JPH04251740A - Exterior material - Google Patents
Exterior materialInfo
- Publication number
- JPH04251740A JPH04251740A JP3025728A JP2572891A JPH04251740A JP H04251740 A JPH04251740 A JP H04251740A JP 3025728 A JP3025728 A JP 3025728A JP 2572891 A JP2572891 A JP 2572891A JP H04251740 A JPH04251740 A JP H04251740A
- Authority
- JP
- Japan
- Prior art keywords
- layer
- resin
- fibrous layer
- base material
- laminated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 239000000463 material Substances 0.000 title abstract description 54
- 229920005989 resin Polymers 0.000 claims abstract description 49
- 239000011347 resin Substances 0.000 claims abstract description 49
- 239000004925 Acrylic resin Substances 0.000 claims abstract description 30
- 229920000178 Acrylic resin Polymers 0.000 claims abstract description 30
- 239000011230 binding agent Substances 0.000 claims abstract description 18
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 14
- 239000010410 layer Substances 0.000 claims description 87
- 239000011241 protective layer Substances 0.000 claims description 33
- 239000000203 mixture Substances 0.000 claims description 6
- 230000009477 glass transition Effects 0.000 abstract description 8
- 239000004566 building material Substances 0.000 abstract description 6
- 230000000694 effects Effects 0.000 abstract description 4
- 239000004640 Melamine resin Substances 0.000 description 12
- 229920000877 Melamine resin Polymers 0.000 description 12
- 238000005034 decoration Methods 0.000 description 10
- 238000007639 printing Methods 0.000 description 10
- 239000000123 paper Substances 0.000 description 9
- 239000004744 fabric Substances 0.000 description 8
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 7
- 238000000465 moulding Methods 0.000 description 6
- 229920003002 synthetic resin Polymers 0.000 description 5
- 239000000057 synthetic resin Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 229920001169 thermoplastic Polymers 0.000 description 4
- 239000004416 thermosoftening plastic Substances 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 230000006866 deterioration Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000005562 fading Methods 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 239000011888 foil Substances 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 238000007731 hot pressing Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- -1 silica sand Chemical compound 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 229910001845 yogo sapphire Inorganic materials 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 229910021532 Calcite Inorganic materials 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 229920002978 Vinylon Polymers 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 239000000440 bentonite Substances 0.000 description 1
- 229910000278 bentonite Inorganic materials 0.000 description 1
- SVPXDRXYRYOSEX-UHFFFAOYSA-N bentoquatam Chemical compound O.O=[Si]=O.O=[Al]O[Al]=O SVPXDRXYRYOSEX-UHFFFAOYSA-N 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000010411 cooking Methods 0.000 description 1
- 239000011889 copper foil Substances 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 238000004049 embossing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000002241 glass-ceramic Substances 0.000 description 1
- 239000003779 heat-resistant material Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000003879 lubricant additive Substances 0.000 description 1
- 125000005397 methacrylic acid ester group Chemical group 0.000 description 1
- 239000002557 mineral fiber Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 238000009428 plumbing Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 238000000275 quality assurance Methods 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
Abstract
Description
【０００１】0001
【産業上の利用分野】本発明は、外装材、詳しくは無機
質骨材とバインダー樹脂としての熱硬化性樹脂との混和
物でなる基材層を備えた外装材に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheathing material, and more particularly to a sheathing material having a base layer made of a mixture of inorganic aggregate and a thermosetting resin as a binder resin.
【０００２】0002
【従来の技術】無機質骨材をバインダー樹脂で結合した
基材層を備えた板状の建材は、たとえば特公昭５６−３
１２６０号公報で周知である。このものは、主たる骨材
として結晶水を含む水酸化アルミニウム（Ａｌ２Ｏ３・
３Ｈ２Ｏ） とバインダー樹脂としての熱硬化性樹脂（
たとえばメラミン樹脂）との混和物を板状に熱圧成形し
たものである。また、上記基材層を板状に熱圧成形する
ときに、プレス内にその基材層と共に印刷用インクで種
々の柄模様やモザイク模様などの表面装飾を施した紙布
などの繊維質層を配置し、基材層と繊維質層とを同時に
熱圧成形して両者を一体化して積層したものも上記公報
において既に知られている。[Prior Art] A plate-shaped building material having a base material layer made of inorganic aggregate bonded with a binder resin is known, for example, from the Japanese Patent Publication No. 56-3.
