JP2004204604A

JP2004204604A - Composite panel and its manufacturing method

Info

Publication number: JP2004204604A
Application number: JP2002376775A
Authority: JP
Inventors: Yasuo Kadoi; 康雄角井; So Doi; 創土井
Original assignee: Nitto Boseki Co Ltd
Current assignee: Nitto Boseki Co Ltd
Priority date: 2002-12-26
Filing date: 2002-12-26
Publication date: 2004-07-22

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method continuously manufacturing composite panels of arbitrary dimensions suited to an interior material and having non-flammability and impact resistance at a low cost. <P>SOLUTION: This manufacturing method includes two methods, or a method for continuously sticking a composite sheet comprising a decorative sheet and metal foil with a fiber reinforced thermoplastic resin plate and a method for mounting the composite sheet comprising three layers of the decorative sheet, the metal foil and a cloth on fiber reinforced thermoplastic resin liquid, hardening the thermoplastic resin and continuously integrating them together so as to provide the long composite panel at low cost. The use of aluminium foil with the thickness of 50 μm or less and a resin or resin-coated decorative sheet with a basic weight of 100 g/m<SP>2</SP>or less can provide the composite panel with non-flammability and the impact resistance. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

【０００１】
【発明が属する技術分野】
本発明は、建築物の内装壁材或は不燃性壁装材、例えば内装用の腰壁材、キッチンパネルやパーテーション材等の用途に適した複合パネル及びその製造方法に関する。
【０００２】
【従来の技術】
従来、パネル状の建築材料の製造方法としては、アルミニウムなどの金属の板や箔を介して、天然木の化粧合板を繊維強化熱硬化性樹脂板などに接着剤で貼り合わせた木質調の化粧パネルが記述されている（例えば、特許文献１）。また化粧シート、アルミニウム箔、珪酸カルシウム等の無機材料からなるパネル（例えば、特許文献２）、及び化粧シート、アルミニウム板、樹脂層からなるパネル及び製造方法が示されている（例えば、特許文献３）。これら特許文献に記載されたパネル状の建築材料の製造方法は、いずれも金型プレスを使うバッチ成形法が記載されている。
【０００３】
【特許文献１】
特開平８−１１２８８２号公報（第２〜３頁）
【特許文献２】
特開平１０−１０９３８６号公報（第２〜４頁）
【特許文献３】
特開平１０−８６２７６号公報（第２〜３頁）
【０００４】
【発明が解決しようとする課題】
しかしながら、前記の従来技術の中で、特許文献１の製造方法によって得られた化粧パネルは、表面に貼り合わせた天然木を使っている為に脆くて耐衝撃性がなく、また長尺のパネルを連続的に製造できないという欠点を持っている。更に、特許文献２のパネルでは、無機質のボードを使っている為、パネルの厚みを薄く出来ず、且つ耐衝撃性に著しく欠ける。特許文献３の従来技術では、熱可塑性樹脂を裏面に使っているので、熱によるパネルの強度低下や伸縮が生じ易く、耐熱性が無いと言う欠点があった。
これらの従来技術に記載されたパネル製品を製造するに際しては、いずれも金型プレスを使ういわゆるバッチ成形方法で製造され、連続的に製造できない為に、現在に至るまで内装建材用に好適な長尺なパネルは製造されておらず、更に従来技術に見られるバッチ成形では、得られたパネルがコスト高になるという問題点があった。
【０００５】
更に、これらの欠点に加えて、さらに詳しく見てみると、これら従来の製造方法によって得られる材料は、いずれも外部から加えた応力によって変形しやすく、また変形した場合には復元し難い（耐衝撃性に欠ける）と言う致命的な性質を有しており、内装建築材料としての使用に対して不適であるという問題点を持っていることがわかった。
【０００６】
本発明は上記の問題を解決する為になされたもので、その目的とするところは、不燃性且つ耐衝撃性を有する建築材料を得ること、及び、そのような特性を有する長尺ものの複合パネルを連続的に低コストで製造する方法を提供する事にある。
【０００７】
【課題を解決するための手段】
発明者は、上記目的を達成する為に鋭意検討した結果、低コストで長尺な複合パネルを連続的に製造する方法として、一つは化粧シートと金属箔を接着した金属箔付き化粧シート（以下、複合シート（Ａ）と言う）を、繊維強化熱硬化性樹脂板に連続的に接着する方法（これを連続接着法とする）と、他方は、該複合シート（Ａ）の金属箔面に布帛を接着した別のタイプの金属箔付き化粧シート（以下複合シート（Ｂ）と言う）の布帛面を強化繊維混合熱硬化性樹脂液上に載置し、該熱硬化性樹脂を加熱硬化させて連続一体化する方法（これを連続積層法とする）で製造する２通りの製造方法を見出した。
【０００８】
更に、内装建築材料として好適の性質を有する建築材料を得る課題には、化粧シート／金属箔／繊維強化熱硬化性樹脂の３層、または化粧シート／金属箔／布帛／繊維強化熱硬化性樹脂の４層からなる複合パネルで解決できる事を見出した。
また、不燃性且つ耐衝撃性を有する建築材料を得る為には、前記複合パネルで、前記複合シート（Ａ）又は（Ｂ）に使われる化粧シートを、オレフィン樹脂製、ポリエチレンテレフタレート（ＰＥＴ）樹脂製または塩化ビニル樹脂製の化粧シートか、またはウレタン樹脂製、アクリル樹脂製またはアクリルウレタン樹脂を紙に塗布したコート紙からなる群から化粧シートを選択し、前記化粧シートの坪数を１００ｇ／ｍ^２以下にすると共に、前記複合シート（Ａ）または（Ｂ）の金属箔に、アルミニウム箔を使用し、且つ前記アルミニウム箔の厚さを５０μｍ以下にする事によって、複合パネルに耐衝撃性（復元性）と不燃性が付与される事を見出し、本発明を完成するに至った。
【０００９】
すなわち、本発明に係る複合パネルは、化粧シート／金属箔からなる複合シートの金属箔面上に接着剤を塗布し、前記接着剤が塗工された複合シートを、コンベア上を走行する繊維強化熱硬化性樹脂板に連続して重ね合せ、上下に位置する２個の加圧ローラの間に送り込み、挟むことで、前記複合シートを繊維強化熱硬化性樹脂板に加圧、密着させて、貼り合せることを特徴とする。
【００１０】
また、本発明に係る複合パネルの連続製造法は、第１のキャリアフィルムをコンベア上を連続走行させながら、前記第１のキャリアフィルム上に未硬化の熱硬化性樹脂液に強化繊維が混合されてなる強化繊維混合熱硬化性樹脂液を連続して供給し、次に、該強化繊維混合熱硬化性樹脂液上に、金属箔を中間に介在させ表側に化粧シート、裏側に布帛から成る複合シートの布帛側を載置し、更に、該複合シート上に第２のキャリアフィルムを被せ、その後、第１、第２のキャリアフィルムと共に、前記熱硬化性樹脂液上に載置してなる前記複合シートを、上下に離れて位置する２個のローラの間に送り込んで挟むことで、所定の厚さとし、加熱して、前記強化繊維混合熱硬化性樹脂液中の熱硬化性樹脂を硬化させて、連続一体化することを特徴とする。
【００１１】
この複合パネルの連続製造法によって、薄くて軽量、且つ強靭なパネルで、且つ任意の長さの複合パネルが容易に得られるので、任意の面積を有する建築物に対しても施工が可能であると共に、低コストで製造できる。
【００１２】
また、本発明に係る複合パネルは、化粧シート／金属箔からなる複合シートの金属箔側に、繊維強化熱硬化性樹脂板を貼り合せてなることを特徴とする。
また、本発明に係る複合パネルは、化粧シート／金属箔／布帛からなる複合シートの布帛側に、繊維強化熱硬化性樹脂を重ね合せて一体化成形させてなることを特徴とする。
