Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
  • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
  • B44C1/005—Processes, not specifically provided for elsewhere, for producing decorative surface effects by altering locally the surface material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
  • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
  • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
  • B27N3/02—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from particles

Definitions

• This invention relates to a cork decorative sheet useful as flooring, walling or other construction materials, and the method for producing the same.
• a cork sheet produced by hardening the cork material with resin and molding, features unique feeling, thermal insulation, flexibility, sound-proofing properties and bore-proofness, and has come to be utilized in the field of interior work, as an interior construction material or furniture.
• the present Assignee proposed in JP Patent Kokai A-2-117831 a decorative sheet in which a coating containing radiation-proof opaque pigments having various color tones is applied on the surface of a cork base plate to form a fading preventative coating film and in which a moire pattern unique to the cork is produced in the color fading preventative coating film based upon the difference in absorption of the coating by the cork base plate for maintaining the moire pattern or the color tone proper to the cork and for suppressing color fading by UV rays.
• Such decorative board has the appearance proper to the cork and excellent durability so that it is expected to be used as e.g., flooring material.
• the cork sheet In order for the cork sheet to come into widespread use as the interior construction material, it is essential not only to exploit the properties unique to the cork, but also to impart some added value to the cork to raise its commercial value. Of course, the feeling proper to the cork needs to be maintained at any rate.
• a cork decorative sheet according to a first subject-matter of the present invention contains far-infrared radiating ceramics, and is produced by molding a crushed cork material into a sheet using a resin binder.
• cork decorative sheet containing far-infrared radiating ceramics is employed as an interior construction material, far-infrared rays are routinely radiated to promote health of the tenant.
• the coating material not only promotes health of the tenant, but acts as a surface protective layer to improve radiation-proofness.
• a crushed or granulated cork material is molded into a sheet using a resin binder and the inorganic anti-bacterial agent and/or the far-infrared radiating ceramics is contained therein.
• the inorganic anti-bacterial agent contained in the cork decorative sheet acts on cells of bacteria in general or fungi by ionic effects to cause their extinction.
• the cork decorative according to the first subject-matter of the present invention containing far-infrared radiating ceramics, has the feeling proper to the cook and exhibits not only heat insulating properties, flexibility, bore-proofness, sound-proofness or air permeability but also thermal and circulation promoting effects, so that the cork decorative sheet promotes health of the tenant simply on being employed as the interior construction material, such as a flooring material.
• the cork decorative sheet according to the second subject-matter of the present invention contains the inorganic anti-bacterial agent and hence is able to cause extinction of fungi or bacteria, such as E. Colis or yellow staphylococci, in order to maintain a sanitary environment.
• the cork decorative sheet of the present invention is free from fungi or bacteria, while it is not afflicted with mites or termites, so that it is advisably employed by those suffering from allergic constitution, atopic dermatitis, infantile asthma, rhinitis or hives.
• the cork decorative sheet of the present invention is surface-treated with the fluorine or silicon resin, the surface thus treated not only serves for promoting health but also acts for promoting pollution-proofness, radiation-proofness and durability, thereby significantly improving surface properties. That is, treatment with fluorine or silicon resins improves pollution resistance, radiation-proofness or durability, thereby further prohibiting intrusion of fungi or bacteria.
• the far-infrared radiating ceramics radiates far-infrared rays with a wavelength of 5 to 15 ⁇ m with high efficiency.
• such far-infrared radiating ceramics is known which radiates far infrared rays on heating or absorption of solar beams.
• these well-known far infrared radiating ceramics may be employed in the present invention, non-heated type far-infrared radiating ceramics, radiating far infrared rays to some extent even at ambient temperature, is most preferred.
• the non-heated type far-infrared radiating ceramics is formed of a ceramic material consisting mainly of, for example, amorphous silica or amorphous amino silicate and having the composition of 52.5 to 70 wt% of SiO2, 20 to 47 wt% of Al2O3 and not more than 3 wt% of Fe2O3.
• a specific example of the non-heated type far-infrared radiating ceramics is "Radi-Echo", a kind of amorphous ceramics manufactured by NIPPON PLATE GLASS CO. LTD.
• inorganic anti-bacterial agents generate active oxygen by ionic effects which in turn acts on cells of bacteria in general or fungi to cause their extinction.
• any of commercially available inorganic anti-bacterial agents may be employed.
• these agents include. "Radi-Echo Anti-Bacterial Powders” manufactured by NISSHO RADI-ECHO CO. LTD.