It is well known from the publication No. 1260. This material consists of aluminum hydroxide (Al2O3.
3H2O) and a thermosetting resin as a binder resin (
For example, a mixture with melamine resin) is hot-pressed into a plate shape. In addition, when the base material layer is hot-press molded into a plate shape, a fibrous layer such as paper cloth whose surface has been decorated with various patterns or mosaic patterns with printing ink is placed in the press together with the base material layer. It is already known from the above-mentioned publication that a base material layer and a fibrous layer are simultaneously formed by thermo-pressing to integrate and laminate them.
【０００３】これら公知の建材は、主として浴室のよう
な室内の水廻り箇所や、室内調理場の火元箇所などに好
適に利用されている。この建材がこのように室内装飾用
の内装材として汎用されるのは、基材層が難燃性や耐水
性に富み、繊維質層に印刷された表面装飾が長期間に亘
って褪色せずに優れた室内装飾性を発揮し、しかも上記
基材層との剥離を生じにくいということが一つの要因に
なっている。しかしながら、繊維質層における表面装飾
に用いられている印刷用インクは紫外線にさらされると
早期に褪色して装飾効果を失い、また、繊維質層自体も
紫外線にさらされると早期に劣化して褐色化しやすい。
そのため、上述した公知の建材は内装材としては優れた
ものであるけれども、直射日光や風雨にさらされる外装
材としてはそのままでは使用しにくいものであるといえ
る。[0003] These known building materials are suitably used mainly in indoor plumbing areas such as bathrooms and fire sources in indoor cooking areas. The reason why this building material is widely used as an interior decoration material is that the base material layer is highly flame retardant and water resistant, and the surface decoration printed on the fibrous layer does not fade over a long period of time. One of the factors is that it exhibits excellent interior decoration properties and is less likely to peel off from the base layer. However, the printing ink used to decorate the surface of the fibrous layer quickly fades and loses its decorative effect when exposed to ultraviolet rays, and the fibrous layer itself deteriorates quickly and turns brown when exposed to ultraviolet rays. easy to change. Therefore, although the above-mentioned known building materials are excellent as interior materials, they are difficult to use as they are as exterior materials exposed to direct sunlight, wind and rain.
【０００４】他方、外装材として用いられる熱可塑性合
成樹脂板の紫外線劣化を抑制するために、その熱可塑性
合成樹脂板に耐候性に優れた樹脂であるアクリル系の樹
脂層をコーテイング処理やフィルム貼付処理などの手段
で一体に積層して保護層とする技術は既に知られている
。On the other hand, in order to suppress UV deterioration of thermoplastic synthetic resin plates used as exterior materials, the thermoplastic synthetic resin plates are coated with an acrylic resin layer, which is a resin with excellent weather resistance, or a film is pasted on the thermoplastic synthetic resin plates. Techniques for forming a protective layer by integrally laminating them through processing or other means are already known.
【０００５】周知のようにアクリル系樹脂は熱可塑性合
成樹脂であり、無機質骨材を主体とする基材層やその上
に積層された繊維質層に対する接合性はほとんど具備し
ていないといってもよい。そのため、アクリル系樹脂が
耐候性に富む合成樹脂であるからといって、アクリル系
樹脂を直ちに上述の基材層に一体的に積層することは困
難である。すなわち、アクリル系樹脂フィルムを上記基
材層やその基材層と繊維質層との積層体に重ねてそれを
熱圧成形しても、両者が強固に接合しにくいため、アク
リル系樹脂フィルムの紫外線吸収性によって繊維質層の
劣化やその表面装飾に用いられている印刷用インクの褪
色を抑制する機能は剥離によって損なわれやすい。この
ような事情があったため、従来は、難燃性や耐水性、さ
らには室内装飾性にも優れた上述の建材を外装材として
用いると、近時の建築仕様たとえば難燃性、耐水性は勿
論、軽薄性や装飾性などを充足することが判っていても
、外装材としては用いられず専ら内装材として用いられ
ていたに過ぎなかった。[0005] As is well known, acrylic resin is a thermoplastic synthetic resin and has almost no bonding properties to the base material layer mainly composed of inorganic aggregate and the fibrous layer laminated thereon. Good too. Therefore, even though the acrylic resin is a synthetic resin with excellent weather resistance, it is difficult to immediately and integrally laminate the acrylic resin on the above-mentioned base material layer. In other words, even if an acrylic resin film is stacked on the base material layer or a laminate of the base material layer and the fibrous layer and then hot-press molded, it is difficult to firmly bond the two. The function of suppressing the deterioration of the fibrous layer and the fading of the printing ink used for its surface decoration due to ultraviolet absorption is likely to be impaired by peeling. Due to these circumstances, in the past, when the above-mentioned building materials, which were excellent in flame retardancy, water resistance, and even interior decoration, were used as exterior materials, recent architectural specifications such as flame retardancy and water resistance were not met. Of course, even though it was known to be lightweight and decorative, it was only used as an interior material and not as an exterior material.