また、本発明に係る複合パネルは、前記化粧シートが、オレフィン樹脂製、ポリエチレンテレフタレート（ＰＥＴ）樹脂製または塩化ビニル樹脂製の化粧シートであり、且つ前記化粧シートの坪数が１００ｇ／ｍ^２以下であって、更に前記複合シートの金属箔の厚さが５０μｍ以下のアルミニウム箔であることを特徴とする。
また、本発明に係る複合パネルは、前記化粧シートが、ウレタン樹脂、アクリル樹脂またはアクリルウレタン樹脂を紙に塗布した化粧シートであり、且つ前記化粧シートの坪数が１００ｇ／ｍ^２以下であって、更に前記複合シートの金属箔の厚さが５０μｍ以下のアルミニウム箔であることを特徴とする。
【００１３】
前記の構成にする事により本発明の複合パネルは強靭且つ薄くて軽いので使い易く、内装建築材料として好適である。更に従来併せ持たせる事が困難だったこの種複合パネルに耐衝撃性（復元力）と不燃性が付与できる。
【００１４】
【発明の実施の形態】
以下に添付図面及び符号を参照して本発明に係る複合パネル及びその製造方法の好適な実施形態について説明する。
本発明の複合パネルの構成において使われている基材は、下記の様にして選定される。
【００１５】
化粧シート：複合シート（Ａ）または（Ｂ）に使われる化粧シートは、柄、耐蝕性及び燃焼時の発熱量を考慮して、化粧シートの種類や厚さを決定するが、材質は特に限定されない。特に好ましい例を挙げるならば、オレフィン樹脂製、ポリエチレンテレフタレート（ＰＥＴ）樹脂製または塩化ビニル樹脂製等の樹脂製の化粧シート、またはウレタン樹脂製、アクリル樹脂製またはアクリルウレタン樹脂等の樹脂を紙に塗布したコート紙が好適である。また該化粧シートに意匠性や化粧性を付与させる事も出来る。
建材の不燃性認定を得る為に、後で述べる不燃性試験の燃焼時の発熱量を考慮して化粧シートの材質や坪量を選定する。通常、不燃性は、化粧シートの材質によるよりは、坪数に関係する。好ましい化粧シートの坪数の例を挙げると、品種によって発熱量が一様でない為に限定し難いが、不燃性の付与された複合パネルを得る為には、１００ｇ／ｍ^２以下の坪数の化粧シートが好ましい。
【００１６】
金属箔：前記複合シート（Ａ）または（Ｂ）に使われる金属箔としては、コスト面を考慮してアルミニウム箔が最も使われるが、それだけに限定されることなく、例えば錫箔、鉄（ステンレス（ＳＵＳ）箔を含む）箔、チタン箔等を用いる事が出来る。金属箔の厚さは通常１〜１００μｍ、より好ましくは、１〜５０μｍである。金属箔の厚さが１μｍ未満であると本発明の複合パネルの不燃性が失われたり１００μｍを超えると外部応力に対する複合パネルの復元性（耐衝撃性）を失う事があり、本発明の複合パネルを壁材等の内装建材としての使用が限定される場合がある。
【００１７】
接着剤：請求項1に記載の複合シート（Ａ）または請求項２に記載の複合シート（Ｂ）、または複合パネルの製造に際して、化粧シート／金属箔、金属箔／布帛または金属箔／繊維強化熱硬化性樹脂板の各基材間の接着には、いずれも以下の接着剤を使用する。接着剤は基材間の塗工適性、及び接着剤自身の耐熱性を主眼に選定される。好ましい例を挙げるならば、合成樹脂系のドライラミネート用の接着剤（ウレタン、アクリル、ゴム、エポキシまたはポリエステル系等）または無機（セラミック）系接着剤等で、溶剤系、エマルジョン系、水系または無溶媒系を問わない。また、前記接着剤の基材への塗布量は特に限定されないが、それぞれの基材または界面当り通常１〜１５０ｇ／ｍ^２の塗布量が好ましい。
【００１８】
布帛：布帛は前記複合シート（Ｂ）の金属箔側に接着されているので、請求項２に記載の連続積層法によって繊維強化熱硬化性樹脂液と密着させられた時、布帛が前記樹脂液に含浸し、加熱硬化に際して、前記繊維強化熱硬化性樹脂と複合シート（Ｂ）の界面で物理的な接合力（アンカー効果）を発揮して密着し、一体化成形に重要な役割を担うと考えられる。この為、該熱硬化性樹脂との密着性を損なわないように留意して布帛を選定するならば、各種の有機又は無機繊維の不織布または織布が使用可能であり、材質や種類を問わない。好ましい例を挙げるならば、ガラス繊維、ビニロン繊維、ポリエステル繊維等の不織布、またはそれらの織布（クロス）等がある。また、布帛の坪数も適宜選択可能である。
【００１９】
繊維強化熱硬化性樹脂：請求項１又は２に記載の複合パネルの製造に際して、繊維強化熱硬化性樹脂に使われる熱硬化性樹脂は、前記布帛との密着性や、硬化した時の樹脂の耐熱性、靭性、成形性、及びコスト等の諸条件を考慮して選定するが、安価な点で最も良く使われるものとして、不飽和ポリエステル樹脂、尿素ホルマリン樹脂がある。他の素材としては、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、及びウレタン樹脂等がある。また、樹脂中に難燃性、抗菌性又は軽量性等の機能を付与する為に、水酸化アルミニウム等の難燃化剤、各種抗菌剤又は中空バルーン等の軽量化材を混入することも可能である。
繊維強化熱硬化性樹脂に使用される強化繊維としては、ガラス繊維、炭素繊維、ロックファイバ−、水酸化アルミニウム繊維等の無機繊維、ビニロン繊維、ポリエステル繊維またはアラミド繊維等の有機繊維を用いる事が出来るが、特にガラス繊維は強度が大きいので好まれる。これらの繊維の形態としては、織布、不織布または組布等を挙げることが出来る。不織布を構成する繊維の長さも短繊維、長繊維いずれでも良い。形態は通常チョップストランド（長さは自由）が用いられるが、場合によっては織布（クロス）であっても問題は無い。
請求項１に記載の繊維強化熱硬化性樹脂板は、板状の繊維強化熱硬化性樹脂の加熱硬化によって得られ、厚さは通常強化繊維の含有量によって決定され、その含有量は適宜選択できる。前記繊維強化熱硬化性樹脂板は、固くて曲り難い板に限定されず、柔軟性があって曲げやすくロール状に巻き取ることが可能なシートでもよく、またその長さも限定されない。
【００２０】
次に複合パネルの請求項１および２に記載の製造法について述べる。
化粧シート／金属箔からなる複合シート（Ａ）、または化粧シート／金属箔／布帛からなる複合シート（Ｂ）の製造方法は、図1を使って以下に説明する連続製造工程でも製造できるが、必ずしもこの種の連続製造方法に限定されるものでなく、ハンドレイアップ等の他の手法でも製造できる。
図１は請求項１に記載の複合シート（Ａ）または請求項２に記載の複合シート（Ｂ）の製造に係る連続製造工程の一例を模式的に示したものである。
図２は請求項１に記載の複合パネルの製造に係る連続接着法の製造工程の一例を模式的に示したものである。
図３は請求項２に記載の複合パネルの製造に係る連続積層法の製造工程の一例を模式的に示したものである。
【００２１】
（１）複合シート（Ａ）又は（Ｂ）の連続製造法：
図1で模式的に示す様な連続製造工程で、金属箔３の長尺ロールをセットし、接着剤塗布コータおよびドクターナイフ４で、例えばドライラミネート用溶剤型（またはエマルジョン）の接着剤を金属箔３表面に連続的に一定量塗布（通常、１〜１５０ｇ／ｍ^２）し、昇温（通常８０〜１５０℃）した乾燥炉６内を、１〜１０分、好ましくは１〜３分間通過させて金属箔に塗布された接着剤中の溶剤を蒸発させる。加圧ローラ５の手前で、ロール状にセットした長尺の化粧シート２を該工程に導入し、接着剤が塗布された金属箔の上に重ね合わせた後、上下の加圧ローラ５に挟んで加圧、密着させて貼り合せ、化粧シート／金属箔からなる複合シート（Ａ）１として巻取機でロール状に巻き取る。巻き取った該複合シート（Ａ）はそのまま次工程で使うか、およそ４０℃で４〜５日養生して接着力を向上させることもできる。またこの工程では、接着剤の塗布面が化粧シート側で、その面に金属箔を貼り合せても構わない。この際のラインスピードは、特に限定されないが、通常１〜１００ｍ／分が好ましい。
【００２２】
同様に、図1に模式的に示す連続製造工程で、化粧シート／金属箔からなる前記複合シート（Ａ）（養生は行っていてもいなくても良い）の長尺ロールを、図１の３としてセットし、該複合シート（Ａ）３の金属箔面に、接着剤塗布コータおよびドクターナイフ４で、例えばドライラミネート用溶剤型（またはエマルジョン）の接着剤を一定量塗布（通常１〜１５０ｇ／ｍ^２）し、昇温（通常８０〜１５０℃）した乾燥炉６を１〜１０分、好ましくは１〜３分間通過させて接着剤中の溶剤を蒸発させ、前記溶剤を蒸発させた複合シート３の金属箔面上に、加圧ローラ５の手前でロール状にセットした長尺な布帛２を工程に導入して重ね合せ、上下の加圧ローラに挟んで複合シート３と布帛５を密着一体化させて、化粧シート／金属箔／布帛の３層から成る複合シート（Ｂ）１をロール状に巻き取る。該複合シート（Ｂ）１は、そのまま次工程で使うか、または４０℃で４〜５日養生して接着力を向上させることも出来る。この際のラインスピードは、特に限定されないが、通常１〜１００ｍ／分が好ましい。
【００２３】
但し、複合シート（Ａ）または（Ｂ）は、接着剤を塗布する工程と、基材を重ね合せて接着する工程が含まれていれば、必ずしも図１に例示した連続工程で製造する必要はなく、他の連続製造法、ハンドレイアップ等の手作業、または手作業と自動または連続製造工程を組合わせた半自動の方法等、製造方法は適宜選択できる。前記連続塗布に際して、接着剤塗布コータおよびドクターナイフ４を使う場合が記載されているが、前記シートの表面に接着剤を均一に塗布する事ができるなら、塗布方法及び装置は特に限定されない。
