaf, a second adhesive layer and a decorative sheet are arranged in this order on one surface of a volcanic vitreous multilayer plate. It is characterized by being laminated.

According to one aspect of the present invention, the amount of organic matter between the metal foil and the decorative sheet can be reduced. Therefore, it is possible to suppress the amount of heat generated by heating with respect to heating from the decorative sheet side. In addition, by using a reactive hot melt adhesive or a two-component curable solvent-based adhesive, it is possible to shorten the curing period because the moisture drying time is not required to exert the adhesive force unlike the water-based adhesive. it can.

It is an end view which shows the non-combustible decorative board which concerns on embodiment. It is an end view which shows the non-combustible decorative board which concerns on the modification. It is an end view which shows the non-combustible decorative board which concerns on the modification.

Next, an embodiment 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 material, shape, structure, etc. of the constituent parts as follows. It is not specific to the thing. 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.

(Non-combustible decorative board 1)
In the non-combustible decorative board 1 of the present embodiment, as shown in FIG. 1, a second adhesive layer 3 and a decorative sheet 4 are laminated in this order on one surface of a flame-retardant base material 2, and the flame-retardant group is formed. A double-sided thin paper-covered aluminum foil 5 is bonded to the other surface of the material 2. The flame-retardant base material 2 is obtained by laminating a first adhesive layer 22 and a metal foil 23 in this order on one surface of a volcanic vitreous multilayer plate 21. The surface of the metal foil 23 constitutes one surface of the flame-retardant base material 2, and the other surface of the volcanic vitreous multilayer plate 21 constitutes the other surface of the flame-retardant base material 2.

(Volcanic vitreous multi-layer plate 21)
The volcanic glassy double glazing plate 21 is an inorganic double glazing plate having high fire resistance. As the volcanic vitreous multilayer plate 21, for example, one conforming to JIS A5440 can be used. For example, there are Dailite FA manufactured by Daiken Corporation and Omar manufactured by Iwakura Chemical Industry Co., Ltd.

(First Adhesive Layer 22)
The first adhesive layer 22 is a layer for adhering the volcanic vitreous multilayer plate 21 and the metal foil 23. The first adhesive layer 22 is formed by, for example, drying an aqueous emulsion adhesive composition containing an aqueous emulsion resin and a cross-linking agent. Since the aqueous emulsion adhesive composition does not use an organic solvent, the burden on the environment is low. As the aqueous emulsion resin, for example, vinyl acetate resin such as ethylene-vinyl acetate, acrylic resin, urethane resin, polyester resin, and epoxy resin can be used. Further, as the cross-linking agent, for example, an agent having an isocyanate group in the molecule and imparting a cross-linked structure by a chemical reaction can be used.
The aqueous emulsion adhesive composition is applied by a known method such as gravure coating, bar coating, spray coating, roll coating, reverse roll coating, and comma coating. The coating amount is preferably 10 g / m ² or more and 60 g / m ² or less (solid content conversion), and more preferably 20 g / m ² or more and 50 g / m ² or less (solid matter conversion).

Further, a thickener may be added to the aqueous emulsion adhesive composition. As a result, thixotropy can be obtained, coating suitability can be improved, and the coating amount can be reduced. By reducing the coating amount, the residual moisture content of the first adhesive layer 22 can be reduced to less than 30% by mass and the moisture content can be reduced to less than 10.0 g / m ² by drying in a short time, and the non-combustible decorative plate 1 can be used. The production speed can be increased. Further, conventionally, aluminum hydroxide has been blended in the aqueous emulsion adhesive composition in order to impart good nonflammability, but by reducing the coating amount, the blending amount of aluminum hydroxide can be reduced and the cost can be reduced. As the thickener, for example, a water-soluble resin can be used. In particular, acrylic thickeners, cellulose derivatives, polyether-based thickeners, and urethane-modified polyether-based thickeners are preferable.
The blending amount of the thickener is determined so that a suitable viscosity can be obtained according to the coating method. For example, it is 0.001% by mass or more and 5.0% by mass or less with respect to the total mass of the aqueous emulsion adhesive composition. If the blending amount is more than 5.0% by mass, the viscosity becomes high and it becomes difficult to reduce the coating amount.