• the "Radi-Echo Anti-Bacterial Powders" manufactured by NISSHO RADI-ECHO CO. LTD is mainly composed of basic ceramics having the schematic composition of SiO2 > 50%, Al2O3 ⁇ 30%, MgO or CaO ⁇ 10% and Na2O or K2O ⁇ 5% and peculiarly tends to absorb bacteria such as E-coli because of its pore size.
• the anti-bacterial powders contain a small amount of anti-bacterial metal (silver) which acts on the cells of bacterial in general or fungi to cause their extinction.
• the cork decorative sheet of the present invention is formed of the crushed or pulverized cork material, optionally admixed with colored pigments, which crushed or pulverized cork material is molded into a plate shape by a resin binder, such as phenolic resin, urethane resin adhesive, epoxy urethane resin adhesive or vinyl acetate adhesive, optionally admixed with glycol.
• a resin binder such as phenolic resin, urethane resin adhesive, epoxy urethane resin adhesive or vinyl acetate adhesive, optionally admixed with glycol.
• the aforementioned far-infrared radiating ceramics and inorganic anti-bacterial agent may be previously mixed, either alone or as a mixture, into another starting material, such as a resin binder, during manufacture of the cork sheet. Alternatively, they may be coated in the form of a coating on the surface of the molded cork sheet. What is crucial is that the aforementioned far-infrared radiating ceramics and inorganic anti-bacterial
• the far-infrared radiating ceramics and the inorganic anti-bacterial agent be contained in amounts of 5 to 30 wt% and 0.5 to 3 wt%, based on the total weight of the cork sheet, respectively. If the amounts of the far-infrared radiating ceramics and the inorganic anti-bacterial agent are lower than the above range, sufficient effects cannot be expected, whereas, if the amounts are in excess of the above range, the risk is high that the feeling or flexibility proper to the cork be lost.
• the far-infrared radiating ceramics and the inorganic anti-bacterial agent be contained in amounts of 20 to 40 wt% and 2 to 4 wt%, based on the total weight of the cork sheet, respectively, and that the coating be applied so that the amount of the inorganic anti-bacterial agent per each process be 0.05 g/m2 to 2 g/m2 and above all 0.3 g/m2 to 0.7 g/m2, while the amount of the far-infrared radiating ceramics per each process be ten times as much as that of the inorganic anti-bacterial agent, that is 0.5 g/m2 to 20 g/m2 and above all 3 g/m2 to 7 g/m2.
• the amounts of the far-infrared radiating ceramics and the inorganic anti-bacterial agent in the cork sheet are determined by the content amounts and the coating amounts of the far-infrared radiating ceramics and the inorganic anti-bacterial agent in the coating.
• the inorganic anti-bacterial agents be present on the surface of the cork sheet in an amount of 0.1 g/m2 to 4 g/m2 and more desirably in an amount of 0.6 g/m2 to 1.4 g/m2, and that the far-infrared radiating ceramics be present in an amount ten times as much as that of the inorganic anti-bacterial agent, that is 1 g/m2 to 40 g/m2 and more desirably in an amount of 6 g/m2 to 14 g/m2.
• the cork base sheet presents a serious problem that it is markedly susceptible to color fading.
• the technique of applying an opaque coating on the surface of the cork base sheet in order to prevent color fading by the UV rays is useful. If the far-infrared radiating ceramics and the inorganic anti-bacterial agent is admixed into the opaque coating, improvement in the radiation-proofness of the cork sheet and promotion of human health may be achieved simultaneously.
• the far-infrared radiating ceramics and the inorganic anti-bacterial agent are not sufficiently effective in improving radiation-proofness, it is desirable that the inorganic pigments exhibiting color fading preventative properties be added effectively in the coating material.
• the pigments employed are preferably less permeable to UV rays and excellent in radiation-proofness, and may be enumerated by chrome yellow, carbon, iron oxide red and rutile titanium. Although organic pigments, such as benzine yellow, or organic transparent iron oxide red, lead white, zinc flower or anase titanium are usable, they are somewhat inferior in radiation-proofness to the aforementioned pigments. If desired, pigments of color tones different from those of the conventional cork, such as white, pink, orange or red, may be selected and employed to produce cork decorative sheets of various color tones.
• the resin components used in the coating material may be any resins commonly employed for the coating material. Although urethane or acrylic resins may be used in view of pliability, fluorine or silicon resins are most preferred because these resins are excellent in resistance against pollution, water-proofness, radiation-proofness or durability.