【００２４】
（２）連続接着法：
図２で示す様な連続製造工程に、前記複合シート（Ａ）１の長尺ロールをセットし、該複合シート（Ａ）１の金属箔面に、接着剤塗布コータおよびドクターナイフ４で、例えばドライラミネート用溶剤型（またはエマルジョン、または水性）の接着剤を一定量塗布（通常、１〜１５０ｇ／ｍ^２）し、昇温（通常８０〜１５０℃）した乾燥炉６内を１〜１０分、好ましくは１〜３分間通過させて接着剤中の溶剤を蒸発させ、前記溶剤を蒸発させた前記複合シート（Ａ）１の金属箔側を、コンベア１０によって走行してくる任意の長さの繊維強化熱硬化性樹脂板７上に連続的に重ね合せ、上下の加圧ローラー５に挟むことで、前記化粧シート／金属箔からなる複合シート（Ａ）を繊維強化熱硬化性樹脂板に加圧密着させて貼り合せ、更にカット機８で任意の寸法にカットして複合パネル９を得る。複合パネル９は、４０℃で４〜５日養生して接着力を向上させる。この際のラインスピードは、特に限定されないが、通常１〜１０ｍ／分である。
図４は、この方法によって製造された複合パネルの構成を示す模式図であり、化粧シート２２／金属箔１９／繊維強化熱硬化性樹脂７の３層からなり、各基材間は接着剤１８で接着されている。該接着剤１８は必ずしも同じものとは限らず、適宜選択される。
【００２５】
（３）連続積層法：
図３で示す連続製造工程で、ロール状にセットした第１のキャリアフィルム（第１又は第２のキャリアフィルムは、通常ＰＥＴ、ナイロン及びＰＶＡ等の長尺フィルムが良く使われるがそれらに限定されない）１３を走行させ、その上に樹脂タンクから未硬化の熱硬化性樹脂１４を一定量連続供給し、その上に強化繊維１５を連続添加し、含浸ローラ１６で押付けて、該強化繊維を該熱硬化性樹脂に含浸させ強化繊維混合熱硬化性樹脂液を得る。第２のキャリアフィルム１２を該複合シート（Ｂ）１１の化粧シート面に接する様にセットし、該第２のキャリアフィルム１２と該複合シート（Ｂ）１１を同時に該製造工程に導入し、前記未硬化の強化繊維混合熱硬化性樹脂液上に、前記第２のキャリアフィルムと一緒に複合シート（Ｂ）１１の布帛面を向けて連続的に載置し、上下のスクイズローラ２１の間に送り込んで、挟むことにより、該熱硬化性樹脂液を脱泡させると共に厚みを調整し、昇温（５０〜１５０℃）した硬化炉６内を通過させて前記強化繊維混合熱硬化性樹脂液中の熱硬化性樹脂１４を硬化させることによって連続一体化させた後、前記硬化物の両面に付着している第１及び第2のキャリアフィルム１２及び１３を剥がして巻き取り、カット機８で任意の寸法にカットして複合パネル９を得る。この場合のラインスピードは特に限定されないが、通常０．１〜１０ｍ／分である。
図５は、この製造法で得られた複合パネルの構成を示す模式図である。その構成は化粧シート２２／金属箔１９／布帛２０／繊維強化熱硬化性樹脂７の４層からなり、化粧シート２２／金属箔１９／布帛２０の各基材間は接着剤１８で接着されている。該接着剤１８は必ずしも同じものとは限らず、適宜選択される。一方、布帛２０／繊維強化熱硬化性樹脂７の基材間の結合は、該熱硬化性樹脂の加熱硬化によってなされている。
【００２６】
本発明に係る複合パネルは、化粧シート／金属箔／繊維強化熱硬化性樹脂の３層から、または化粧シート／金属箔／布帛／繊維強化熱硬化性樹脂の４層から構成されているが、更にこの複合パネルに使われる化粧シートを、オレフィン樹脂製、ポリエチレンテレフタレート（ＰＥＴ）樹脂製または塩化ビニル樹脂製の化粧シートから選び、前記化粧シートの坪数が１００ｇ／ｍ^２以下且つ前記複合シートの金属箔の厚さが５０μｍ以下のアルミニウム箔で構成されていてもよい。この様な構成の複合パネルは、不燃性と耐衝撃性の両機能を兼ね備えた複合パネルになる。
同様に前記化粧シートを、ウレタン樹脂、アクリル樹脂またはアクリルウレタン樹脂を紙に塗布した化粧シートから選び、且つ前記化粧シートの坪数が１００ｇ／ｍ^２以下且つ前記複合シートの金属箔の厚さが５０μｍ以下のアルミニウム箔で構成されていてもよい。この様な構成の複合パネルも、不燃性と耐衝撃性の両機能を兼ね備えた複合パネルになる。
【００２７】
以下、実施例により本発明に係る複合パネル、及びその製造方法について更に具体的に説明するが、本発明は実施例だけに限定されるものではない。
【００２８】
【実施例】
［実施例１］連続接着法による複合パネルの製造例
図１及び２に示す連続製造工程によって、以下のようにして複合パネルを製造した。
図１に示す連続製造工程で、ウレタンコート紙（凸版印刷株式会社製、目付け８０ｇ／ｍ^２）にアルミニウム箔（東海アルミ株式会社製、厚さ５０μｍ）を工程速度６０ｍ／分でドライラミネート（東洋インキ株式会社製ウレタン型接着剤をアルミニウム箔に４０ｇ／ｍ^２塗布し、８０℃で１分間乾燥させて溶剤を蒸発させた後、該コート紙を貼り合せた。それを巻取った後、４０℃で４日間養生）し、複合シート（Ａ）を製造した。
【００２９】
次に、図２に示す連続製造工程で、ライン速度５ｍ／分で前記複合シート（Ａ）のアルミニウム箔面と繊維強化熱硬化性樹脂板（日東紡績株式会社製、不飽和ポリエステル樹脂とガラス繊維の加熱硬化から得られる厚さ１．０ｍｍの長尺な板）を接着加工（東洋インキ株式会社製、ウレタン型接着剤をアルミニウム箔に３０ｇ／ｍ^２塗布し、８０℃で１〜２分間乾燥させて溶剤を蒸発させた後、該繊維強化熱硬化性樹脂板と重ね合わせて、加圧ローラで挟んで圧着し貼り合せた）し、所望の長さに切断して、厚さ１．５ｍｍの複合パネルを得た。
【００３０】
［実施例２］連続積層法による複合パネルの製造例
図1及び３に示す連続製造工程で、以下のようにして複合パネルを製造した。最初に、図１に示す連続接着工程でウレタンコート紙（凸版印刷株式会社製、目付け８０ｇ／ｍ^２）にアルミニウム箔（東海アルミ株式会社製、厚さ５０μｍ）をライン速度６０ｍ／分でドライラミネート（東洋インキ株式会社製のウレタン型接着剤を該アルミニウム箔に、４０ｇ／ｍ^２塗布し、８０℃、１分間乾燥させて溶剤を蒸発させた後、ウレタンコート紙を貼り合せる）して複合シート（Ａ）を得る。
更に、同じく図1に示す製造工程で、複合シート（Ａ）のアルミニウム箔面にポリエステル繊維不織布（ユニチカ株式会社製、５０ｇ／ｍ^２）を５０ｍ／分でドライラミネート（東洋インキ株式会社製のウレタン型接着剤を前記アルミニウム箔に５０ｇ／ｍ^２塗布し、８０℃、１分間乾燥させて溶剤を蒸発させた後、該ポリエステル繊維不織布を重ねて貼り合せ、圧着した後巻き取り、４０℃で４日間養生する）し、複合シート（Ｂ）を製造した。
【００３１】
引き続き図３で示す連続積層工程で、ライン速度１．５ｍ／分で走行するポリエチレンテレフタレート製の第１のキャリアフィルム（ユニチカ株式会社製、厚さ２５μｍ）上に未硬化の不飽和ポリエステル樹脂液（大日本インキ工業株式会社製）及びガラス繊維（日東紡績（株）製、平均直径０．０２ｍｍ、平均長さ５０ｍｍのガラス繊維のマット）を投入して含浸ローラで含浸混合させた。第２のキャリアフィルム（ユニチカ株式会社製、厚さ２５μｍ）を該複合シート（Ｂ）の化粧シート面に被せる様にセットして該第２のキャリアフィルムと該複合シート（Ｂ）を同時にラインに導入し、前記未硬化のガラス繊維強化不飽和ポリエステル樹脂液上に、布帛面を向けた該複合シート（Ｂ）を載置、上下のスクイズローラの間に送って挟み込み、密着させると共に前記ガラス繊維強化不飽和ポリエステル樹脂液を脱泡させ、厚さを１．５ｍｍに調整した後、硬化炉内に送り込んで該不飽和ポリエステル樹脂液を加熱硬化（１００℃、３０分間）させる事によって複合シート（Ｂ）とガラス繊維強化不飽和ポリエステル樹脂を連続的に一体成形させた。走行して硬化炉から出てきた複合パネルの第１及び第２のキャリアフィルムを複合パネルから剥して巻き取り、該パネルをカッターによって所望の長さにカットし、複合パネルを製造した。
【００３２】
実施例１及び２で製造した複合パネルを、下記の不燃性試験及び耐衝撃性試験によって複合パネルの性能を評価した。
［評価１］不燃性試験
建築基準法第６８条の２６第１項の規定に基づき、以下の様に不燃性試験を行った。
コーンカロリー試験機（東洋精機株式会社製）中に、不燃性試験に付される試験片（通常、１０ｃｍ幅×１０ｃｍ長）を置き、該試験機のコーンヒータ（輻射強度５０ＫＷ／ｍ^２）で、着火用スパークを常時点火させて、１０分間または２０分間加熱する。試験片の総発熱量を測定し、相当時間の総発熱量が８ＭＪ／ｍ^２以下である事と、同時に加熱処理後の試験片の表面状態を観察し、試験片の裏面まで貫通する亀裂や穴が発生しない事が試験片の不燃性の判定基準である（加熱時間１０分間が準不燃相当、同２０分間が不燃相当と判定される）。
不燃性試験に付される材料として、実施例１で得られた本発明の複合パネルから試験片（１０ｃｍ幅×１０ｃｍ長×厚さ１．５ｍｍ）を作成した。比較試験試料として、塩化ビニル樹脂製の腰壁材（株式会社エービーシー商会製、１０ｃｍ幅×１０ｃｍ長×厚さ３．０ｍｍ）、及びオレフィン樹脂製のシート（凸版印刷株式会社製、１０ｃｍ幅×１０ｃｍ長×厚さ１．０ｍｍ）を使用し、前記コーンカロリー試験機内に設置して不燃性試験に付し、試験（加熱）を１０分間（準不燃相当）行い、試験片の総発熱量と表面状態を観察した。試験結果を下表１に示す。
【００３３】
【表１】

