JP2001030421A - Mineral decorative plate and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance productivity of a decorative plate having excellent masking property and resistance to a release or a change in properties of decorative paper by providing a minutely alkaline or neutral mineral base plate layer, an adhesive layer having masking property and a decorative sheet layer. SOLUTION: In order to manufacture the mineral decorative plate, a minutely alkaline or neutral mineral base plate layer, an adhesive layer having a masking layer and a decorative sheet are sequentially formed. As the plate layer to be used, a layer which does not exert an adverse influence to a release or a change in properties of a decorative sheet layer may be used, and the layer which contains a powder-like and/or particulate mineral material and a mineral fiber as main components is preferred or particularly the layer which is fixed by a thermosetting resin having heat resistance as a normal bonding component is preferred. As the powder-like and/or particulate mineral material, an igneous vitreous deposit is used. A s the adhesive layer having the masking property, a layer containing an inorganic pigment capable of giving the masking property is preferred. As the decorative sheet, a paper sheet or a plastic sheet is used.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic decorative board which is excellent in concealing property and suppresses peeling and deterioration of a decorative sheet.

[0002]

2. Description of the Related Art As a conventional inorganic decorative board, an asbestos cement board, a calcium silicate board, a gypsum board and the like have been used. Among these, the calcium silicate plate is excellent in terms of nonflammability, mechanical strength, etc.
It has been mainly used as a decorative base material for interior. However, calcium silicate plates contain a large amount of alkali components,
If a decorative sheet is applied to the surface, the decorative sheet peels off, or if applied directly, causes discoloration or deterioration, etc., and also lacks surface smoothness as a base material for interiors, so apply direct makeup It was difficult.

[0003] Therefore, in order to use a calcium silicate plate as a base material for an interior, it is necessary to appropriately perform an alkali stopper and a plugging treatment.

[0004] As an effective undercoating method for a calcium silicate plate, Japanese Patent Publication No. Sho 55-18680 and Japanese Patent No.
Although a proposal is made in Japanese Patent No. 9897, the processing steps are complicated in these techniques, and the weight of the calcium silicate plate is heavy, which causes a decrease in production efficiency when processed into an inorganic decorative plate. There was a problem.

[0005]

SUMMARY OF THE INVENTION The present invention provides an inorganic decorative board which is excellent in concealing property and suppresses peeling and deterioration of decorative paper.

[0006]

SUMMARY OF THE INVENTION The present invention relates to an inorganic decorative board comprising a slightly alkaline or neutral inorganic substrate layer, an adhesive layer having concealing properties, and a decorative sheet layer. The present invention relates to the inorganic decorative board, wherein the inorganic substrate layer contains a powdery and / or granular inorganic material and inorganic fibers. The present invention relates to the inorganic decorative board, wherein the inorganic substrate layer is not subjected to a surface treatment. The present invention relates to the inorganic decorative board, wherein the inorganic substrate layer is obtained by binding a powdery and / or granular inorganic material and inorganic fibers with a thermosetting resin.

[0007] The present invention relates to the described inorganic decorative board, wherein the powdery and / or granular inorganic material is an ignitable vitreous deposit. The present invention relates to a described inorganic decorative board in which an adhesive layer having a hiding property contains an inorganic pigment capable of imparting a hiding property. The present invention relates to the inorganic decorative plate, wherein the inorganic pigment contained in the adhesive layer having a concealing property and capable of imparting a concealing property is titanium oxide, zinc white, or lead white.

The present invention relates to the inorganic decorative board, wherein the decorative sheet of the decorative sheet layer (C) is a paper sheet or a plastic sheet. Further, the present invention provides an inorganic decorative board characterized in that an adhesive having a masking property is applied on a slightly alkaline or neutral inorganic substrate with a natural reverse roll coater or a reverse roll coater, and then a decorative sheet is laminated. Regarding the manufacturing method.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION The inorganic substrate layer constituting the inorganic decorative board of the present invention is slightly alkaline or neutral, and may be any material which does not adversely affect the decorative paper layer by peeling or alteration. In some cases, slightly acidic ones can also be applied. Whether the inorganic substrate layer is slightly alkaline or neutral can be confirmed by placing the material in water and allowing it to stand, and in some cases, promoting heating or the like.

The inorganic substrate layer preferably comprises a powdery and / or granular inorganic material and an inorganic fiber as main components, and is particularly one which is usually fixed with a heat-resistant thermosetting resin as a binding component. Is preferred.

The above-mentioned powdery and / or granular inorganic materials are usually slightly alkaline, neutral, and sometimes slightly acidic,
It is preferable that the composition contains little or no alkaline component such as CaO, MgO, and Na ₂ O, and contains SiO ₂ in a small amount even if it is contained, for example, quartz, granite, feldspar,
Basalt etc. can be given. In particular, ignitable glassy deposits mainly composed of SiO ₂ and AL ₂ O ₃ , for example, shirasu, clay, and pumice are particularly preferably used. From the viewpoint of reducing the weight of the inorganic decorative board, it is more preferable to include a porous granular inorganic material.

