JP2002019066A - Composite decorative material for gypsum board and method for manufacturing decorative gypsum board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite decorative material for a gypsum board made of base paper and a decorative sheet having excellent gas permeability and moisture permeability and a method for manufacturing the decorative gypsum board using the same. SOLUTION: The composite decorative material for the gypsum board comprises the base paper for the gypsum board having a gas permeability of 125 sec or less specified according to JIS P 8117, and a decorative sheet having a moisture permeability specified according to JIS Z 0208 of 800 g/m2.24 hrs or more adhered to the base paper via an adhesive. The method for manufacturing the decorative gypsum board comprises the steps of casting a gypsum stock slurry between a surface of the base paper of the decorative material and another base paper, and then curing the slurry.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite decorative material for gypsum board and a method for producing a decorative gypsum board using the same.

[0002]

2. Description of the Related Art Gypsum board is widely used as a building material excellent in fire resistance, fire resistance and heat insulation, as an interior wall material, a ceiling material, a roof base material and the like.

[0003] Gypsum board is disclosed, for example, in Japanese Patent Application Laid-Open No. 7-256.
As disclosed in Japanese Patent Publication No. 56-56, it has a layer configuration in which board base paper is bonded to the front and back surfaces of a board main body containing gypsum as an essential component. Thus, for the purpose of imparting design properties to the gypsum board, a decorative layer is formed on at least one of the front and back surfaces as disclosed in, for example, Japanese Utility Model Laid-Open No. 54-128307.

[0004]

A large amount of water vapor is generated during the drying process in the gypsum board manufacturing process. However, if the water vapor permeability of the layer consisting of the base paper for the board and the decorative sheet is not good, the gypsum board body and There is a possibility that delamination may occur between the base papers or between the base paper and the decorative sheet.

On the other hand, in order to prevent dew condensation in a room such as a dwelling and to form a comfortable dwelling space, development of gypsum board excellent in moisture absorption and desorption has been promoted. Such gypsum board often contains a humidity control material such as zeolite, sepiolite, and diatomaceous earth together with organic reinforcing fibers and the like.

[0006] Even in such a gypsum board having a moisture absorbing / releasing function, it is required that the coating layer composed of the base paper and the decorative sheet has excellent air permeability and moisture permeability.

SUMMARY OF THE INVENTION An object of the present invention is to provide a composite decorative material for gypsum board comprising a base paper and a decorative sheet, which is excellent in air permeability and moisture permeability, and a method for producing a decorative gypsum board using the same.

[0008]

According to the first aspect of the present invention, there is provided a gypsum board base paper having an air permeability of 125 seconds or less specified in JIS P 8117. Is 800
It is a composite decorative material for a gypsum board obtained by adhering a decorative sheet having a g / m ² · 24 hrs or more via an adhesive.

The invention described in claim 2 is based on JIS P 8
A decorative sheet having a moisture permeability of 800 g / m ² · 24 hrs or more specified by JIS Z 0208 is adhered to a gypsum board base paper having an air permeability of 125 seconds or less specified by 117 via an adhesive. A method for producing a decorative gypsum board, characterized in that a gypsum raw material slurry is poured so that a board body is in contact between a base paper surface of a gypsum board composite decorative material and another base paper and then hardened.

[0010]

Since the present invention has the above constitution, it is excellent in breathability and moisture permeability, and also has excellent fire resistance, fire protection and heat insulation properties of the gypsum board, and also has excellent design. Can be provided.

[0011]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described based on preferred embodiments.

FIG. 1 shows a longitudinal section of a gypsum board using the composite decorative material of the present invention. In FIG. 1, 1 is a board body, 2 is a board base paper, and 3 is a decorative sheet. FIG.
2 shows a woodgrain pattern which is an example of a pattern formed on the surface of the decorative sheet. FIG. 3 shows a cross section taken along the line AA in FIG. In FIG. 3, reference numeral 13 denotes a decorative sheet, 15 denotes a concave portion, 16 denotes a top coat layer, 41 denotes a paper base material, and 42 denotes a second base material.
The printing ink layer 43 is a resin layer.

In the present invention, the board body 1 is made of, for example, a hemihydrate gypsum alone, or a hemihydrate gypsum mixed with a lightweight aggregate such as pearlite, a resin, and a small amount of fibers.

As the board base paper 2, base paper obtained by papermaking from waste paper pulp, ground wood pulp, unbleached sulfite pulp, or the like can be used. The thickness of the base paper for the board is
Basis weight: about 300 g / m ² . The base paper obtained by papermaking from these pulp needs to have an air permeability specified in JIS P 8117 of 125 seconds or less.

[0015] If the air permeability of the base paper 2 exceeds 125 seconds, it is not possible to achieve smooth gas emission during the drying and solidifying processes in the gypsum board manufacturing process. Further, even when the gypsum board is made of a moisture-absorbing and releasing gypsum board, the moisture-absorbing and releasing ability of the gypsum board body 1 cannot be sufficiently exhibited.