• fluorine or silicon resins are employed as the resins for coating, the surface of the cork decorative sheet is treated with these resins, so that water-proofness, resistance against pollution, radiation-proofness or durability may be afforded to the decorative sheet. Consequently, the fluorine resins or the silicon resins may be selectively employed according to the usage and application.
• the fluorine resins or the silicon resins may be employed only for surface treatment.
• the urethane reins or the acrylic resins may be employed as the resins for the coating material, while the fluorine resins or silicon resins may be coated to a thin thickness on the surface.
• the far-infrared radiating ceramics and the inorganic anti-bacterial agent may be mixed into the fluorine or silicon resins coated on the surface for utmost effects.
• any of well-known coating techniques such as roll coating, spray coating or flow coating, may be employed for applying the above coating material on the cork sheet surface
• the coating material be permeated under pressure into the cork sheet surface with the aid of a roll coater because it becomes possible in this manner to maintain the texture, air permeability and feeling proper to the natural cork sheet surface.
• the cork base sheet is prepared by mixing an adhesive (resin binder) to cork powders produced on crushing and granulating the starting cork material (bark of cork oak) with a granulator and molding the resulting mixture under application of pressure and heating. Consequently, extremely small pores proper to the bark of the cork oak exist on the cork sheet surface.
• the cork base sheet is a molded product of numerous cork granules, as discussed above, there exist numerous small-sized pits and recesses looking like worm-eaten spots.
• the coating material containing the far-infrared radiating ceramics and the inorganic anti-bacterial agent as well as various pigments is applied to and permeated under pressure into such cork base sheet, the above-mentioned small-sized pits and recesses are left unaltered on the surface, while air permeability is also maintained.
• the texture and the feeling may be maintained on the cork sheet surface in such a manner that the cork sheet can hardly be distinguished from the untreated cork sheet.
• Such surface conditions may be achieved only with the use of the roll coater, while such effect can hardly be achieved with any other coating method since the coating film is then produced on the cork sheet surface.
• the coating conditions need to be selected suitably for roll coating in order to produce the above-mentioned surface conditions.
• the coating quantity per coating operation be 22 g/m2 to 44 g/m2 and the viscosity of the coating material be 15 to 30 seconds in terms of the viscosity cup.
• the proportion of the pigment contained in the coating material is crucial, such that, if the pigment quantity is excessive, the appearance of the cork sheet surface becomes monotonous in its entirety. Consequently, the proportion of the pigments in their entirety, that is the sum of the quantities of the various pigments, is set to 5 to 65 wt%, and the proportion of the inorganic pigments exhibiting the color fading preventative properties, is set to 5 to 20 wt%, with the remainder being the resin components.
• the pigment proportion exceeds the above range, the ground pattern of the cork base sheet is hidden such that it becomes difficult to maintain the texture and feeling of the cork. On the contrary, if the pigment proportion is short of the above range, the color fading preventative effect becomes insufficient such that the product becomes inferior in radiation-proofness.
• the coating material may be applied by the roll coater once for all or in plural fractions. In the latter case, the number of times of fractional coating may be judiciously selected for finely changing the color tones of the resulting cork decorative sheet.
• a cork base sheet was prepared by previously introducing the far-infrared radiating ceramics into the resin binder.
• the cork oak was freed of bark and dried to a starting cork material which was then crushed and granulated by a granulator.
• the resulting granulated material was admixed with the resin binder (urethane resin adhesive) and far-infrared radiating ceramics sold under the trade name of "Radi-Echo".
• the resulting mixture was agitated and pressed to a compacted mass.
• the starting components were used in the following proportions: starting cork material 70 wt% resin binder 20 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo" 10 wt%
• the compacted mass was cut into a sheet the surface of which was ground to a cork decorative sheet.
• the resulting cork decorative sheet which was in the form of a molded product made up of numerous granulated cork grains, had the appearance in no way different from that of the natural cork sheet despite that the far-infrared radiating ceramics were contained therein.
• Cork decorative sheets were prepared in the similar manner with addition of colored pigments of various color tones besides the far-infrared radiating ceramics. Thus the cork decorative sheets containing the far-infrared radiating ceramics and colored in various color tones were obtained.
• a coating material containing far-infrared radiating ceramics was applied on the surface of a usual cork base sheet.