As the inorganic fibers that can constitute the inorganic substrate layer of the present invention, conventionally known inorganic fibers can be used, and specific examples thereof include glass fibers, carbon fibers, metal fibers, and mineral fibers. In particular, cotton-like materials such as rock wool and glass wool are preferable. The ratio between the powdery and / or granular inorganic material and the inorganic fibers contained in the inorganic substrate layer of the present invention is not particularly limited, but is appropriately selected in consideration of the strength and smoothness of the decorative board. Examples of the thermosetting resin that binds the powdery and / or granular inorganic material and the inorganic fibers include a urea resin, a melamine resin, a phenol resin, and an epoxy resin. Phenolic resins are preferred in terms of moldability. The phenol resin may be any one of a novolak type phenol resin and a resol type phenol resin, and may be in any form such as solid, powder, liquid (solution, water dispersion). Absent. However, a solid or powdery novolak type phenol resin is preferable in that mixing with a volcanic glassy sediment / rock wool as a main raw material and matting can be easily performed. It is also effective to add two or more organic binders such as starch to the thermosetting resin in order to increase the bending strength of the base material. The inorganic substrate layer of the present invention preferably has a structure in which the above-described inorganic material and inorganic fibers are bonded with a thermosetting resin, and is not particularly limited in structure, but is considered in view of weight reduction. Thus, a structure in which another kind of inorganic substrate layer is laminated in one or more layers can also be used. For example, a layer (1) in which a thermosetting resin is added and fixed to a composite mainly composed of inorganic fibers and ignitable glassy deposits.
On both sides of the layer, another type of inorganic substrate layer (2 layers) formed by adding a thermosetting resin to a composite mainly composed of inorganic fibers is formed by heating and pressing to form a three-layered multilayer. An inorganic substrate layer having a structure.

Since the inorganic substrate layer of the present invention is slightly alkaline or neutral, it has little adverse effect on the decorative sheet layer laminated thereon via the adhesive layer. There is no need to perform treatment such as filling. Of course, in some cases, surface treatment may be performed,
In consideration of productivity, it is preferable not to perform such surface treatment. As the adhesive constituting the adhesive layer having a concealing property of the present invention, a generally used known aqueous adhesive can be used. For example, urethane-modified vinyl resin, vinyl acetate resin, EVA resin, aqueous vinyl urethane and the like can be mentioned. Among them, urethane-modified vinyl resin is preferable from the viewpoint of water resistance, heat resistance and the like. Also,
An inorganic pigment is used in combination to impart hiding power to the adhesive layer. Such inorganic pigments include, but are not particularly limited to, titanium oxide, carbon black, zinc white, lead white, and graphite. Titanium oxide is particularly preferred in terms of white opacity suitable for cosmetic use. In addition to the inorganic pigment, it is preferable to use a general constitutional inorganic pigment, for example, carbon char, in combination, and the inorganic pigment imparting hiding power in the adhesive layer is 5% by weight or more (in terms of solid content of the adhesive layer). ), And the extender inorganic pigment may be contained more than the inorganic pigment.
In particular, it is preferable to use the pigment so that the total amount of the inorganic pigment imparting hiding properties and the extender inorganic pigment is 15% by weight or more.

The amount of the inorganic pigment to be added is not particularly limited, but from the viewpoint of the viscosity and hiding power of the adhesive,
The amount is preferably 2 to 40 parts by weight with respect to 0 parts by weight.

The adhesive may contain an extender pigment, an organic pigment and various fillers in addition to the inorganic pigment. The adhesive has a viscosity of 10,000 to 10 by the addition of the inorganic pigment.
By adjusting to 0.000 mPa · s, it is possible to suppress the permeability to a substrate having a porous surface layer. For this viscosity adjustment, various thickeners may be used in combination. Examples of the decorative sheet constituting the decorative sheet layer of the present invention include a plastic decorative sheet, a paper decorative sheet, and a transfer type decorative sheet. Examples of the plastic decorative sheet include a sheet made of a synthetic resin such as polyvinyl chloride, polyethylene, polypropylene, acrylic resin, polyurethane, and polyethylene terephthalate (PET). In addition, a composite material of a metal foil, paper, and a different kind of synthetic resin sheet on the synthetic resin sheet can also be used.

The paper-based decorative sheet weighs 20 g / m2 per square meter.
Those having about ^{2 to} 300 g / m ² and having printable surface smoothness and strength such as gravure printing and planographic printing can be used. Basis weight 23g / m ² ~30g / m ² and basis weight 50g of building materials for titanium paper having colored pigment added to titanium to the tissue paper for building materials using e.g. softwood pulp
/ M ^{2 to} 160 g / m ² are most suitable.