【０００６】そこで、本願発明者は、無機質骨材を主体
とする基材層と繊維質層と耐候性に富む保護層とが、屋
外使用でも長期に亘って剥離を起こさないような強固な
接合力で接合されるようにする手段を見出すために鋭意
研究を重ね、本発明を完成させるに至った。[0006] Therefore, the inventors of the present application have developed a method for creating a strong bond between a base material layer mainly composed of inorganic aggregate, a fibrous layer, and a highly weather-resistant protective layer that will not peel off over a long period of time even when used outdoors. We have conducted extensive research to find a means for joining by force, and have finally completed the present invention.
【０００７】[0007]
【発明が解決しようとする課題】すなわち、本発明は、
基材層と繊維質層とを熱圧成形して一体化する工程では
基材層にバインダー樹脂として含まれている熱硬化性樹
脂が繊維質層の表面に滲出してくるという事実、熱硬化
性樹脂とアクリル系樹脂フィルムとは密着接合が可能で
あるという事実などに着目してなされたもので、繊維質
層の表面に滲出してきた熱硬化性樹脂、あるいは繊維質
層にあらかじめ含浸させた熱硬化性樹脂を利用してアク
リル系樹脂フィルムなどの耐候性に富む保護層を接合し
、基材層と繊維質層と保護層との接合性を高めて屋外使
用での保護層の剥離を抑制することによって、繊維質層
に印刷用インクで施された装飾模様の紫外線による褪色
や繊維質層の劣化を抑制することのできる外装材を提供
することを解決課題とする。[Problem to be solved by the invention] That is, the present invention
In the process of heat-pressing and integrating the base material layer and the fibrous layer, the thermosetting resin contained in the base material layer as a binder resin oozes out onto the surface of the fibrous layer. This technology was developed based on the fact that adhesive bonding is possible between thermosetting resin and acrylic resin film. A thermosetting resin is used to bond a highly weather-resistant protective layer such as an acrylic resin film to improve bonding between the base material layer, fibrous layer, and protective layer, making it easier to peel off the protective layer during outdoor use. An object to be solved is to provide an exterior material that can suppress fading of decorative patterns applied to a fibrous layer with printing ink and deterioration of the fibrous layer due to ultraviolet rays.
【０００８】[0008]
【課題を解決するための手段】本発明の外装材は、無機
質骨材とバインダー樹脂としての熱硬化性樹脂との混和
物でなる基材層と、基材層のバインダー樹脂と同質の樹
脂が含浸された繊維質層と、保護層とがこの順に積層さ
れ、保護層はアクリル系樹脂フィルムよりなり、上記繊
維質層における含浸樹脂の密着力によりその繊維質層に
一体化されて積層されているものである。[Means for Solving the Problems] The exterior material of the present invention includes a base material layer made of a mixture of inorganic aggregate and a thermosetting resin as a binder resin, and a resin of the same quality as the binder resin of the base material layer. The impregnated fibrous layer and the protective layer are laminated in this order, the protective layer is made of an acrylic resin film, and is integrated and laminated with the fibrous layer due to the adhesion of the impregnated resin in the fibrous layer. It is something that exists.
【０００９】[0009]
【作用】本発明の構成によれば、繊維質層に含浸されて
いる熱硬化性樹脂と保護層であるアクリル系樹脂フィル
ムとが一体化されており、繊維質があるにもかかわらず
強固に接合される。[Function] According to the structure of the present invention, the thermosetting resin impregnated in the fibrous layer and the acrylic resin film serving as the protective layer are integrated, so that it is strong even though it is fibrous. Joined.