(Metal leaf 23)
The metal leaf 23 is a layer for imparting nonflammability to the noncombustible decorative plate 1. As the metal foil 23, for example, aluminum foil, copper foil, silver foil, iron foil, and stainless steel foil can be used. In particular, aluminum foil is preferable in consideration of workability and corrosion resistance. The thickness of the metal foil 23 is preferably 5 μm or more and 50 μm or less, and more preferably 7 μm or more and 30 μm or less.
Here, the nonflammability is a cone calorimeter tester that complies with ISO5660-1 and conforms to the fire resistance test method and performance evaluation standard based on Article 2-9 of the Building Standards Act and Article 108-2 of the Construction Standards Act Construction Ordinance. (1) The total calorific value for 20 minutes after the start of heating is 8 MJ / m ² or less, and (2) The maximum heat generation rate continues for 10 seconds or more for 20 minutes after the start of heating and exceeds 200 KW / m ² . (3) It is preferable to have nonflammability sufficient to satisfy the condition that there are no cracks or holes harmful to fire prevention for 20 minutes after the start of heating.

(Second adhesive layer 3)
The second adhesive layer 3 is a layer for adhering the flame-retardant base material 2 and the decorative sheet 4. The second adhesive layer 3 is formed by, for example, a reactive hot melt adhesive or a two-component curable solvent-based adhesive. As a result, the curing time after the decorative sheet 4 is attached can be shortened. As the reactive hot melt adhesive, for example, an adhesive containing urethane resin as a main component and imparting reactive system characteristics to the hot melt can be used. For example, there is "Thai Force" manufactured by DIC Corporation. Further, as the two-component curable solvent-based adhesive, for example, an adhesive containing a polyol compound as a main agent and a polyisocyanate compound as a curing agent can be used.

(Cosmetic sheet 4)
The decorative sheet 4 is a layer for imparting design to the non-combustible decorative board 1. The decorative sheet 4 is not particularly limited, and a resin sheet or the like as a base material can be used. Examples of the resin forming the resin sheet include polyester resins such as polyethylene terephthalate (PET) and polybutylene terephthalate (PBT); polyethylene, polypropylene, polybutene, ethylene-propylene copolymer resin, and ethylene-propylene-butene copolymer. Polyethylene-based resins such as resins and olefin-based thermoplastic elastomers; polyurethane-based resins such as acrylic-modified urethane-based resins, polyester-modified urethane-based resins, vinyl chloride-vinyl acetate copolymer-modified urethane-based resins; acrylic-based resins; polycarbonate-based resins Polyethylene resin; Vinyl chloride resin, vinyl acetate resin, and vinyl chloride-vinyl acetate copolymer resin can be used. Further, as the resin forming the resin sheet, two or more of these resins can be used in combination.

Further, as the decorative sheet 4, a colored resin sheet made of the above resin and a transparent resin sheet can be used as a doubling sheet obtained by sandwiching a pattern. In this case, the resins used for the colored resin sheet and the transparent resin sheet may be the same or different. For example, a polyolefin resin is preferable. The resin combination is preferably a combination of polyethylene-polyethylene, polyethylene-polypropylene, polypropylene-polypropylene, polybutylene terephthalate-polypropylene, polybutylene terephthalate-polyethylene, or polybutylene terephthalate-polybutylene terephthalate. The doubling sheet is, for example, a resin made of the above resin after corona discharge treatment or the like is applied to the surface of the resin sheet A made of the above resin to provide a primer layer, and a solid layer or a pattern layer is printed and formed on the resin sheet A. It is obtained by pressure-bonding the sheet B by a lamination method. As the lamination method, for example, extrusion lamination, dry lamination, wet lamination, and thermal lamination can be used.