The transfer type decorative sheet is prepared by backprinting with a printing ink using a nitriding cotton, cellulose acetate, vinyl chloride vinyl chloride, or urethane resin as a vehicle on the polyethylene surface of polyethylene-laminated paper or a PET-based separator. Get. Particularly, a transfer type decorative sheet made of a urethane resin-based ink is most preferable in terms of heat resistance and suitability for post-processing.

The inorganic decorative board of the present invention comprises an inorganic substrate layer obtained by binding a powdery and / or granular inorganic material and an inorganic fiber with a thermosetting resin, an adhesive layer containing an inorganic pigment, and a decorative sheet layer. The production method is not particularly limited, and a generally used known method can be applied as it is. For example, it can be obtained by applying an adhesive for imparting concealing properties to an inorganic substrate with a roll coater or the like, drying the applied adhesive, and then laminating the decorative sheet by a hot roll press. The method for directly applying the adhesive to the inorganic substrate is not particularly limited, and a conventionally known method can be used. For example, a natural roll coater, a natural reverse squeeze roll coater, a natural reverse roll coater, a coating method using a reverse roll coater, and the like, and the like. Alternatively, a coating method using a reverse roll coater is preferable. The inorganic decorative board of the present invention may further have a protective coating layer on the decorative sheet layer. There is no particular limitation on the paint for forming the protective coating layer, and various paints can be used depending on the application. Examples of the paint include energy ray-curable paints such as aminoalkyd paint, urethane paint, nitrocellulose lacquer paint, urethane-modified acrylate paint, epoxy-modified acrylate paint, and unsaturated polyester paint. The inorganic decorative board obtained in the present invention has a low penetration of the adhesive into the substrate, and the color of the base material does not affect the decorative surface due to the concealing property of the adhesive, so that the color can be easily adjusted. So the kitchen panel,
It is preferably used in fields such as bus panels and building interior materials.

[0019]

EXAMPLE 1 A layer obtained by solidifying an inorganic material containing a volcanic glassy sediment (porous granular material) and inorganic fibers of rock wool with a thermosetting resin, and an inorganic fiber above and below the layer. An inorganic substrate (Dailight: manufactured by Daiken Kogyo Co., Ltd., thickness: 6 mm, about pH 8) in which layers hardened with a thermosetting resin were laminated, and the substrate was directly concealed using a natural reverse roll coater. 190 of CVC22T [aqueous emulsion adhesive containing titanium oxide, manufactured by Konishi Co., Ltd.] was used as the adhesive.
After applying g / m ² and drying with hot air at 80 ° C. for 30 seconds, decorative paper (manufactured by Nippon Decor Co., Ltd.) was laminated with a hot roll press at 100 ° C. to obtain an inorganic decorative plate. Since the inorganic substrate of the obtained decorative board was slightly alkaline, peeling and deterioration of the decorative paper did not occur. In addition, since the adhesive used had concealing properties, the color of the base of the inorganic substrate was beautiful and did not appear on the surface. Example 2 190 g / m ^{2 of} CVC22T was applied directly to the inorganic substrate of Example 1 using a natural reverse roll coater and dried with hot air at 80 ° C. for 30 seconds. Decor Co., Ltd.] using a hot roll press at 100 ° C. to obtain an inorganic decorative plate. The decorative board obtained did not have peeling or deterioration of the decorative sheet. In addition, the color of the base of the inorganic substrate was beautiful without appearing on the surface. Example 3 190 g / m ^{2 of} CVC22T was applied directly to the inorganic substrate of Example 1 using a natural reverse roll coater, and dried with hot air at 80 ° C. for 30 seconds. ] Is laminated by a hot roll press at 100 ° C. and left for 24 hours, and then a polyester base coat [Dainippon Ink Chemical Industry Co., Ltd. ) Is coated with a roll coater at 100 g / m ² , the coating film is cured by irradiating ultraviolet rays, and the surface thereof is polished using a wide belt sander equipped with # 600 sandpaper to obtain a polyester-based top coating [ Manufactured by Hamani Paint Co., Ltd.], coated with a flow coater at 100 g / m ² , irradiated with ultraviolet rays, and cured to obtain an inorganic decorative plate. The decorative board obtained did not suffer from peeling or deterioration of decorative paper. In addition, the color of the base of the inorganic substrate was beautiful without appearing on the surface.