【００１０】0010
【実施例】図１は本発明の典型的な実施例による外装材
Ａの模識図で、１は基材層、２は繊維質層、３，４は保
護層を示している。DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a schematic diagram of an exterior material A according to a typical embodiment of the present invention, in which 1 is a base layer, 2 is a fibrous layer, and 3 and 4 are protective layers.
【００１１】基材層１は主たる骨材として結晶水を含む
水酸化アルミニウム（Ａｌ２Ｏ３・３Ｈ２Ｏ） の固形
粉末とバインダー樹脂としてのメラミン樹脂との混和物
でなる。主たる骨材としての水酸化アルミニウムは２０
０℃以下では熱変形を起こさず、周囲温度が３００〜５
５０℃になると結晶水を放出して燃焼抑制機能を発揮す
ると同時に、耐熱材としての Ａｌ２Ｏ３になるため外
装材Ａに不燃性を与える。また、水酸化アルミニウムは
外装材Ａの機械的強度部材ともなる。骨材としては水酸
化アルミニウム以外の無機質材料、たとえば珪砂、方解
石粉、珪酸カルシウムなどの無機質粉末材料を用いるこ
とができるが、これらは水酸化アルミニウムを主体とす
る骨材の補助骨材として用いることによって基材層１の
機械的強度の向上や増量によるコスト引下げ、難燃性の
助長などに役立つものである。また、成形時の流動性付
与のためには、ゼオライト、カオリン、ベントナイト、
酸性白土などの粘土類を用いることが可能である。石綿
のような鉱物質繊維、ガラス繊維やセラミックス繊維の
ような無機繊維、ウィスカーなどの金属繊維、ナイロン
やビニロンなどの化学繊維を骨材に混ぜて機械的強度を
改善することも可能である。バインダー樹脂としてはメ
ラミン樹脂やその誘導体であるメラミン−ホルマリン樹
脂を好適に用いられている。しかし、それ以外の樹脂、
たとえばフェノール樹脂やその誘導体などを用いること
も可能てある。バインダー樹脂は骨材や補助骨材などの
材料に成形流動性を与え、しかも熱圧によって硬化する
性質を有する熱硬化性樹脂である必要がある。The base material layer 1 is made of a mixture of solid powder of aluminum hydroxide (Al2O3.3H2O) containing crystal water as a main aggregate and melamine resin as a binder resin. Aluminum hydroxide as the main aggregate is 20
No thermal deformation occurs below 0℃, and when the ambient temperature is 300~5℃
When the temperature reaches 50°C, it emits crystal water and exhibits a combustion suppressing function, and at the same time, it becomes Al2O3 as a heat-resistant material, giving the exterior material A non-combustibility. Moreover, aluminum hydroxide also serves as a mechanical strength member of the exterior material A. As the aggregate, inorganic materials other than aluminum hydroxide, such as silica sand, calcite powder, calcium silicate, etc., can be used, but these should not be used as auxiliary aggregates for aggregates mainly composed of aluminum hydroxide. This is useful for improving the mechanical strength of the base material layer 1, reducing costs by increasing the amount, and promoting flame retardancy. In addition, to provide fluidity during molding, zeolite, kaolin, bentonite,
It is possible to use clays such as acid clay. It is also possible to improve mechanical strength by mixing mineral fibers such as asbestos, inorganic fibers such as glass fibers and ceramic fibers, metal fibers such as whiskers, and chemical fibers such as nylon and vinylon with the aggregate. As the binder resin, melamine resin and its derivative melamine-formalin resin are preferably used. However, other resins,
For example, it is also possible to use phenol resin or its derivatives. The binder resin needs to be a thermosetting resin that provides molding fluidity to materials such as aggregates and auxiliary aggregates, and has the property of being hardened by heat and pressure.
【００１２】基材層１に含まれる主たる骨材としての水
酸化アルミニウムの固形粉末配合量は重量比で４０〜９
７％（好ましくは５０〜７０％）であり、この範囲外で
あると十分な不燃性が得られなかったり、バインダー樹
脂による結合力が低くなり過ぎてひび割れや欠落を生じ
やすくなる。バインダー樹脂の配合量は重量比で３〜１
２％（好ましくは６〜１０％）であり、この範囲外であ
ると結合力の不足や不燃化が阻害されたりする。The amount of aluminum hydroxide solid powder contained in the base material layer 1 as the main aggregate is 40 to 9 by weight.