（注、○は合格：総発熱量＜８ＭＪ／ｍ^２並びに、表面に亀裂や穴がみられない。×は不合格：総熱量＞８ＭＪ／ｍ^２で、燃焼によって表面に穴が発生した）。
【００３４】
［評価２］耐衝撃性試験
耐衝撃性試験用の試験片（約１０ｃｍ幅×１０ｃｍ長）に鉄枠を取りつけて平面上に置き、該試験片の上方４、３、２、１ｍの高さから、ナス型錘（１Ｋｇ、鉄製）を自由落下させ、表面状態を観察する。試験片に貫通孔若しくは凹みまたは穴、またはクラックや傷の存在の有無を目視観察する事によって、耐衝撃性を判定する。
耐衝撃性試験に使用される試験片として、本発明の実施例２の複合パネル（３０ｃｍ幅×３０ｃｍ長×厚さ１．５ｍｍ）、及び比較試験用試験片として塩化ビニル樹脂製腰壁材（株式会社エービーシー商会、厚さ３ｍｍ）、オレフィン樹脂製壁クロス（凸版印刷株式会社、厚さ１・０ｍｍ）、カラーアルミニウム板（福田金属箔粉工業株式会社製、厚さ１ｍｍ）を、共通の下地材として使う石膏ボード（吉野石膏株式会社製、１２ｍｍ厚）に、弾性ウレタン接着剤（コニシボンド株式会社、ＫＵ９１０、塗布量５００ｇ／ｍ^２）を使って接着したパネル（３０ｃｍ幅×３０ｃｍ長）を準備し、各パネルに鉄製の枠を取りつけた。
前記耐衝撃性試験に従って、各試験片の上１、２、３、４ｍの高さから、重さ１Ｋｇのナス型錘を自然落下させて、落下後の試験片の表面状態を観察した。結果を下表２に示す。
【００３５】
【表２】

