JPS6154588B2 - - Google Patents

Description

[Detailed description of the invention]

TECHNICAL FIELD OF THE INVENTION The present invention relates to a noncombustible inorganic decorative board suitably used for the interior and exterior of buildings such as tile boards and wall boards. PRIOR ART Conventionally, organic plastic base materials have been widely used as decorative laminates for the interior and exterior of buildings, as they are inexpensive, lightweight, and easy to process.
Such materials had problems such as being easily flammable and emitting toxic gas when burned. Therefore, in recent years, decorative laminates using inflammable inorganic base materials have been developed and used as nonflammable inorganic decorative laminates. This type of noncombustible decorative board is generally known to be one in which a decorative layer with a decorative surface is integrally molded by heat and pressure on a base material whose main aggregate is aluminum hydroxide. Products that use aluminum as the main aggregate have excellent nonflammability because aluminum hydroxide releases its crystal water when the surrounding temperature reaches 300 to 550°C, suppressing combustion. However, on the other hand, aluminum hydroxide is more expensive than organic plastics, has inferior impact resistance, and is less safe because if the board is damaged by a strong impact, fragments will scatter. The current situation is that improvements are strongly desired in these areas as well. Summary of the Invention The present invention was developed as a result of intensive studies by the present inventors in order to meet such demands. ) of aluminum hydroxide Al ₂ O ₃ .
_3H2O containing 3-9% flame retardant thermosetting resin binder, 60-70% mineral filler and 0.5-5
% of an auxiliary material and hardened into a plate shape, a resin shielding layer laminated on the surface of this base material, a decorative layer consisting of a pattern layer and a surface resin layer thereon, and a paper material A backer layer impregnated with a thermosetting resin is disposed on the surface of the base material and integrally molded by heat pressure, and a backer layer is formed inside the base material or on at least one of the upper and lower surfaces of the base material. The point is that it is formed into a multilayered plate shape by interposing an anti-scattering layer made of a fibrous net material with ~15 meshes. Effects of the Invention The features and advantages of the nonflammable inorganic decorative board of the present invention are as follows. (1) That is, in the present invention, the amount of relatively expensive aluminum hydroxide in the inorganic substrate is reduced to 20%.
While suppressing the amount to ~35% (weight ratio, below % indicates weight ratio), use 60-70% of cheap inorganic fillers such as silicon and zeolite, and reinforcing materials such as glass fiber.
Adding 0.5 to 5% made it possible to significantly reduce material costs. (2) In addition to the above-mentioned inorganic fillers and reinforcing materials, the reduction in mechanical strength caused by minimizing the amount of aluminum hydroxide can be reduced by impregnating paper material with thermosetting resin on the back side of the substrate. In addition to layering the backer layer, a scattering prevention layer made of a fibrous net material of 2 to 15 meshes is interposed on the inside of the substrate or on at least one of the upper and lower surfaces of the substrate. I was able to compensate for this. (3) Furthermore, the above-mentioned backer layer not only reinforces the mechanical strength but also prevents the decorative board from warping when the temperature rises, thereby realizing a decorative board that is resistant to thermal deformation. (4) Furthermore, the above-mentioned anti-scattering layer not only complements the mechanical strength but also makes it possible to obtain a safe decorative board that will not scatter fragments when broken. Thus, according to the inorganic decorative board of the present invention,
In addition to a significant reduction in material costs, it has become possible to obtain architectural decorative laminates that are improved in many aspects: non-combustibility, prevention of thermal deformation, and safety in the event of damage. In addition to the above, the present invention also has excellent durability, water resistance, mechanical strength, chemical resistance, lightness, workability, and workability of the decorative board as a whole, and has a three-dimensional design by embossing. It can be widely applied to architectural interiors, exterior materials, and decorative laminates for furniture. Detailed Structure of the Invention The constituent materials of the decorative board of the present invention will be described in detail below. [1] Adjustment of inorganic substrate material Each material constituting the inorganic substrate has the following characteristics, and is appropriately selected from among those shown below. Aluminum hydroxide solid powder is used, and it does not change thermally when the molding temperature is below 200℃, but when the ambient temperature reaches 300 to 550℃, it releases crystal water and suppresses combustion. At the same time, it is used as AIO as a heat-resistant material. This makes the board nonflammable. It also serves as the main constituent material of the substrate and serves as a mechanical strength material. In order for the base material to have nonflammability, the content is preferably 25% or more. Inorganic fillers are used to improve the mechanical strength and reduce costs of molded products (decorative laminates), and are used as auxiliary binders to provide fluidity and increase volume during molding. For the former purpose, inorganic powders such as silica sand, calcite powder, and calcium silicate are used, and for the latter purpose, clays such as zeolite, kaolin, bentonite, and clay oxide are used. The amount of these inorganic fillers used is 70% or less, and if it exceeds 70%, nonflammability will be impaired, so it is preferably 60 to 70%. Reinforcing materials To further improve the mechanical strength of the molded product (veneer board), mineral fibers (asbestos, etc.), inorganic fibers (glass fibers, ceramic fibers), metal fibers (iron fibers,