7% (preferably 50 to 70%), and if it is outside this range, sufficient nonflammability may not be obtained, or the binding strength of the binder resin will be too low, making it easy to crack or chip. The amount of binder resin blended is 3 to 1 by weight.
2% (preferably 6 to 10%), and if it is outside this range, the binding strength may be insufficient or the nonflammability may be inhibited.
【００１３】繊維質層２はセルローズパルプ製の紙や不
織布、織布で作られており、その繊維質層２には上述の
バインダー樹脂と同質の未硬化の樹脂が含浸されている
。この実施例ではメラミン樹脂が含浸されている。繊維
質層２に対するメラミン樹脂の含浸は、基材層１に繊維
質層２を積層一体化する前に含浸しておいても、熱圧し
て積層一体化するときに繊維質層２に滲出してくる基材
層２のメラミン樹脂を繊維質層２に含浸させてもよい。
繊維質層２の表面には印刷用インクを用いて柄模様など
の表面装飾が施されている。したがって、この表面装飾
による装飾性を阻害させないためには、含浸樹脂として
無色透明の熱硬化性樹脂を採用することが得策であり、
その意味では透明性に優れるメラミン樹脂を含浸樹脂と
することが最適である。表面装飾には、印刷用インクの
ほか、アルミ箔、銅箔などの極薄金属箔を用いることも
でき、その金属箔に導電性を有するものを用いると保護
層３に制電性が与えられ、外装材Ａに対する塵芥の静電
付着が抑制される。The fibrous layer 2 is made of cellulose pulp paper, nonwoven fabric, or woven fabric, and is impregnated with an uncured resin of the same quality as the above-mentioned binder resin. In this example it is impregnated with melamine resin. Even if the melamine resin is impregnated into the fibrous layer 2 before the fibrous layer 2 is laminated and integrated into the base layer 1, it will not ooze into the fibrous layer 2 when the fibrous layer 2 is laminated and integrated by hot pressing. The fibrous layer 2 may be impregnated with the melamine resin of the base material layer 2. The surface of the fibrous layer 2 is decorated with a pattern or the like using printing ink. Therefore, in order not to hinder the decorativeness of this surface decoration, it is a good idea to use a colorless and transparent thermosetting resin as the impregnating resin.
In this sense, it is optimal to use melamine resin, which has excellent transparency, as the impregnating resin. In addition to printing ink, ultra-thin metal foil such as aluminum foil or copper foil can be used for surface decoration, and if the metal foil is conductive, antistatic properties can be imparted to the protective layer 3. , electrostatic adhesion of dust to the exterior material A is suppressed.
【００１４】本実施例では保護層３，４としてフィルム
が用いられている。保護層３，４にはいずれもアクリル
系樹脂フィルムが用いられているのであるが、下層側の
保護層３に用いられているアクリル系樹脂フィルムは上
層側の保護層４に用いられているアクリル系樹脂フィル
ムよりもメラミン樹脂との相溶性に優れ、柔軟性に富ん
でおり、１２０〜１６０℃の熱圧でメラミン系樹脂と積
層一体化する。アクリル系樹脂フィルムの相溶性の良し
悪しはガラス転移点の高低により変わる。このガラス転
移点はたとえばゴム分含有量の多少により変化し、ゴム
分含有量が多いほどガラス転移点が低くなって柔軟性に
富むものになる。実施例の場合、下層側の保護層３にお
けるアクリル系樹脂フィルムの含有ゴム分を１８％とし
、上層側の保護層４におけるアクリル系樹脂フィルムの
含有ゴム分を１５％としてある。このほか、ガラス転移
点を下げるには、メタクリル酸エステルなどを添加して
アロイ化したり、滑剤系添加物を増やしたりすることで
ある。この実施例のように繊維質層２の含浸樹脂がメラ
ミン樹脂である場合、繊維質層２に対するアクリル系樹
脂フィルムの密着接合性は、そのアクリル系樹脂フィル
ムが柔軟なほど相溶性が良好である。したがって、上述
のように含有ゴム分が多く相溶性の大きい柔軟なアクリ
ル系樹脂フィルムを下層側の保護層３としてそれを繊維
質層２に一体に接合して積層し、その上に含有ゴム分が
少なく相溶性のやゝ悪い硬いアクリル系樹脂フィルムを
一体に接合して積層することにより、繊維質層２には下
層側の保護層３が強固に接合され、下層側の保護層３に
は上層側の保護層４が強固に接合されることになり、そ
れら３層の接合強度が大きくなって層間剥離をきわめて
生じにくいものになる。含有ゴム分を１５％としてガラ
ス転移点を低くしたアクリル系樹脂フィルムの表面硬度
は鉛筆硬度に換算してＨＢ〜Ｂ程度であり、傷つきを生
じにくいのに反し、上述した成分組成の基材層１に繊維
質層２を積層一体化したものの表面硬度は鉛筆硬度に換
算して２Ｂ程度かそれ以下で比較的傷つきやすいもので
ある。そのため、実施例の外層材Ａは、上層側の保護層
４が高硬度を有するために磨耗や傷つきによる損傷を受