（注、○：合格、試験片に凹みがみられない、×：不合格、凹み発生）
【００３６】
【発明の効果】
本発明の複合パネルは、不燃性を損なわないで外部からの応力に耐える耐衝撃性（復元性）の機能を有し、薄くて軽い為に内装建材向けの各種パネルとして好適である。
複合パネルの構成は２種類あり、その連続製造方法は異なっているが、どちらの方法を採った場合でも、前記機能を有する複合パネルの長尺物を低コストで得る事が出来る。
【００３７】
【図面の簡単な説明】
【図１】請求項１に係る複合シート（Ａ)または請求項２に係る複合シート（Ｂ)の連続接着法による製造工程を示す模式図である。
【図２】請求項１に係る連続接着法による複合パネルの製造工程を示す模式図である。
【図３】請求項２に係る連続積層法による複合パネルの製造工程を示す模式図である。
【図４】本発明の請求項４に係る複合パネルの構成を示す模式図である。
【図５】本発明の請求項５に係る複合パネルの構成を示す模式図である。
【００３８】
【符号の説明】
１複合シート（Ａ）または複合シート（Ｂ）
２化粧シートまたは布帛
３金属箔または複合シート（Ａ）
４接着剤塗布コータおよびドクターナイフ
５加圧ローラ
６乾燥炉または硬化炉
７繊維強化熱硬化性樹脂板
８カット機
９複合パネル
１０コンベア
１１複合シート（Ｂ）
１２第２のキャリアフィルム
１３第１のキャリアフィルム
１４熱硬化性樹脂液
１５強化繊維
１６含浸ローラ
１７複合シート（Ａ）
１８接着剤
１９金属箔
２０布帛
２１スクイズローラ
２２化粧シート[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a composite panel suitable for use as an interior wall material or a non-combustible wall material of a building, for example, an interior waist wall material, a kitchen panel, a partition material, and the like, and a method of manufacturing the same.
[0002]
[Prior art]
Conventionally, a panel-like building material has been manufactured using a wood-like decorative material in which natural wood decorative plywood is bonded to a fiber-reinforced thermosetting resin plate or the like with an adhesive via a metal plate or foil such as aluminum. A panel is described (for example, Patent Document 1). Further, a decorative sheet, an aluminum foil, a panel made of an inorganic material such as calcium silicate (for example, Patent Document 2), a decorative sheet, an aluminum plate, and a panel made of a resin layer and a manufacturing method are shown (for example, Patent Document 3). ). In all of the methods for producing panel-like building materials described in these patent documents, a batch molding method using a mold press is described.
[0003]
[Patent Document 1]
JP-A-8-112882 (pages 2-3)
[Patent Document 2]
JP-A-10-109386 (pages 2 to 4)
[Patent Document 3]
JP-A-10-86276 (pages 2-3)
[0004]
[Problems to be solved by the invention]
However, among the above-mentioned prior arts, the decorative panel obtained by the manufacturing method of Patent Document 1 is brittle and has no impact resistance because it uses natural wood bonded to the surface, and also has a long panel. Has the disadvantage that it cannot be manufactured continuously. Further, in the panel of Patent Document 2, since an inorganic board is used, the thickness of the panel cannot be reduced and the impact resistance is significantly lacking. In the prior art of Patent Document 3, since the thermoplastic resin is used on the back surface, there is a disadvantage that the strength of the panel is easily reduced or expanded and contracted by heat, and there is no heat resistance.
When manufacturing the panel products described in these prior arts, all are manufactured by a so-called batch molding method using a mold press, and cannot be manufactured continuously. A long panel has not been manufactured, and the batch molding found in the prior art has a problem that the obtained panel is expensive.
[0005]
Furthermore, in addition to these drawbacks, when looking at in more detail, all of the materials obtained by these conventional manufacturing methods are easily deformed by stress applied from the outside, and when deformed, are difficult to recover (resistance to resistance). It lacks impact resistance) and has a problem of being unsuitable for use as an interior building material.
[0006]
The present invention has been made in order to solve the above-mentioned problems, and an object of the present invention is to obtain a nonflammable and impact-resistant building material, and to provide a long composite panel having such characteristics. Is to provide a method for continuously producing the same at low cost.
[0007]
[Means for Solving the Problems]
The present inventors have conducted intensive studies to achieve the above object, and as a method of continuously manufacturing a long composite panel at low cost, one method is to provide a decorative sheet with a metal foil in which a decorative sheet and a metal foil are bonded. Hereinafter, the composite sheet (A)) is continuously bonded to the fiber-reinforced thermosetting resin plate (this is referred to as a continuous bonding method), and the other is a metal foil surface of the composite sheet (A). Another type of decorative sheet with a metal foil (hereinafter referred to as a composite sheet (B)) having a cloth adhered thereto is placed on a thermosetting resin liquid mixed with a reinforcing fiber, and the thermosetting resin is cured by heating. And a continuous integration method (this is referred to as a continuous lamination method).
[0008]
Further, the problem of obtaining a building material having suitable properties as an interior building material includes three layers of decorative sheet / metal foil / fiber reinforced thermosetting resin, or decorative sheet / metal foil / fabric / fiber reinforced thermosetting resin. It was found that the problem could be solved with a composite panel consisting of four layers.
Further, in order to obtain a nonflammable and impact-resistant building material, in the composite panel, the decorative sheet used for the composite sheet (A) or (B) is made of olefin resin, polyethylene terephthalate (PET) resin. Or a decorative sheet made of vinyl chloride resin, or a decorative sheet made of urethane resin, acrylic resin or coated paper coated with acrylic urethane resin on paper, and the basis weight of the decorative sheet is 100 g / m2. ² The aluminum foil is used as the metal foil of the composite sheet (A) or (B), and the thickness of the aluminum foil is set to 50 μm or less. ) And incombustibility were imparted, and the present invention was completed.
[0009]
That is, in the composite panel according to the present invention, an adhesive is applied to the metal foil surface of the composite sheet composed of the decorative sheet / metal foil, and the composite sheet coated with the adhesive is fiber-reinforced traveling on a conveyor. The composite sheet is pressed and adhered to the fiber-reinforced thermosetting resin plate by continuously superimposing the thermosetting resin plate, feeding between two pressure rollers located above and below and sandwiching the composite sheet, It is characterized by laminating.
[0010]
Further, in the continuous manufacturing method of the composite panel according to the present invention, the reinforcing fibers are mixed with the uncured thermosetting resin liquid on the first carrier film while continuously running the first carrier film on the conveyor. The reinforced fiber mixed thermosetting resin liquid is continuously supplied, and then a composite sheet comprising a decorative sheet on the front side and a cloth on the back side with a metal foil interposed on the reinforced fiber mixed thermosetting resin liquid. The fabric side of the sheet is placed, and further, a second carrier film is put on the composite sheet, and then, together with the first and second carrier films, is placed on the thermosetting resin liquid. By feeding and sandwiching the composite sheet between two rollers positioned vertically apart, the composite sheet has a predetermined thickness and is heated to cure the thermosetting resin in the reinforcing fiber mixed thermosetting resin liquid. It is characterized by continuous integration To.
[0011]
According to the continuous manufacturing method of the composite panel, a composite panel having a thin, lightweight, tough panel and an arbitrary length can be easily obtained, so that it can be applied to a building having an arbitrary area. In addition, it can be manufactured at low cost.
[0012]
Further, the composite panel according to the present invention is characterized in that a fiber-reinforced thermosetting resin plate is bonded to the metal foil side of a composite sheet composed of a decorative sheet / metal foil.
Further, the composite panel according to the present invention is characterized in that a fiber-reinforced thermosetting resin is superposed and integrally formed on the fabric side of a composite sheet composed of a decorative sheet / metal foil / fabric.
Further, in the composite panel according to the present invention, the decorative sheet is a decorative sheet made of an olefin resin, a polyethylene terephthalate (PET) resin or a vinyl chloride resin, and the basis number of the decorative sheet is 100 g / m2. ² The metal foil of the composite sheet is an aluminum foil having a thickness of 50 μm or less.
Further, in the composite panel according to the present invention, the decorative sheet is a decorative sheet obtained by applying a urethane resin, an acrylic resin, or an acrylic urethane resin to paper, and the basis number of the decorative sheet is 100 g / m2. ² The metal foil of the composite sheet is an aluminum foil having a thickness of 50 μm or less.
[0013]
By adopting the above configuration, the composite panel of the present invention is tough, thin and light, so that it is easy to use and is suitable as an interior building material. Furthermore, impact resistance (restoring force) and incombustibility can be imparted to this type of composite panel, which has been difficult to provide together.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, preferred embodiments of a composite panel and a method of manufacturing the same according to the present invention will be described with reference to the accompanying drawings and reference numerals.
The substrate used in the construction of the composite panel of the present invention is selected as follows.
[0015]
Decorative sheet: The type and thickness of the decorative sheet used for the composite sheet (A) or (B) is determined in consideration of the pattern, corrosion resistance, and calorific value during combustion, but the material is particularly limited. Not done. Particularly preferred examples include a resin decorative sheet made of an olefin resin, a polyethylene terephthalate (PET) resin or a vinyl chloride resin, or a resin such as a urethane resin, an acrylic resin, or an acrylic urethane resin. Coated paper coated is preferred. In addition, the decorative sheet can be given a design property or a cosmetic property.
In order to obtain the certification of noncombustibility of building materials, the material and basis weight of the decorative sheet are selected in consideration of the calorific value during combustion in the noncombustibility test described later. Usually, the nonflammability is related to the number of tsubo rather than the material of the decorative sheet. A preferred example of the basis weight of the decorative sheet is difficult to limit because the calorific value is not uniform depending on the type, but in order to obtain a composite panel provided with noncombustibility, 100 g / m2 is required. ² A decorative sheet having the following basis weight is preferred.
[0016]
Metal foil: As the metal foil used for the composite sheet (A) or (B), aluminum foil is most used in view of cost, but is not limited thereto, and for example, tin foil, iron (stainless steel (SUS) ) Including foil), titanium foil and the like can be used. The thickness of the metal foil is usually 1 to 100 μm, more preferably 1 to 50 μm. If the thickness of the metal foil is less than 1 μm, the incombustibility of the composite panel of the present invention may be lost, and if it exceeds 100 μm, the composite panel may lose its resilience (impact resistance) to external stress. The use of panels as interior materials such as wall materials may be limited.
[0017]
Adhesive: In the production of the composite sheet (A) according to claim 1 or the composite sheet (B) according to claim 2, or a composite panel, decorative sheet / metal foil, metal foil / fabric or metal foil / fiber reinforced The following adhesives are used for bonding between the respective substrates of the thermosetting resin plate. The adhesive is selected mainly for the suitability of coating between the substrates and the heat resistance of the adhesive itself. Preferred examples include synthetic resin-based adhesives for dry lamination (urethane, acrylic, rubber, epoxy or polyester-based adhesives) or inorganic (ceramic) -based adhesives, and are solvent-based, emulsion-based, water-based or non-adhesive. Regardless of the solvent system. The amount of the adhesive applied to the substrate is not particularly limited, but is usually 1 to 150 g / m per substrate or interface. ² Is preferred.
[0018]
Fabric: Since the fabric is adhered to the metal foil side of the composite sheet (B), when the fabric is brought into close contact with the fiber-reinforced thermosetting resin solution by the continuous laminating method according to claim 2, the fabric forms the resin solution. At the interface between the fiber reinforced thermosetting resin and the composite sheet (B) during physical curing and exerts a physical bonding force (anchor effect) on the interface, and plays an important role in integral molding. Conceivable. For this reason, if a cloth is selected with care not to impair the adhesion to the thermosetting resin, various organic or inorganic fiber non-woven fabrics or woven fabrics can be used, regardless of the material and type. . Preferred examples include non-woven fabrics such as glass fiber, vinylon fiber and polyester fiber, and woven fabrics (cloths) thereof. In addition, the basis weight of the fabric can be appropriately selected.
[0019]
Fiber-reinforced thermosetting resin: In the production of the composite panel according to