Approximately 0.5 to 5%, preferably approximately 1.0%, of a fiber tip selected from among natural fibers (cotton, linen), and synthetic chemical fibers (vinylon, nylon, Tetron, etc.) (aluminum fiber, whisker fiber) is added. Thermosetting resin binder It binds the above-mentioned substrate materials to each other by imparting molding fluidity to each other, and must be cured by heat and pressure. Generally, phenol-formalin condensates and their derivatives, urea, Resins such as melamine-formalin condensates and their derivatives, furan-formalin condensates and their derivatives, and polydiphenyl oxide resins and their derivatives are used, and the preferred amount used is 5 to 6.0%. However, if it is less than 3%, the bonding strength is insufficient, and if it exceeds 8%, it is difficult to make it a noncombustible material even if the amount of Al ₂ O ₃ .3H ₂ O is increased. [2] Decorative layer This decorative layer is formed by further laminating the following layers on the upper surface of the above-described substrate. Surface resin layer and pattern layer member There are two types of these members as follows. (1) When the surface resin layer is transparent or semitransparent and a pattern layer is provided separately from the resin layer. In this case, materials used as overlayers of ordinary thermosetting resin decorative laminates, such as cellulose, pulp paper, cloth (including non-woven fabrics), urea, melamine, thialyl phthalate, acrylic acid and methacrylic ester, etc. A surface resin layer member is made by impregnating and drying a transparent to translucent thermosetting resin liquid such as the derivative resin, and a patterned paper cloth impregnated and drying with the same thermosetting resin liquid is used as a pattern layer member. The pattern layer member may be placed under the surface resin layer member, or a pattern formed by printing on the surface of the shielding layer described later, or a thin metal foil such as aluminum foil or copper foil. (preferably about 0.3 mm) or this metal foil with a colored coating (0.1 mm or less), for example, by anodizing, and then glue the entire surface of the shielding layer with a synthetic resin adhesive to the surface of the shielding layer. Attach the target or partially. (2) It is also possible to share the surface resin layer and the pattern layer member. In this case, the pattern layer may be formed by direct printing on the surface of the cellulose pulp paper or cloth itself used as the overlayer in (1). Shielding layer member When the shielding layer is hot-press molded, the above-mentioned binder oozes out to the decorative layer (layer composed of the surface resin layer and pattern layer) side, causing stains, dirt, pattern defects, etc. It is provided between the substrate and the decorative layer so as to prevent the above-mentioned surface resin layer from occurring, and is made of, for example, a thermosetting resin liquid similar to that used for the surface resin layer member or vinyl acetate, vinyl chloride, or acrylic ester emulsion. A resin-treated shielding paper, etc., which is obtained by impregnating ordinary shielding paper or cloth with a thermosetting resin liquid and drying it, is used. [3] Backer layer Kraft paper, Japanese paper, paperboard, etc. impregnated with a thermosetting resin in advance is used. It is used to reinforce the mechanical strength of decorative boards and prevent them from warping when heated. The material forming the backer layer may have an uneven surface formed thereon in advance, or the uneven portion may be formed by embossing when the decorative board is integrally molded by heat pressure. [4] Scattering prevention layer In order to prevent fragments from scattering when the decorative board is damaged, an intermediary layer is provided inside the substrate or on at least one of the top and bottom surfaces of the substrate, instead of or together with the reinforcing material. be done. A net-like material such as an inorganic or organic fiber net having 2 to 15 meshes is preferred. Manufacturing method Next, to outline the manufacturing method of the decorative board of the present invention, the substrate materials are weighed and mixed using a Konida, Henschel mixer, etc., and the mixture thus obtained is placed in a mold. Each member for the layer and the surface resin layer and the pattern layer member are arranged in a predetermined positional relationship, the substrate material is filled from above, a backer layer is further covered, the mold is closed, and the mold is integrally molded by hot pressing. After that, it is finished and inspected to become a product. The molding conditions applied in the present invention are a temperature of 200℃ or less,
Heat pressure is applied for ^several minutes at a pressure of 100 to 150 kg/cm. As the pressing means, a conventionally known direct pressure press equipped with an embossing press plate or a mold may be used. In addition, in order to mask the top of the decorative layer, crushed natural stones (kansui crushed stone, snake crushed stone, canary, minoguro, etc.) are used to coat acrylic esters, methacrylic esters, resins copolymerized with these, and ethylene- A mixture of vinyl acetate emulsion resin and the like may be fixed on the decorative layer by spraying or coating, and the surface may be textured with crushed stone to emphasize the pattern. Embodiments of the Invention Finally, typical embodiments of the present invention will be described. <Example 1> In this example, as shown in FIG. 1, a three-layer decorative layer 2 is placed on the top surface of a substrate 1 which has a scattering prevention layer 4 interposed therein, and a backer layer 3 is placed on the bottom surface. These three parts are integrally molded by heat and pressure, and the decorative layer 2
Further, from the top, it is composed of a surface resin layer 21, a pattern layer 22 forming a pattern surface, and a resin shielding layer 23. The material according to this example was nonflammable and had excellent workability, and did not cause any fragments to scatter even when broken, and did not warp even when the temperature rose. The composition of each material forming each layer of the decorative board A of this example is as follows.