けにくくなる。In this embodiment, films are used as the protective layers 3 and 4. Acrylic resin films are used for both the protective layers 3 and 4, but the acrylic resin film used for the lower protective layer 3 is different from the acrylic resin film used for the upper protective layer 4. It has better compatibility with melamine resin than other resin films, is more flexible, and can be laminated and integrated with melamine resin under heat and pressure at 120 to 160°C. The compatibility of acrylic resin films varies depending on the glass transition point. This glass transition point changes depending on the rubber content, for example, and the higher the rubber content, the lower the glass transition point and the more flexible the material becomes. In the example, the rubber content of the acrylic resin film in the lower protective layer 3 is 18%, and the rubber content of the acrylic resin film in the upper protective layer 4 is 15%. In addition, the glass transition point can be lowered by adding methacrylic acid ester or the like to form an alloy, or by increasing the amount of lubricant additives. When the impregnating resin of the fibrous layer 2 is a melamine resin as in this example, the compatibility of the acrylic resin film with the fibrous layer 2 is better as the acrylic resin film is more flexible. . Therefore, as mentioned above, a flexible acrylic resin film with a high rubber content and high compatibility is integrally bonded and laminated to the fibrous layer 2 as the lower protective layer 3, and the rubber content is laminated on top of the fibrous layer 2. By integrally bonding and laminating hard acrylic resin films with low compatibility and poor compatibility, the lower protective layer 3 is firmly bonded to the fibrous layer 2; The upper protective layer 4 is firmly bonded, and the bonding strength of these three layers increases, making it extremely difficult for interlayer peeling to occur. The surface hardness of the acrylic resin film, which has a low glass transition point with a rubber content of 15%, is about HB to B in terms of pencil hardness, and is not easily scratched. The surface hardness of the fibrous layer 2 integrated with the fibrous layer 1 is about 2B or less in terms of pencil hardness, and it is relatively easily scratched. Therefore, in the outer layer material A of the example, since the upper protective layer 4 has high hardness, it is less susceptible to damage due to wear and scratches.
【００１５】保護層を積層する態様としては、図２のよ
うに相溶性がさらによく柔軟なアクリル系樹脂フィルム
（下層側の保護層３に相当する。）と相溶性が悪く硬い
アクリル系樹脂フィルム（上層側の保護層４に相当する
。）との間にそれらの中間のガラス転移点を有する保護
層５を介在してそれらを積層一体化しておいてもよい。
このようにしておくと、下層側−中間−上層側の各アク
リル系フィルムの硬さがこの順に徐々に硬くなるため、
それら相互の接合強度が一層大きくなり、層間剥離がさ
らに生じにくくなる。保護層３，４，５の厚み全体で５
０μ程度あればよい。なお、保護層としては相溶性のよ
い柔軟なアクリル系樹脂フィルムを一層用いてもよいが
、表面硬度が悪いため、２層や３層にして表面硬度を高
めた方が好ましい。As shown in FIG. 2, the protective layer can be laminated using a flexible acrylic resin film with better compatibility (corresponding to the lower protective layer 3) and a hard acrylic resin film with poor compatibility. (corresponding to the upper protective layer 4) may be laminated and integrated by interposing a protective layer 5 having a glass transition point between them. By doing this, the hardness of each acrylic film on the lower layer side, intermediate layer side, and upper layer side will gradually become harder in this order.
The bonding strength between them becomes even greater, and delamination becomes more difficult to occur. The total thickness of protective layers 3, 4, and 5 is 5.
It is sufficient if it is about 0μ. Note that one layer of a flexible acrylic resin film with good compatibility may be used as the protective layer, but since the surface hardness is poor, it is preferable to use two or three layers to increase the surface hardness.