As the decorative sheet 3, decorative paper having a pattern printed on its surface or a synthetic resin film having moisture permeability can be suitably used. The decorative sheet 3 is JIS Z
The moisture permeability specified in 0208 is 800 g / m ² · 24h
rs or more.

The moisture permeability of the decorative sheet 3 is 800 g / m ^2.
If it is less than 24 hours, the gypsum board main body 1 cannot fully exhibit the moisture absorbing / releasing ability. The moisture permeability of the decorative sheet 3 is preferably as high as possible within a range that does not impair the design of the decorative sheet 3.

As the decorative sheet 3 satisfying the above-mentioned air permeability, paper having a basis weight of 30 g / m ² or less, a synthetic resin film having a thickness of about 0.1 mm, and a coating weight of 3 g / m ^{2 to} 8 g can be used.
/ M ^{2 having} a thin synthetic resin coating layer formed thereon can be suitably used. If the coating weight is less than 3 g / m ² , it is difficult to form a uniform coating on the surface of the decorative sheet, while if it exceeds 8 g / m ² , the moisture permeability becomes insufficient.

As the decorative sheet 3, any sheet (paper or film) satisfying the conditions described in claim 1 can be used, but as shown in FIG.
Printing ink layer 42, resin layer 43 and top coat layer 1
Alternatively, a decorative paper 13 made of 6 may be used.

The decorative paper 13 has a base material 41 made of paper, and has at least a printing ink layer 42 and a resin layer 43 formed thereon, and the concave portion 15 is formed in the resin layer 43. The print ink layer exposed on the bottom surface of the concave portion 15 is given a different color from the others, so that a visually recognizable pattern is formed.

If the visible pattern on the decorative paper 13 has a woodgrain, it can be used as a high-quality building material. In order to manufacture such a decorative paper 13, a paper base material 41 is required.
A first printing ink layer, which becomes a light-colored portion of the wood pattern, is formed on the entire upper surface, and then a dark-colored portion of the wood pattern is printed with ink mixed with a substance that reacts with a curing agent in the resin layer to generate gas. After forming the second printing ink layer, a resin layer containing a curing agent is formed on the first printing ink layer and the second printing ink layer.

Then, the curing agent in the resin reacts with the contaminants in the second printing ink layer to generate gas, and the resin located on the second printing ink layer foams and protrudes. This foamed / raised portion is brittle and can be easily removed by grinding with a sander or the like. The foamed and raised portions removed by grinding become concave portions, and the second printing ink layer is exposed on the bottom surface. Part of the gas generated at this time also passes through the back side of the paper substrate 41, so that the air permeability of the decorative paper can be maintained at a higher level than that of the conventional decorative paper.

Instead of mixing a substance which generates a gas by reacting with a curing agent in the resin, a substance which decomposes by heating to generate a gas may be mixed in the second printing ink layer.

As means for providing a concave portion in the resin layer synchronized with the printing pattern in the second printing ink layer, for example, as disclosed in JP-A-48-777,
On the first printing ink layer, a printing pattern is formed by a second printing ink layer mixed with a substance which generates a gas by reacting with a curing agent in the resin layer, for example, DPT (dinitrosopentamethylenetetramine). A method in which a resin located on the printing ink layer is foamed and raised, and the foamed and raised portion is ground and removed with, for example, a sander to form a concave portion, and the second printing ink layer is exposed on the bottom surface of the concave portion. As disclosed in JP-A-63-77571, instead of the above-mentioned "substance which reacts with the curing agent in the resin layer to generate gas", a substance which decomposes by heating to generate gas, For example, using an ink mixed with toluenesulfonyl hydrazide, for example,
Printing is performed on the printing ink layer, and the resin located on the second printing ink layer is foamed and raised, and the foamed and raised portion is ground and removed with a sander or the like to form a concave portion. How to expose the layer. And the like.

The set of concave portions synchronized with the printing pattern by the second printing ink is, for example, the pattern shown in FIG. The pattern formed by such a set of recesses is a woodgrain pattern formed by a set of conduits appearing on the board surface. In this embodiment, the black portions in FIG. 2 are colored black brown, and the white portions are colored light brown.

FIG. 3 shows a cross section taken along the line AA in FIG. In FIG. 3, 41 is a paper substrate, 42 is a printing ink layer, and 43 is a resin layer. 5 is a concave portion, and 16 is a top coat layer. When the transparent top coat layer 16 is thinly applied, the concave portions 15 remain without being filled with the top coat layer 16 and function to increase the moisture permeability of the decorative sheet 13 to a high level. The depth of the recess 15 is 12 μm or more.
14 μm.

As the resin forming the resin layer 43, it is preferable to use a resin other than polyvinyl chloride. This is because, when disposed, harmful gases derived from chlorine such as dioxin due to combustion are not generated. In this embodiment, polyolefin resin, acrylic resin, epoxy resin, polyurethane resin, polyester resin, alkyd resin, styrene-butadiene resin, vinyl acetate resin and the like are used.