claim

1 or 2, the thermosetting resin used for the fiber-reinforced thermosetting resin has an adhesive property to the cloth and a resin when cured. Selection is made in consideration of various conditions such as heat resistance, toughness, moldability, and cost. Unsaturated polyester resins and urea formalin resins are most often used in terms of inexpensiveness. Other materials include an epoxy resin, a phenol resin, a vinyl ester resin, and a urethane resin. It is also possible to add a flame retardant such as aluminum hydroxide, various antibacterial agents, or a lightening material such as a hollow balloon in order to impart functions such as flame retardancy, antibacterial property or light weight to the resin. It is.
As the reinforcing fibers used in the fiber-reinforced thermosetting resin, it is possible to use inorganic fibers such as glass fiber, carbon fiber, rock fiber, and aluminum hydroxide fiber, and organic fibers such as vinylon fiber, polyester fiber or aramid fiber. Yes, but glass fibers are preferred because of their high strength. Examples of the form of these fibers include a woven fabric, a nonwoven fabric, and a braided fabric. The length of the fibers constituting the nonwoven fabric may be either short fibers or long fibers. Normally, chop strands (free length) are used. However, in some cases, there is no problem even if woven cloth (cloth) is used.
The fiber-reinforced thermosetting resin plate according to claim 1 is obtained by heating and curing a plate-like fiber-reinforced thermosetting resin, and the thickness is usually determined by the content of the reinforcing fiber, and the content is appropriately selected. it can. The fiber-reinforced thermosetting resin plate is not limited to a hard and hard-to-bend plate, but may be a sheet that is flexible, easy to bend, and can be wound into a roll, and its length is not limited.
[0020]
Next, a method of manufacturing the composite panel according to the first and second aspects will be described.
The method for producing the composite sheet (A) composed of decorative sheet / metal foil or the composite sheet (B) composed of decorative sheet / metal foil / fabric can also be produced by a continuous production process described below with reference to FIG. It is not necessarily limited to this type of continuous manufacturing method, and it can be manufactured by other methods such as hand lay-up.
FIG. 1 schematically shows an example of a continuous production process for producing the composite sheet (A) according to the first aspect or the composite sheet (B) according to the second aspect.
FIG. 2 schematically shows an example of the manufacturing process of the continuous bonding method according to the first embodiment of the present invention.
FIG. 3 schematically shows an example of a manufacturing process of a continuous laminating method according to a second embodiment of the present invention.
[0021]
(1) Continuous production method of composite sheet (A) or (B):
In a continuous manufacturing process as schematically shown in FIG. 1, a long roll of metal foil 3 is set, and an adhesive of a solvent type (or emulsion) for dry lamination is applied to the metal with an adhesive coating coater and a doctor knife 4, for example. A fixed amount is continuously applied to the surface of the foil 3 (usually 1 to 150 g / m ² Then, the solvent is passed through the drying furnace 6 at an elevated temperature (usually 80 to 150 ° C.) for 1 to 10 minutes, preferably 1 to 3 minutes to evaporate the solvent in the adhesive applied to the metal foil. In front of the pressure roller 5, the long decorative sheet 2 set in a roll shape is introduced into the process, and is superposed on the metal foil coated with the adhesive, and then sandwiched between the upper and lower pressure rollers 5. Then, the laminate is pressed and brought into close contact with each other, and laminated as a composite sheet (A) 1 comprising a decorative sheet and a metal foil in a roll shape by a winder. The wound composite sheet (A) can be used as it is in the next step, or can be cured at about 40 ° C. for 4 to 5 days to improve the adhesive strength. In this step, the surface to which the adhesive is applied may be the decorative sheet side, and a metal foil may be bonded to the surface. The line speed at this time is not particularly limited, but is usually preferably 1 to 100 m / min.
[0022]
Similarly, in a continuous manufacturing process schematically shown in FIG. 1, the long roll of the composite sheet (A) (which may or may not be cured) composed of a decorative sheet and a metal foil is used as a part of FIG. And a fixed amount of, for example, a solvent type (or emulsion) adhesive for dry lamination is applied to the metal foil surface of the composite sheet (A) 3 with an adhesive application coater and a doctor knife 4 (usually 1 to 150 g / m 2). m ² ), And passed through a drying oven 6 at an elevated temperature (usually 80 to 150 ° C.) for 1 to 10 minutes, preferably 1 to 3 minutes to evaporate the solvent in the adhesive and to form a composite sheet 3 having the solvent evaporated. A long cloth 2 set in a roll shape before the pressure roller 5 is introduced into the process on the metal foil surface and superposed, and the composite sheet 3 and the cloth 5 are tightly integrated by being sandwiched between upper and lower pressure rollers. Then, the composite sheet (B) 1 composed of three layers of decorative sheet / metal foil / fabric is wound into a roll. The composite sheet (B) 1 can be used in the next step as it is, or can be cured at 40 ° C. for 4 to 5 days to improve the adhesive strength. The line speed at this time is not particularly limited, but is usually preferably 1 to 100 m / min.
[0023]
However, if the composite sheet (A) or (B) includes a step of applying an adhesive and a step of laminating and bonding substrates, it is not always necessary to manufacture the composite sheet in the continuous step illustrated in FIG. Instead, a manufacturing method such as another continuous manufacturing method, a manual operation such as hand lay-up, or a semi-automatic method combining a manual operation and an automatic or continuous manufacturing process can be appropriately selected. Although the case where an adhesive application coater and a doctor knife 4 are used for the continuous application is described, the application method and apparatus are not particularly limited as long as the adhesive can be uniformly applied to the surface of the sheet.
[0024]
(2) Continuous bonding method:
In a continuous manufacturing process as shown in FIG. 2, a long roll of the composite sheet (A) 1 is set, and an adhesive application coater and a doctor knife 4 are applied to the metal foil surface of the composite sheet (A) 1, for example. Solvent type (or emulsion or aqueous) adhesive for dry lamination is applied in a fixed amount (usually 1 to 150 g / m ² The composite sheet obtained by evaporating the solvent in the adhesive by passing it through the drying oven 6 heated for 1 to 10 minutes, preferably 1 to 3 minutes, and preferably 1 to 3 minutes (usually 80 to 150 ° C.), and evaporating the solvent (A) The metal foil side of 1 is continuously superimposed on a fiber-reinforced thermosetting resin plate 7 of an arbitrary length traveling by a conveyor 10 and is sandwiched between upper and lower pressure rollers 5. A composite sheet (A) composed of a decorative sheet / metal foil is adhered to a fiber-reinforced thermosetting resin plate under pressure and adhesion, and further cut to an arbitrary size by a cutting machine 8 to obtain a composite panel 9. The composite panel 9 is cured at 40 ° C. for 4 to 5 days to improve the adhesive strength. The line speed at this time is not particularly limited, but is usually 1 to 10 m / min.
FIG. 4 is a schematic diagram showing the configuration of a composite panel manufactured by this method, which is composed of three layers of a decorative sheet 22 / metal foil 19 / fiber-reinforced thermosetting resin 7, and an adhesive 18 It is glued. The adhesive 18 is not always the same, and is appropriately selected.
[0025]
(3) Continuous lamination method:
In the continuous manufacturing process shown in FIG. 3, a first carrier film set in a roll shape (a first or second carrier film is usually a long film such as PET, nylon and PVA, but is not limited thereto. ) 13, the uncured thermosetting resin 14 is continuously supplied from the resin tank in a fixed amount, the reinforcing fiber 15 is continuously added thereon, and the reinforcing fiber 15 is pressed by the impregnation roller 16 to remove the reinforcing fiber. A thermosetting resin is impregnated to obtain a reinforced fiber mixed thermosetting resin liquid. The second carrier film 12 is set so as to be in contact with the face of the decorative sheet of the composite sheet (B) 11, and the second carrier film 12 and the composite sheet (B) 11 are simultaneously introduced into the manufacturing process. The composite sheet (B) 11 and the second carrier film are successively placed on the uncured reinforcing fiber mixed thermosetting resin liquid with the fabric surface of the composite sheet (B) 11 facing, and between the upper and lower squeeze rollers 21. By feeding and sandwiching, the thermosetting resin liquid is defoamed and the thickness thereof is adjusted, and the thermosetting resin liquid is passed through a curing furnace 6 at an elevated temperature (50 to 150 ° C.) so that the reinforcing fiber mixed thermosetting resin liquid After the thermosetting resin 14 is continuously integrated by curing, the first and