【００１６】以上説明した外装材Ａは建築物の外壁など
、直射日光や風雨にさらされる場所でも十分な耐久性を
保ち、繊維質層２に印刷用インクを用いて装飾が施され
ているととしても、その装飾の褪色や繊維質層２自体の
褐色化をほとんど生じなくなり、長期間にわたり初期の
外観が持続する。したがって、繊維質層２に印刷用イン
クを用いて自由にデザインされた緻密な柄模様や装飾模
様などの装飾を印刷することができるようになる。また
、保護層であるアクリル系樹脂フィルム表面にフッ素樹
脂フィルムを積層しておけば、さらなる耐候性の向上を
達成できる。The exterior material A described above maintains sufficient durability even in places exposed to direct sunlight and wind and rain, such as the exterior walls of buildings, and the fibrous layer 2 is decorated using printing ink. Even so, fading of the decoration and browning of the fibrous layer 2 itself hardly occur, and the initial appearance is maintained for a long period of time. Therefore, decorations such as freely designed elaborate patterns and decorative patterns can be printed on the fibrous layer 2 using printing ink. Furthermore, by laminating a fluororesin film on the surface of the acrylic resin film serving as the protective layer, further improvement in weather resistance can be achieved.
【００１７】次に製造方法を説明する。雌金型６の底部
に保護層３，４，５を形成するためのアクリル系フィル
ム３´，４´，５´と、印刷インクなどで装飾の施され
た繊維質層２を形成する紙布２´とを配置してから、そ
の上に秤量した基材層１の材料１´をコニーダやヘンシ
ェルミキサーなどを用いて混合した後に投入する。その
後、雄金型７を閉じ、熱圧成形して製品に仕上げる。熱
圧成形時にエンボス処理したり、目地を形作るための深
溝を形成させることも可能である。Next, the manufacturing method will be explained. Acrylic films 3', 4', 5' for forming the protective layers 3, 4, 5 on the bottom of the female mold 6, and paper cloth for forming the fibrous layer 2 decorated with printing ink etc. 2', and then the weighed material 1' for the base layer 1 is mixed using a co-kneader, Henschel mixer, etc., and then added thereto. Thereafter, the male mold 7 is closed, and the product is finished by hot-pressing. It is also possible to perform embossing during hot-press molding or to form deep grooves to form joints.
【００１８】この製法に用いられる繊維質層の紙布２´
は、あらかじめメラミン樹脂などの熱硬化性樹脂を含浸
したものを好適に用いることができ、そのような紙布２
´を用いると、熱圧成形時に紙布２´の表面に滲出した
含浸樹脂と下層側の保護層のアクリル系樹脂フィルム３
´とが互いに相溶し、かつ混ざり合って熱硬化時に積層
一体化して強固に密着し、層間剥離を起こす心配のない
大きな密着接合力が得られる。樹脂を含浸していない繊
維質層の紙布２´を使用した場合でも、熱圧成形時に基
材層の材料１´にバインダー樹脂として含まれているメ
ラミン樹脂などの熱硬化性樹脂が繊維質層の紙布２´に
しみ込み、その樹脂が紙布２´の表面に滲出して同様の
現象が得られることもある。熱圧成形は、温度２００℃
以下、圧力１００〜１５０ｋｇ／ｃｍ２で数分間という
条件で行うことができる。なお、あらかじめ基材層１と
繊維質層２とを熱圧積層一体化したものにアクリル系樹
脂フィルムを積層一体化することも可能ではあるが、硬
化した繊維質層２の表面へのアクリル系樹脂フィルムの
密着強度が弱くなる懸念があり、上述したように未硬化
の熱硬化性樹脂を含浸した繊維質層２と熱圧一体化して
硬化と同時に密着積層するようにすれば強固に一体化す
る。Fibrous layer paper cloth 2' used in this manufacturing method
The paper cloth 2 can be preferably impregnated with a thermosetting resin such as melamine resin.
When '' is used, the impregnated resin exuded onto the surface of the paper cloth 2' during hot-press molding and the acrylic resin film 3 of the lower protective layer are removed.