(Double-sided thin paper-covered aluminum foil 5)
The double-sided thin paper-covered aluminum foil 5 is a layer for imparting nonflammability and strength to the nonflammable decorative plate 1. As a result, the warp of the non-combustible decorative plate 1 is suppressed and the dimensional stability is improved. As the double-sided thin paper-covered aluminum foil 5, for example, a laminate including two thin papers 51 and 52 and a metal foil 53 arranged between the two thin papers 51 and 52 can be used. As the metal foil 53, for example, aluminum foil, copper foil, silver foil, iron foil, and stainless steel foil can be used. In particular, aluminum foil is preferable in consideration of workability and corrosion resistance. The emissivity of the metal foil 53 is preferably 60% or more. In particular, from the viewpoint of nonflammability, 70% or more is preferable.

As described above, in the present embodiment, the first adhesive layer 22, the metal leaf 23, the second adhesive layer 3, and the decorative sheet 4 are laminated in this order on the volcanic vitreous multilayer plate 21. There is. Therefore, since the amount of organic matter between the decorative sheet 4 and the metal leaf 23 can be reduced, the amount of heat generated by the non-combustible decorative plate 1 can be suppressed with respect to heating from the decorative sheet 4 side. In addition, by using a reactive hot melt adhesive or a two-component curable solvent-based adhesive, it is possible to shorten the curing period because the moisture drying time is not required to exert the adhesive force unlike the water-based adhesive. it can.
Further, for example, unlike a non-combustible decorative board having thin paper or the like between the decorative sheet 4 and the metal foil 23, the adhesive strength between the decorative sheet 4 and the metal foil 23 can be improved because the paper does not peel off.

Incidentally, in the conventional non-combustible decorative board having thin paper between the decorative sheet 4 and the metal leaf 23, the amount of heat generated by heating may be high. In addition, the thin paper may be peeled off from each other, and the adhesive strength between the decorative sheet 4 and the metal leaf 23 may decrease.
The obtained non-combustible decorative board 1 can be used for interior and exterior building materials such as ceilings and wall materials of buildings, doors, furniture and the like. In particular, by utilizing the non-combustibility of the non-combustible decorative plate 1, it can be suitably used for kitchen materials such as sinks, gas stoves, hoods, and other parts of buildings that are required to be non-combustible under the Building Standards Act. ..

(Effect of this embodiment)
The invention according to the present embodiment has the following effects.
(1) The non-combustible decorative plate 1 according to the present embodiment has a first adhesive layer 22, a metal leaf 23, a second adhesive layer 3, and a decorative plate on one surface of a volcanic vitreous multilayer plate 21. The sheets 4 are laminated in this order.
According to such a configuration, the amount of organic matter between the decorative sheet 4 and the metal leaf 23 can be reduced, so that the amount of heat generated by the non-combustible decorative plate 1 can be suppressed with respect to heating from the decorative sheet 4 side. In addition, by using a reactive hot melt adhesive or a two-component curable solvent-based adhesive, it is possible to shorten the curing period because the moisture drying time is not required to exert the adhesive force unlike the water-based adhesive. it can.

(2) In the non-combustible decorative plate 1 according to the present embodiment, the second adhesive layer 3 is made of a reactive hot melt adhesive or a two-component curable solvent-based adhesive.
According to such a configuration, the curing time after the decorative sheet 4 is attached can be shortened.
(3) In the non-combustible decorative plate 1 according to the present embodiment, the metal foil 23 is an aluminum foil.
According to such a configuration, processing is easy and corrosion of the metal foil 23 can be suppressed.
(4) In the non-combustible decorative plate 1 according to the present embodiment, the first adhesive layer 22 and the third adhesive layer 25 are made of an aqueous emulsion adhesive composition.
According to such a configuration, since no organic solvent is used, the environmental load can be reduced.