Reference Example 1 A calcium silicate plate having a thickness of 6 mm was placed on an inorganic substrate (about pH 1).
0), and using a roll coater, an alkali stopper sealer [Bond 383: manufactured by Konishi Co., Ltd.] is 100 g / m2.
² Apply, air dry, using a reverse coater,
100 g / m ^{2 of a} filling agent [UV filling HV7, manufactured by Dainippon Ink and Chemicals, Ltd.] is applied, cured by irradiating ultraviolet rays, and the surface thereof is polished using a wide belt sander equipped with # 320 sand paper. I do. The above-mentioned alkali stopper and filler treatment of the inorganic base material
Using a reverse roll coater, 190 g / CVC22T [aqueous emulsion adhesive, manufactured by Konishi Co., Ltd.]
After applying m ² and drying with hot air at 80 ° C. for 30 seconds, decorative paper [Nippon Decor Co., Ltd.] was laminated with a hot roll press at 100 ° C. to obtain an inorganic decorative plate.

REFERENCE EXAMPLE 2 A calcium silicate plate having a thickness of 6 mm was used as an inorganic plate substrate, and an alkali stopper sealer [Bond 383, manufactured by Konishi Co., Ltd.] was applied at 100 g / m ² using a roll coater and allowed to dry naturally. , Using a reverse coater, the filler [U
V seal HV7, manufactured by Dainippon Ink and Chemicals]
g / m ² , cured by irradiating ultraviolet rays, and the surface thereof is polished using a wide belt sander equipped with # 320 sand paper. Using a natural roll coater on the inorganic base material that has been subjected to the above alkali stopping and filling treatments, CVC22T [aqueous emulsion adhesive,
Konishi Co., Ltd.] was applied at 90 g / m ² , and dried with hot air at 80 ° C. for 30 seconds.
Laminating was performed with a hot roll press at 00 ° C. to obtain an inorganic decorative plate. The results of comparing the characteristics of the inorganic decorative boards obtained in the above Examples and Reference Examples are shown in the table.

A method for evaluating characteristics will be described below. <Lightweight> The specific gravity of the decorative inorganic plate was measured, and a material having a small value was evaluated as having high lightness. <Workability> The decorative inorganic plate was cut with a saw, and the cut surface was evaluated on the following three levels. ：: There is no burr on the cut surface.

Δ: Burrs are present either above or below the cut surface. ×: There are burrs both above and below the cut surface. <Productivity> The time required to produce one decorative inorganic plate was measured, and a product having a shorter time was evaluated as having higher productivity. <Surface Properties> The surface of the obtained inorganic plate was visually observed and evaluated according to the following three grades. ：: The surface is finished smoothly. Δ: The surface is slightly uneven.

[0024]

[Table 1]

From the above results, it was found that the inorganic substrate containing a volcanic glassy deposit and the aqueous emulsion-based adhesive applied using a natural reverse roll coater (Example 1) were lightweight and workable. , Productivity and surface properties.

[0026]

Industrial Applicability The inorganic decorative board of the present invention has excellent concealing properties, suppresses peeling and deterioration of decorative paper, does not require an alkali stopping treatment or a sealing treatment step, is nonflammable, and has good workability. And excellent productivity. Further, the inorganic decorative board of the present invention can be further excellent in lightness by being able to contain a lightweight inorganic material as the inorganic substrate.

 ────────────────────────────────────────────────── ─── Continued on the front page F-term (reference) 4F100 AA00A AA00C AA00H AA21C AA21H AA25C AA25H AA30C AA30H AG00A AK01A AK01B AR00C AT00B BA03 BA07 BA10A BA10B CA13C DE01A DG01A J182 J08BJL01 J182B08JB01J182

Claims (9)

[Claims] 1. An inorganic decorative plate comprising a slightly alkaline or neutral inorganic substrate layer, a hiding adhesive layer and a decorative sheet layer. 2. The inorganic decorative board according to claim 1, wherein the inorganic substrate layer contains a powdery and / or granular inorganic material and inorganic fibers. 3. The inorganic decorative board according to claim 1, wherein the inorganic substrate layer is not surface-treated. 4. The inorganic decorative board according to claim 1, wherein the inorganic substrate layer is formed by binding a powdery and / or granular inorganic material and an inorganic fiber with a thermosetting resin. 5. The inorganic decorative board according to claim 2, wherein the powdery and / or granular inorganic material is an ignitable vitreous deposit. 6. The inorganic decorative board according to claim 1, wherein the adhesive layer having a hiding property contains an inorganic pigment capable of imparting a hiding property. 7. The inorganic decorative board according to claim 1, wherein the inorganic pigment contained in the adhesive layer having a masking property and capable of imparting a masking property is titanium oxide, zinc white, or lead white. 8. The decorative sheet of the decorative sheet layer (C) is a paper sheet or a plastic sheet.
The inorganic decorative plate according to any one of the above. 9. A method for producing an inorganic decorative board, comprising applying a hiding adhesive to a slightly alkaline or neutral inorganic substrate with a natural reverse roll coater or a reverse roll coater, and then laminating a decorative sheet. .