' are mutually compatible and mixed, and when heat cured, they are laminated into an integral unit and firmly adhered to each other, resulting in a large adhesion bonding force without the risk of delamination. Even when paper cloth 2' with a fibrous layer that is not impregnated with resin is used, the thermosetting resin such as melamine resin contained as a binder resin in the material 1' of the base layer will be absorbed into the fibrous material during hot press molding. A similar phenomenon may occur when the resin soaks into the paper fabric 2' of the layer and oozes out onto the surface of the paper fabric 2'. Heat pressure molding is performed at a temperature of 200℃
Hereinafter, it can be carried out under the conditions of a pressure of 100 to 150 kg/cm2 for several minutes. Note that it is possible to integrate an acrylic resin film onto a base material layer 1 and a fibrous layer 2 that have been laminated together under heat and pressure in advance. There is a concern that the adhesion strength of the resin film will be weakened, so if it is heat-press integrated with the fibrous layer 2 impregnated with uncured thermosetting resin and laminated closely at the same time as curing, as described above, it will be firmly integrated. do.
【００１９】[0019]
【発明の効果】本発明による外装材は、無機質骨材とバ
インダー樹脂との混和物である基材層の難燃性により耐
火性を備えるに至り、基材層に積層された繊維質層に印
刷インクを用いて種々の装飾を施すことによって優れた
装飾性を発揮するようになる。その上、繊維質層やそれ
に施された装飾模様が耐候性に優れたアクリル系樹脂フ
ィルムでなる保護層によって保護されるから、それらが
早期に紫外線劣化して褐色化したり褪色したりすること
がなくなるという効果がある。したがって、近時の外装
材に要求される長期間にわたる品質保証や、優れた装飾
性や、軽薄性や、施工の簡素化をきわめて容易に達成す
ることができるものである。Effects of the Invention The exterior material according to the present invention has fire resistance due to the flame retardancy of the base material layer which is a mixture of inorganic aggregate and binder resin, and the fibrous layer laminated on the base material layer has fire resistance. Excellent decorative properties can be achieved by applying various decorations using printing ink. Furthermore, since the fibrous layer and the decorative patterns on it are protected by a protective layer made of an acrylic resin film with excellent weather resistance, they will not deteriorate prematurely due to UV rays and will not turn brown or fade. It has the effect of disappearing. Therefore, it is possible to extremely easily achieve the long-term quality assurance, excellent decorativeness, lightness and thinness, and simplification of construction required of modern exterior materials.
【図１】本発明の実施例による外装材の模識図である。FIG. 1 is a schematic diagram of an exterior material according to an embodiment of the present invention.
【図２】他の実施例による外装材の模識図である。FIG. 2 is a schematic diagram of an exterior material according to another embodiment.
【図３】本発明の製造方法を示す断面図である。FIG. 3 is a cross-sectional view showing the manufacturing method of the present invention.
１ 基材層 ２ 繊維質層 ３，４，５ 保護層 1 Base material layer 2. Fibrous layer 3, 4, 5 Protective layer
Claims (1)
熱硬化性樹脂との混和物でなる基材層と、基材層のバイ
ンダー樹脂と同質の樹脂が含浸された繊維質層と、保護
層とがこの順に積層され、保護層はアクリル系樹脂フィ
ルムよりなり、上記繊維質層における含浸樹脂の密着力
によりその繊維質層に一体化されて積層されていること
を特徴とする外装材。Claim 1: A base layer made of a mixture of inorganic aggregate and a thermosetting resin as a binder resin, a fibrous layer impregnated with a resin of the same quality as the binder resin of the base layer, and a protective layer. are laminated in this order, the protective layer is made of an acrylic resin film, and is laminated integrally with the fibrous layer due to the adhesion of the impregnated resin in the fibrous layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3025728A JPH04251740A (en) | 1991-01-25 | 1991-01-25 | Exterior material |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3025728A JPH04251740A (en) | 1991-01-25 | 1991-01-25 | Exterior material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH04251740A true JPH04251740A (en) | 1992-09-08 |
Family
ID=12173867
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3025728A Pending JPH04251740A (en) | 1991-01-25 | 1991-01-25 | Exterior material |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH04251740A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102794964A (en) * | 2012-09-12 | 2012-11-28 | 常熟市金亿复合材料有限公司 | Continuous glass steel decorative plate and manufacturing method thereof |
-
1991
- 1991-01-25 JP JP3025728A patent/JPH04251740A/en active Pending
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102794964A (en) * | 2012-09-12 | 2012-11-28 | 常熟市金亿复合材料有限公司 | Continuous glass steel decorative plate and manufacturing method thereof |
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