• the cork oak was freed of bark and dried to a starting cork material which was then granulated by a granulator.
• the resulting crushed material was admixed with the resin binder (urethane resin adhesive) and the resulting mixture was agitated and pressed to a compacted cork base sheet.
• urethane resin coating material 55 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo" 18 wt% additive (curing agent) 14 wt% solvent 13 wt%
• the above coating material was applied on the surface of the above cork base sheet in two portions so that the total coated amount was 66 g/m2.
• the viscosity of the coating material was 25 seconds in terms of the viscosity cup.
• cork decorative sheet With the produced cork decorative sheet, fine pores and pits on the sheet surface were maintained unchanged. In addition, the cork decorative sheet exhibited air permeability and maintained the texture and feeling proper to cork, such that it could hardly be distinguished from the natural cork sheet which was not processed with surface treatment.
• the cork decorative sheets were produced in the same way as in Example 2. However, the composition of the coating material was now changed to the following:
• urethane resin coating 45 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo" 18 wt% toning pigment 10 wt% additive (curing agent) 14 wt% solvent 13 wt%
• urethane resin coating 45 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo" 18 wt% toning pigment 10 wt% additive (curing agent) 14 wt% solvent 13 wt%
• urethane resin coating 35 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo" 18 wt% toning pigment 20 wt% additive (curing agent) 14 wt% solvent 13 wt%
• cork decorative sheets similarly to the product of the previous Example 2, fine pores and pits on the sheet surface were maintained unchanged.
• the cork decorative sheets were colored in various color tones, besides exhibiting air permeability and maintaining the texture and feeling proper to cork.
• a coating material containing far-infrared radiating ceramics was coated in the same way as in Example 2 on the surface of the cork decorative sheet containing the far-infrared radiating ceramics prepared in Example 1.
• a coating material A and a curing agent B were mixed at a ratio of 4:1 and a solvent C was then added to the resulting mixture until the viscosity cup of 15 to 20 seconds was reached in order to prepare an opaque coating material.
• the following compositions were used for the coating material A, curing agent B and the solvent C.
• acryl urethane resin 28 wt% cork color toning pigment 3 wt% additive 0.3 wt% aromatic hydrocarbons 32 wt% acetic acid ester 33 wt% ketone 3.7 wt%
• aromatic hydrocarbons 55 wt% acetic acid ester 35 wt% methylethylketone 10 wt%
• the prepared opaque coating material was uniformly coated on the entire surface of a cork decorative sheet (305 mm ⁇ 305 mm) prepared in Example 1 in two portions each of 6 g, and the sheet thus coated was dried by a far infrared drier.
• a photoreactive urethane resin consisting of 54 wt% of acryl urethane resin, 40 wt% of a reactive diluent and 6 wt% of a suspension agent was further coated in an amount of 70 g/m2 and the resulting product was cured by UV irradiation to produce a cork decorative sheet.
• the resulting cork decorative sheets contained far infrared radiating ceramics and exhibited superior radiation-proofness while maintaining the moire-like pattern unique to the cork.
• the produced sheets were exposed to the solar beam by way of color fading tests. It was found that the tested sheets scarcely showed color fading.
• cork base sheets were prepared by previously mixing far-infrared radiating ceramics and an inorganic anti-bacterial agent into a resin binder.
• the cork oak was freed of bark and dried to a starting cork material which was then crushed and granulated by a granulator.
• the resulting granulated material was admixed with a resin binder (urethane resin adhesive), an inorganic anti-bacterial agent having the trade name of "Radi-Echo Anti-Bacterial Powders" and far-infrared radiating ceramics having the trade name of (“Radi-Echo”) and the resulting mixture was agitated and pressed to a compacted mass.
• the starting material had the following composition: starting cork material 70 wt% resin binder 19 wt% inorganic anti-bacterial agent having the trade name of "Radi-Echo Anti-Bacterial Powders" 1 wt% far-infrared radiating ceramics having the trade name of ("Radi-Echo”) 10 wt%
• the compacted mass was cut into a sheet the surface of which was ground to a cork decorative sheet.
• the resulting cork decorative sheet which was in the form of a molded product made up of numerous crushed cork grains, had the appearance in no way different from that of the natural cork sheet despite that the far-infrared radiating ceramics were contained therein.
• Cork decorative sheets were prepared in the similar manner with addition of colored pigments of various color tones besides the inorganic anti-bacterial agent and the far-infrared radiating ceramics. Thus the cork decorative sheets containing the far-infrared radiating ceramics and colored in various color tones were obtained.