(5) In the non-combustible decorative board 1 according to the present embodiment, the thin paper 24 is impregnated with a sealer agent.
According to such a configuration, the thin paper 24 can be provided with the strengthening of the interlayer strength and the sealing effect.
(6) In the non-combustible decorative plate 1 according to the present embodiment, a metal arranged between two sheets of thin paper 51, 52 and two sheets of thin paper 51, 52 on the other surface of the volcanic vitreous multi-layer plate 21. A double-sided thin paper-covered aluminum foil 5 having a foil 53 is attached.
With such a configuration, the warp of the non-combustible decorative plate 1 can be suppressed and the dimensional stability can be improved.

(Modification example)
(1) Further, for example, as shown in FIG. 2, between the first adhesive layer 22 and the metal foil 23, from the first adhesive layer 22 side, the thin paper 24 and the third adhesive layer 25 May be configured to be laminated in this order. In this case, the decorative sheet 4 is made of a polyester resin.
The thin paper 24 is a layer for absorbing irregularities on the surface of the volcanic vitreous multilayer plate 21. As a result, the decorative sheet 4 is prevented from floating, and the adhesive force with the decorative sheet 4 is improved. Further, as the thin paper 24, a resin-impregnated paper impregnated with a sealer agent is preferable. As a result, the interlayer strength between the fibers of the thin paper and the layer adjacent to the thin paper is strengthened, the thin paper is prevented from fluffing, and the surface of the flame-retardant base material 2 is smoothed to obtain a uniform coated surface. A stopping effect can also be obtained.
The third adhesive layer 25 is a layer for adhering the metal foil 23 and the thin paper 24. The third adhesive layer 25 is formed by drying, for example, an aqueous emulsion adhesive composition containing an aqueous emulsion resin and a cross-linking agent, similarly to the first adhesive layer 22. With such a configuration, the amount of organic matter between the decorative sheet 4 and the volcanic vitreous multilayer plate 21 can be reduced, so that the amount of heat generated by the non-combustible decorative plate 1 is further suppressed with respect to heating from the decorative sheet 4 side. be able to.

(2) Further, for example, as shown in FIG. 3, the non-combustible decorative plate 1 has a double-sided thin paper-covered aluminum foil 5, a sealer layer 6, and a second adhesive on one surface of the volcanic vitreous multi-layer plate 21. The layer 3 and the decorative sheet 4 may be laminated in this order so that the content of the sealer agent in the sealer layer 6 is 5 g / m ² or less in terms of solid matter. As the sealer layer 6, for example, resin-impregnated paper impregnated with a sealer agent can be used. In this case, the double-sided thin paper-covered aluminum foil 5 on the other surface of the volcanic vitreous multilayer plate 21 is omitted. As a result, the amount of organic matter (sealer agent) between the decorative sheet 4 and the volcanic vitreous multilayer plate 21 can be reduced, so that the amount of heat generated by the non-combustible decorative plate 1 is further suppressed with respect to heating from the decorative sheet 4 side. it can. At that time, the back surface layer 7 (for example, thin paper) may be provided on the other surface of the volcanic vitreous multilayer plate 21.

Examples of the present invention will be described.
(Example 1)
In Example 1, the aqueous emulsion adhesive composition was applied to one surface (upper surface in the example of FIG. 1) of the volcanic vitreous multilayer plate 21 (manufactured by Daiken Corporation: Dailite FA). The adhesive layer 22 of 1 was formed. The thickness of the volcanic vitreous multi-layer plate 21 was set to 3 mm. The coating amount of the aqueous emulsion adhesive composition was 50 g / m ² . Subsequently, a thin paper 24 having a basis weight of 23 g / m ² is adhered onto the first adhesive layer 22, and an aqueous emulsion adhesive composition is further applied onto the thin paper 24 to apply a third adhesive layer. 25 was formed. The coating amount of the aqueous emulsion adhesive composition was 20 g / m ² . Subsequently, the metal leaf 23 was adhered onto the third adhesive layer 25. As the metal foil 23, an aluminum foil was used. The thickness of the metal foil 23 was 30 μm.