As an adhesive between the base paper 2 and the decorative sheet 3,
Polyvinyl acetate resin such as polyvinyl acetate resin or vinyl acetate / ethylene copolymer (EVA); poly (meth) acrylic acid and / or its ester or (meth) acrylic acid and / or its ester, styrene, vinyl acetate, etc. Acrylic resins such as copolymers with other monomers; polyurethane resins; polyester resins; polyolefin resins;
Adhesives such as styrene resins such as SBS and SIBS; epoxy resins; phenolic resins; alkyd resins; rubbers such as natural rubber and synthetic rubber can be used.

As the resin forming the top coat layer 16, a polyolefin resin, an acrylic resin, an epoxy resin, a polyurethane resin, a polyester resin, an alkyd resin, a styrene-butadiene resin, or the like can be used.
The thickness of the top coat layer 16 is preferably 5 μm or less in order to leave the recess 15.

[0030]

EXAMPLES Example 1 A basis weight of 250 g / m ² and a base paper having an air permeability of 80 seconds specified in JIS P 8117 were applied to a basis weight of 25 g / m ^2.
to form a coating film of 5 g / m ² on a paper substrate m ^2, JIS Z
0208, the moisture permeability defined in the condition B is 1500 g /
A decorative paper of m ² · 24 hrs was adhered using an ethylene vinyl acetate emulsion as an adhesive to obtain a composite decorative material for a gypsum board.

Example 2 A base paper having a basis weight of 250 g / m ² and an air permeability defined in JIS P 8117 of 100 seconds and a thickness of 0.1
A floral pattern is printed on an olefin-based sheet base material having air permeability of 1 mm, and a transparent coating film of 3 g / m ² is formed on the surface thereof. The moisture permeability specified in JIS Z0208, Condition B is 1000 g / m ^2. -A 24 hrs decorative sheet was adhered using an acrylic resin as an adhesive to obtain a composite decorative material for gypsum board.

Example 3 A base paper having a basis weight of 300 g / m ² and an air permeability defined in JIS P 8117 of 80 seconds was applied with a basis weight of 45 g / m2.
Print the grain pattern using a printing ink mixed with heating and foaming agent to the paper substrate in m ^2, degradation in the coating by heating dried middle coating a transparent coating of 5 g / m ² on its surface After capturing the gas to form a brittle coating layer, the foamed portion was removed to form a concave portion, and a 2 g / m ² transparent coating film was overcoated on the surface to form a concave portion. B
A decorative sheet having a moisture permeability of 2,000 g / m ² · 24 hrs, as defined in (1), was adhered using a vinyl acetate emulsion as an adhesive to obtain a composite decorative material for a gypsum board.

Example 4 A slurry obtained by mixing water at a water mixing ratio of 100% with a raw material obtained by adding a foaming agent (stearic acid type) to hemihydrate gypsum was prepared in Example 1.
The gypsum board composite decorative material obtained by the above procedure was used with the base paper side as the inside and the other as the base paper alone.

The cured gypsum board was cut to obtain a moisture-regulated gypsum board having a thickness of 6 mm, a width of 910 mm and a length of 1820 mm. Thereafter, the product was dried at a maximum of 120 ° C. for 1 hour in a dryer to obtain a product.

[0035]

According to the present invention, it is possible to provide a composite decorative material for gypsum board excellent in air permeability and moisture permeability, and it is possible to smoothly and efficiently perform a drying and hardening process in a gypsum board manufacturing process. Further, a gypsum board excellent in design can be provided.

According to the second aspect of the present invention, a gypsum board excellent in design and moisture absorption / release properties can be manufactured with high productivity.

[Brief description of the drawings]

FIG. 1 is a view showing a longitudinal section of a gypsum board obtained by using the gypsum board composite decorative material of the present invention.

FIG. 2 is a view showing an example of a printed pattern formed on the surface of a decorative sheet in the composite decorative material for a gypsum board of the present invention.

FIG. 3 is a sectional view taken along the line AA in FIG. 2;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Board main body 2 Board base paper 3 Decorative sheet 13 Decorative paper 15 Depression 16 Top coat layer 41 Paper base material 42 Printing ink layer 43 Resin layer

Claims (2)

[Claims] 1. A gypsum board base paper having an air permeability of 125 seconds or less specified in JIS P 8117,
Moisture permeability as defined in Z 0208 is 800g / m ² · ²
A composite decorative material for a gypsum board obtained by adhering a decorative sheet having a length of 4 hours or more via an adhesive. 2. A gypsum board base paper having an air permeability of 125 seconds or less as defined in JIS P 8117,
Moisture permeability as defined in Z 0208 is 800g / m ² · ²
The method is characterized in that a gypsum raw material slurry is poured into a gypsum board composite decorative material obtained by adhering a decorative sheet having a length of 4 hours or more through an adhesive so that the board body is in contact with another base paper, followed by curing. And a method for producing a plasterboard.