second carrier films

12 and 13 adhered to both surfaces of the cured product are peeled off and wound, and optionally cut by the cutting machine 8. Cut to dimensions Thus, a composite panel 9 is obtained. The line speed in this case is not particularly limited, but is usually 0.1 to 10 m / min.
FIG. 5 is a schematic diagram showing a configuration of a composite panel obtained by this manufacturing method. The structure is composed of four layers of decorative sheet 22 / metal foil 19 / fabric 20 / fiber-reinforced thermosetting resin 7, and the base material of decorative sheet 22 / metal foil 19 / fabric 20 is adhered by adhesive 18 to each other. I have. The adhesive 18 is not always the same, and is appropriately selected. On the other hand, the bonding between the base material of the fabric 20 and the fiber-reinforced thermosetting resin 7 is performed by heating and curing the thermosetting resin.
[0026]
The composite panel according to the present invention comprises three layers of decorative sheet / metal foil / fiber reinforced thermosetting resin or four layers of decorative sheet / metal foil / fabric / fiber reinforced thermosetting resin, Further, a decorative sheet used for the composite panel is selected from a decorative sheet made of an olefin resin, a polyethylene terephthalate (PET) resin or a vinyl chloride resin, and the basis weight of the decorative sheet is 100 g / m2. ² The composite sheet may be formed of an aluminum foil having a thickness of 50 μm or less. The composite panel having such a configuration is a composite panel having both functions of nonflammability and impact resistance.
Similarly, the decorative sheet is selected from urethane resin, acrylic resin, or a decorative sheet obtained by applying acrylic urethane resin to paper, and the decorative sheet has a basis weight of 100 g / m2. ² The composite sheet may be formed of an aluminum foil having a thickness of 50 μm or less. The composite panel having such a configuration is also a composite panel having both functions of nonflammability and impact resistance.
[0027]
Hereinafter, the composite panel according to the present invention and the method for manufacturing the same will be described more specifically with reference to examples, but the present invention is not limited to the examples.
[0028]
【Example】
[Example 1] Example of manufacturing composite panel by continuous bonding method
A composite panel was manufactured by the continuous manufacturing process shown in FIGS. 1 and 2 as follows.
In the continuous production process shown in FIG. 1, urethane-coated paper (manufactured by Toppan Printing Co., Ltd., 80 g / m ² ) And an aluminum foil (manufactured by Tokai Aluminum Co., Ltd., thickness: 50 μm) was dry-laminated at a process speed of 60 m / min (urethane type adhesive manufactured by Toyo Ink Co., Ltd.) to the aluminum foil at 40 g / m2. ² After coating and drying at 80 ° C. for 1 minute to evaporate the solvent, the coated paper was laminated. After winding it, it was cured at 40 ° C. for 4 days to produce a composite sheet (A).
[0029]
Next, in the continuous manufacturing process shown in FIG. 2, the aluminum foil surface of the composite sheet (A) and the fiber-reinforced thermosetting resin plate (Nitto Boseki Co., Ltd., unsaturated polyester resin and glass fiber) were formed at a line speed of 5 m / min. (A long board with a thickness of 1.0 mm obtained from heat curing of) is bonded to an aluminum foil with a urethane-type adhesive (30 g / m, manufactured by Toyo Ink Co., Ltd.). ² It is applied, dried at 80 ° C. for 1 to 2 minutes to evaporate the solvent, and then superimposed on the fiber-reinforced thermosetting resin plate, sandwiched and pressed by a pressure roller, and bonded to a desired length. Then, a composite panel having a thickness of 1.5 mm was obtained.
[0030]
[Example 2] Example of manufacturing composite panel by continuous lamination method
In the continuous manufacturing process shown in FIGS. 1 and 3, a composite panel was manufactured as follows. First, in the continuous bonding step shown in FIG. 1, urethane-coated paper (manufactured by Toppan Printing Co., Ltd., 80 g / m ² ) And dry laminating (a urethane type adhesive manufactured by Toyo Ink Co., Ltd.) to the aluminum foil at 40 g / m 2 at a line speed of 60 m / min. ² After coating and drying at 80 ° C. for 1 minute to evaporate the solvent, a urethane-coated paper is adhered) to obtain a composite sheet (A).
Further, in the manufacturing process also shown in FIG. 1, a polyester fiber non-woven fabric (manufactured by Unitika Ltd., 50 g / m 2) was applied to the aluminum foil surface of the composite sheet (A). ² ) At 50 m / min. And dry laminating (a urethane type adhesive manufactured by Toyo Ink Co., Ltd.) to the aluminum foil at 50 g / m. ² After coating and drying at 80 ° C. for 1 minute to evaporate the solvent, the polyester fiber non-woven fabric is laminated and bonded, pressed, wound up, and cured at 40 ° C. for 4 days) to give the composite sheet (B). Manufactured.
[0031]
Subsequently, in a continuous lamination step shown in FIG. 3, an uncured unsaturated polyester resin liquid (25 μm in thickness, manufactured by Unitika Ltd.) running on a first carrier film made of polyethylene terephthalate running at a line speed of 1.5 m / min. Dai Nippon Ink Kogyo Co., Ltd.) and glass fibers (a glass fiber mat having an average diameter of 0.02 mm and an average length of 50 mm, manufactured by Nitto Boseki Co., Ltd.) were charged and impregnated and mixed with an impregnation roller. A second carrier film (manufactured by Unitika Ltd., thickness 25 μm) is set so as to cover the decorative sheet surface of the composite sheet (B), and the second carrier film and the composite sheet (B) are simultaneously formed into a line. The composite sheet (B) with the fabric surface facing is placed on the uncured glass fiber reinforced unsaturated polyester resin liquid, and sent between upper and lower squeeze rollers to be sandwiched and adhered to the glass fiber. The reinforced unsaturated polyester resin liquid is defoamed, the thickness is adjusted to 1.5 mm, and then sent into a curing furnace to heat and cure the unsaturated polyester resin liquid (100 ° C., 30 minutes) to obtain a composite sheet ( B) and the glass fiber reinforced unsaturated polyester resin were continuously and integrally molded. The first and second carrier films of the composite panel running out of the curing oven were peeled off from the composite panel and wound up, and the panel was cut to a desired length with a cutter to produce a composite panel.
[0032]
The performance of the composite panels manufactured in Examples 1 and 2 was evaluated by the following nonflammability test and impact resistance test.
[Evaluation 1] Nonflammability test
Based on the provisions of Article 68-26, Paragraph 1 of the Building Standards Act, a nonflammability test was performed as follows.
A test piece (usually, 10 cm width × 10 cm length) to be subjected to a nonflammability test was placed in a cone calorie tester (manufactured by Toyo Seiki Co., Ltd.), and a cone heater (radiant intensity 50 KW / m) of the tester was used. ² ), The ignition spark is constantly ignited and heated for 10 or 20 minutes. The total calorific value of the test piece was measured, and the total calorific value for a considerable time was 8 MJ / m. ² The following criteria, and simultaneously observing the surface condition of the test piece after the heat treatment, and the absence of cracks or holes penetrating to the back surface of the test piece are criteria for judging the nonflammability of the test piece (heating time 10 minutes). Is determined as quasi-nonflammable, and the same 20 minutes is determined as nonflammable.
As a material to be subjected to the nonflammability test, a test piece (10 cm width × 10 cm length × 1.5 mm thickness) was prepared from the composite panel of the present invention obtained in Example 1. As comparative test samples, a waist wall material made of vinyl chloride resin (10 cm wide × 10 cm long × 3.0 mm thick made by ABC Corporation) and a sheet made of olefin resin (10 cm wide × 10 cm made by Toppan Printing Co., Ltd.) Length x thickness 1.0 mm), placed in the corn calorie tester and subjected to a nonflammability test, and the test (heating) was performed for 10 minutes (equivalent to quasi-nonflammable), and the total calorific value and surface of the test piece were measured. The condition was observed. The test results are shown in Table 1 below.
[0033]
[Table 1]