• a coating material containing an inorganic anti-bacterial agent and far-infrared radiating ceramics was applied on the surface of a usual cork base sheet.
• the cork oak was freed of bark and dried to a starting cork material which was then crushed and granulated by a granulator.
• the resulting granulated material was admixed with the resin binder (urethane resin adhesive) and the resulting mixture was agitated and pressed to a compacted cork base sheet.
• urethane resin coating material 55 wt% inorganic anti-bacterial agent having the trade name of "Radi-Echo Anti-Bacterial Powders" 1.8 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo” 18 wt% additive (curing agent) 12.2 wt% solvent 13 wt%
• the above coating material was applied on the surface of the above cork base sheet in two portions so that the total coated amount was 66 g/m2.
• the viscosity of the coating material was 25 seconds in terms of the viscosity cup.
• a fluorine resin coating material containing a fluorine resin coating material containing the inorganic anti-bacterial agent and the far-infrared radiating ceramics was applied to and permeated under pressure into the surface of the produced cork decorative sheet. In this manner, resistance against pollution, radiation-proofness an durability of the cork decorative sheet could be improved further.
• the cork decorative sheets were produced in the same way as in Example 7. However, the composition of the coating material was now changed to the following:
• urethane resin coating 35 wt% inorganic anti-bacterial agent having the trade name of "Radi-Echo Anti-Bacterial Powders” 1.8 wt% far-infrared radiating ceramics marketed under the trade name of "Radi-Echo” 18 wt% toning pigment 20 wt% additive (curing agent) 12.2 wt% solvent 13 wt%
• cork decorative sheets similarly to the product of the previous Example 7, fine pores and pits on the sheet surface were maintained unchanged.
• the cork decorative sheets were colored in various color tones, besides exhibiting air permeability and maintaining the texture and feeling proper to cork.
• the coating material containing an inorganic anti-bacterial agent and far-infrared radiating ceramics was coated in the same way as in Example 7 on the surface of the cork decorative sheet containing the far-infrared radiating ceramics prepared in Example 6.
• cork decorative sheet which maintained the texture and feeling proper to the cork and which contained the inorganic anti-bacterial agent and far-infrared radiating ceramics on the surface and in the inside thereof could be produced.
• the cork decorative sheet thus produced also showed excellent resistance against contamination, excellent radiation-proofness and durability.
• a coating material D and a curing agent E having the following compositions, were mixed at a ratio of 4:1 and a solvent F was then added to the resulting mixture until the viscosity cup of 15 to 20 seconds was reached in order to prepare an opaque coating material.
• the following compositions were used for the coating material D, curing agent E and the solvent F.
• acryl urethane resin 28 wt% cork color toning pigment 3 wt% additive 0.3 wt% aromatic hydrocarbons 32 wt% acetic acid ester 33 wt% ketone 3.7 wt%
• aromatic hydrocarbons 55 wt% acetic acid ester 35 wt% methylethylketone 10 wt%
• the prepared opaque coating material was uniformly coated on the entire surface of a cork decorative sheet (305 mm ⁇ 305 mm) prepared in Example 1 in two portions, each in an amount of 6 g, and the sheet thus coated was dried by a far infrared drier.
• a photoreactive urethane resin consisting of 54 wt% of acryl urethane resin, 40 wt% of a reactive diluent and 6 wt% of a suspension agent was further coated in an amount of 70 g/m2 and the resulting product was cured by UV irradiation to produce a cork decorative sheet.
• the resulting cork decorative sheets contained the inorganic anti-bacterial agent and the far infrared radiating ceramics and exhibited superior radiation-proofness while maintaining the moire-like cork pattern.
• the produced sheets were exposed to the solar beam by way of color fading tests. It was found that the tested sheets scarcely suffered from color fading.

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• Life Sciences & Earth Sciences (AREA)
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• Wood Science & Technology (AREA)
• Forests & Forestry (AREA)
• Chemical And Physical Treatments For Wood And The Like (AREA)
• Laminated Bodies (AREA)
• Dry Formation Of Fiberboard And The Like (AREA)

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• 1994
  • 1994-06-23 WO PCT/JP1994/001005 patent/WO1995000330A1/fr not_active Application Discontinuation
  • 1994-06-23 EP EP94918555A patent/EP0662393A4/fr not_active Withdrawn

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