Subsequently, a reactive hot melt adhesive was applied onto the metal foil 23 to form a second adhesive layer 3. The amount of the reactive hot melt adhesive applied was 34 g / m ² . Subsequently, the decorative sheet 4 was adhered to the upper surface of the second adhesive layer 3. The resin forming the decorative sheet 4 was a polyester resin. The thickness of the decorative sheet 4 was 0.11 mm.
Subsequently, the double-sided thin paper-covered aluminum foil 5 was attached to the other surface (lower surface in the example of FIG. 1) of the volcanic vitreous multi-layer plate 21. As a result, the non-combustible decorative plate 1 of Example 1 was manufactured.

(Example 2)
In Example 2, as shown in FIG. 2, the thin paper 24 and the third adhesive layer 25 were omitted. The coating amount (solid matter equivalent) of the first adhesive layer 22 was set to 40 g / m ² . Further, the resin forming the decorative sheet 4 was an olefin resin. Further, the thickness of the decorative sheet 4 was set to 0.13 mm. Other than that, the configuration was the same as that of Example 1.
(Example 3)
In Example 3, as shown in FIG. 2, the thin paper 24 and the third adhesive layer 25 were omitted. The coating amount (in terms of solid matter) of the first adhesive layer was 40 g / m ² . Further, the resin forming the decorative sheet 4 was a polyester resin. Further, the thickness of the decorative sheet 4 was set to 0.11 mm. Other than that, the configuration was the same as that of Example 1.
(Example 4)
In the fourth embodiment, as shown in FIG. 3, the double-sided thin paper-covered aluminum foil 5 and the sealer layer 6 are replaced with the first adhesive layer 22, the thin paper 24, the third adhesive layer 25, and the metal foil 23. Was provided. The content of the sealer layer 6 was set to 5 g / m ^{2 in} terms of solid matter. Further, the double-sided thin paper-covered aluminum foil 5 on the other surface (lower surface in the example of FIG. 3) of the volcanic vitreous multi-layer plate 21 is omitted. Other than that, the configuration was the same as that of Example 1.

(Comparative Example 1)
In Comparative Example 1, the resin forming the decorative sheet 4 was an olefin resin. The thickness of the decorative sheet 4 was 0.13 mm. Other than that, the configuration was the same as that of Example 1.
(Comparative Example 2)
In Example 4, the coating amount of the sealer layer 6 was set to 11 g / m ² . Other than that, the configuration was the same as that of Example 4.
(Comparative Example 3)
In Example 4, the coating amount of the sealer layer 6 was set to 11 g / m ² . The resin forming the decorative sheet 4 was an olefin resin. Further, the thickness of the decorative sheet 4 was set to 0.13 mm. Other than that, the configuration was the same as that of Example 4.

(Evaluation judgment)
The following evaluation was carried out for the non-combustible decorative board 1 of Example 1 and Comparative Example 1 described above.
(Adhesive strength)
The adhesive strength was evaluated as follows.
・ 180 ° peeling test The edge of the decorative sheet 4 is artificially peeled off with a width of 1 inch, bent in the 180 degree direction, and a tensile load is applied by a tensile tester at room temperature to apply a load at the time of peeling. It was measured.
-Heat-resistant creep test The edge of the decorative sheet 4 was artificially peeled off with a width of 1 inch, and the peeled length was measured by applying a load of 500 g in the 90 ° direction for 1 hour in an environment of 60 ° C. did.
Then, when the load at the time of peeling in the 180 ° peeling test was 24.5 N / inch or more and the peeled length in the heat resistant creep test was 5 mm / inch or less, a pass “◯” was given.

(Incombustibility)
The nonflammability was evaluated as follows.
A heat generation test was performed on the non-combustible decorative plate 1. As a heat generation test, a cone calorimeter tester that complies with ISO5660-1 and conforms to the fireproof test method and performance evaluation standard based on Article 2-9 of the Building Standards Act and Article 108-2 of the Construction Ordinance of the Building Standards Act ( A heat generation test by Toyo Seiki Seisakusho Co., Ltd. was adopted. The total calorific value for 20 minutes after the start of heating is 8 MJ / m ² or less, 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 20 minutes after the start of heating. If there are no cracks or holes that are harmful to fire prevention, the result is "○".