(Note: ○ passed: Total calorific value <8 MJ / m ² In addition, no cracks or holes are found on the surface. X indicates rejection: total calorific value> 8 MJ / m ² And burning caused holes in the surface).
[0034]
[Evaluation 2] Impact resistance test
An iron frame was attached to a test piece (approximately 10 cm wide × 10 cm long) for impact resistance test, and placed on a flat surface. From the height of 4, 3, 2, 1 m above the test piece, an eggplant-shaped weight (1 kg, Free fall) and observe the surface condition. Impact resistance is determined by visually observing the presence or absence of through holes, dents or holes, cracks or scratches in the test piece.
As a test piece used in the impact resistance test, the composite panel (30 cm width × 30 cm length × 1.5 mm thickness) of Example 2 of the present invention, and a vinyl chloride resin waist wall material ( ABC Shokai Co., Ltd., thickness 3 mm), olefin resin wall cloth (Toppan Printing Co., Ltd., thickness 1.0 mm), color aluminum plate (Fukuda Metal Foil & Powder Co., Ltd., thickness 1 mm), common base Elastic urethane adhesive (Konishi Bond Co., Ltd., KU910, coating amount 500 g / m) on gypsum board (12 mm thick, manufactured by Yoshino Gypsum Co., Ltd.) ² ) Was used to prepare bonded panels (30 cm wide × 30 cm long), and an iron frame was attached to each panel.
According to the impact resistance test, an eggplant-shaped weight having a weight of 1 kg was allowed to fall naturally from a height of 1, 2, 3, 4 m above each test piece, and the surface condition of the dropped test piece was observed. The results are shown in Table 2 below.
[0035]
[Table 2]

(Note, ○: pass, no dents on test specimen, ×: reject, dents generated)
[0036]
【The invention's effect】
INDUSTRIAL APPLICABILITY The composite panel of the present invention has a function of impact resistance (restorability) that withstands external stress without impairing incombustibility, and is suitable for various panels for interior building materials because it is thin and light.
There are two types of composite panel configurations, and their continuous manufacturing methods are different. However, whichever method is used, a long composite panel having the above function can be obtained at low cost.
[0037]
[Brief description of the drawings]
FIG. 1 is a schematic diagram showing a manufacturing process of a composite sheet (A) according to claim 1 or a composite sheet (B) according to claim 2 by a continuous bonding method.
FIG. 2 is a schematic view showing a process of manufacturing a composite panel by a continuous bonding method according to claim 1;
FIG. 3 is a schematic view showing a manufacturing process of a composite panel by a continuous laminating method according to claim 2;
FIG. 4 is a schematic diagram showing a configuration of a composite panel according to claim 4 of the present invention.
FIG. 5 is a schematic diagram showing a configuration of a composite panel according to claim 5 of the present invention.
[0038]
[Explanation of symbols]
1 Composite sheet (A) or composite sheet (B)
2 Decorative sheet or cloth
3 Metal foil or composite sheet (A)
4 Adhesive application coater and doctor knife
5 Pressure roller
6 Drying or curing oven
7 Fiber reinforced thermosetting resin plate
8 cutting machine
9 Composite panel
10 Conveyor
11 Composite sheet (B)
12 Second carrier film
13 First carrier film
14 Thermosetting resin liquid
15 Reinforcing fiber
16 Impregnation roller
17 Composite sheet (A)
18 Adhesive
19 Metal foil
20 Cloth
21 Squeeze roller
22 Makeup sheet

Claims

An adhesive is applied to the metal foil surface of the decorative sheet / metal foil composite sheet, and the adhesive-coated composite sheet is successively stacked on a fiber-reinforced thermosetting resin plate running on a conveyor. A composite panel is characterized in that the composite sheet is pressed and adhered to a fiber-reinforced thermosetting resin plate by laminating, sending between two pressure rollers positioned above and below and sandwiching the composite sheet, and laminating the composite sheet. Continuous manufacturing method.

While continuously running the first carrier film on the conveyor, the reinforcing fiber mixed thermosetting resin liquid obtained by mixing the uncured thermosetting resin liquid with the reinforcing fibers on the first carrier film is continuously applied. Then, on the reinforcing fiber mixed thermosetting resin liquid, a decorative sheet is placed on the front side with a metal foil interposed therebetween, and the fabric side of a composite sheet made of fabric is placed on the back side. A second carrier film is placed on the second carrier film, and then, the first and second carrier films, together with the composite sheet placed on the thermosetting resin liquid, are separated from each other by two rollers which are vertically separated from each other. The composite panel is characterized in that it has a predetermined thickness, is heated, cures the thermosetting resin in the reinforced fiber mixed thermosetting resin liquid, and is continuously integrated by being sandwiched by being fed between them. Continuous manufacturing method.

A composite panel comprising a composite sheet comprising a decorative sheet / metal foil and a fiber-reinforced thermosetting resin plate bonded to the metal foil side.

A composite panel comprising a composite sheet consisting of a decorative sheet / metal foil / cloth, and a fiber-reinforced thermosetting resin superposed on the cloth side and integrally molded.

The decorative sheet is a decorative sheet made of an olefin resin, a polyethylene terephthalate (PET) resin, or a vinyl chloride resin, and the decorative sheet has a basis weight of 100 g / m ² or less, and further has a metal foil of the composite sheet. 5. The composite panel according to claim 3, wherein the composite panel is an aluminum foil having a thickness of 50 μm or less. 6.

The decorative sheet is a decorative sheet obtained by applying a urethane resin, an acrylic resin, or an acrylic urethane resin to paper, and the basis number of the decorative sheet is 100 g / m ² or less, and the thickness of the metal foil of the composite sheet is further reduced. The composite panel according to claim 3, wherein is a 50 μm or less aluminum foil.