[Table] <Example 2> In this example, as shown in FIG. 2, a two-layer decorative layer 2 is placed on the upper surface of the substrate 1, a backer layer 3 is placed on the lower surface, and the substrate 1 and the decorative layer 2 are placed on the lower surface. A scattering prevention layer 4 is interposed between them, and all these layers are integrally molded by heat and pressure to form one flat decorative board A'. The decorative layer 2 includes a surface resin layer 21 and a pattern layer 22.
A printed pattern layer is formed on the back side of the surface resin layer 21, and the backer layer 3 is made of melamine-impregnated kraft paper. Note that the material composition of the substrate 1 is the same as that of the first embodiment. Furthermore, the obtained decorative board had the same effect as that of the first example. <Example 3> In this example, as shown in FIG. 3, a decorative layer 2 having a three-layer structure similar to that of the first example is placed on the upper surface of a substrate 1 with a scattering prevention layer 4 interposed therein. A backer layer 3 is arranged on the lower surface, and when these three are integrally molded by heat and pressure, embossing is performed on both the front and back surfaces to form embossed deep grooves 5...
The formed embossed deep grooves 5 form irregularities larger than the thickness of the surface decorative layer and the backer layer 3. The backer layer 3 is composed of phenol-impregnated adhesive paper 31 and melamine-impregnated kraft paper 32.
It is arranged on the back surface of the substrate 1. The composition of the materials forming the other layers of the decorative board A'' of this example is the same as that of the first example, and the obtained decorative board is the same as that of the first and second examples described above. Compared to the above, the backer layer 3 adhered well to the back surface, and was also extremely effective in preventing warping during heating.

[Brief explanation of the drawing]

1 is a cross-sectional view of a main part in a first embodiment of the present invention, FIG. 2 is a cross-sectional view of a main part in a second embodiment of the present invention, and FIG. 3 is a cross-sectional view of a main part in a second embodiment of the present invention. It is a cross section of the main part in the third embodiment. Explanation of the symbols: A, A', A'' are all decorative boards of the present invention, 1... substrate, 2... decorative board, 3...
... Backer layer, 4... Shatter prevention layer, 5... Embossed deep groove.

Claims (1)

[Scope of Claims] 1 20-35% (weight ratio, the same applies hereinafter) of aluminum hydroxide Al ₂ O ₃ 3H ₂ O containing 3-9% of a flame-retardant thermosetting resin binder, An inorganic substrate that is molded and hardened into a plate shape with the addition of 60-70% inorganic filler and 0.5-5% auxiliary material, and an inorganic substrate that is laminated on the surface of this substrate and molded and integrated with the above substrate by heat pressure. A decorative layer consisting of a resin shielding layer, a pattern layer thereon, and a surface resin layer, and a paper material impregnated with a thermosetting resin, which is placed on the back side of the substrate and integrally molded onto the substrate by heat pressure. a non-flammable backer layer made of a fibrous net material with 2 to 15 meshes, and a scattering prevention layer interposed inside the substrate or on at least one of the upper and lower surfaces of the substrate. Inorganic decorative board.