The evaluation results are shown in Table 1.

From Table 1, Example 1, that is, on the volcanic vitreous multilayer plate 21, the first adhesive layer 22, the thin leaf paper 24, the third adhesive layer 25, the metal foil 23, and the second adhesive layer It was found that the non-combustible decorative plate 1 in which 3 and the decorative sheet 4 were laminated in this order and the resin forming the decorative sheet 4 was a polyester resin was excellent in adhesive strength and non-combustibility. That is, it was found that the amount of heat generated by heating can be suppressed. In addition to the non-combustible decorative board 1 described in Example 1, the same effect could be confirmed for various non-combustible decorative boards 1 having the materials and numerical values described in Comparative Example (1). .. On the other hand, it was found that Comparative Example 1, that is, the non-combustible decorative plate 1 in which the resin forming the decorative sheet 4 was an olefin-based resin, had excellent adhesive strength but was inferior in non-combustibility.

Further, in Examples 2 and 3, that is, the non-combustible decorative plate 1 in which the thin leaf paper 24 and the third adhesive layer 25 are omitted from the non-combustible decorative plate 1 of Example 1, the resin forming the decorative sheet 4 is a polyester resin and an olefin. It was found that all of the based resins are excellent in adhesive strength and nonflammability. In addition to the non-combustible decorative board 1 described in Examples 2 and 3, the same effect could be confirmed for various non-combustible decorative boards 1 having the materials and numerical values described in the above-described embodiment.
Further, Example 4, that is, a double-sided thin paper-covered aluminum foil 5 and a sealer layer 6 are provided in place of the first adhesive layer 22, the thin paper 24, the third adhesive layer 25, and the metal foil 23, and a sealer is provided. It was found that even the non-combustible decorative plate 1 in which the coating amount of the layer 6 was 5 g / m ² (that is, the content of the sealer agent in the sealer layer 6 was 5 g / m ^{2 in} terms of solid matter) was excellent in adhesive strength and non-combustibility. It was. In addition to the non-combustible decorative board 1 described in Example 4, the same effect could be confirmed for various non-combustible decorative boards 1 having the materials and numerical values described in the modified example (2). .. On the other hand, Comparative Examples 2 and 3, that is, the non-combustible decorative plate 1 in which the coating amount of the sealer layer 6 was 11 g / m ² (> 5 g / m ² ), had excellent adhesive strength but was inferior in non-combustibility. all right.

1 ... Non-combustible decorative board, 2 ... Flame-retardant base material, 3 ... Second adhesive layer, 4 ... Decorative sheet, 5 ... Double-sided thin paper-covered aluminum foil, 6 ... Sealer layer, 7 ... Back layer, 21 ... Volcanic Vitreous multi-layer board, 22 ... 1st adhesive layer, 23 ... metal leaf, 24 ... thin paper, 25 ... 3rd adhesive layer, 51 ... thin paper, 52 ... thin paper, 53 ... metal leaf

Claims (5)

On one side of the volcanic vitreous multi-layer board, a first adhesive layer, tissue paper, a third adhesive layer, a metal leaf, a second adhesive layer and a decorative sheet are provided without interposing the other layer. It is stacked in this order ,
The first adhesive layer and the third adhesive layer consist of an aqueous emulsion adhesive composition.
The second adhesive layer is a non-combustible decorative board made of a reactive hot melt adhesive or a two-component curable solvent-based adhesive . Before SL decorative sheet is non-combustible decorative board according to claim 1, characterized in including that the polyester resin. The non-combustible decorative board according to claim 1 or 2 , wherein the thin paper is impregnated with a sealer agent. The non-combustible decorative board according to any one of claims 1 to 3 , wherein the metal foil is an aluminum foil. A double-sided thin paper-covered aluminum foil having two sheets of tissue paper and a metal foil arranged between the two sheets of tissue paper is bonded to the other surface of the volcanic vitreous multilayer plate. The non-combustible decorative board according to any one of claims 1 to 4 .

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