JP2005212424A - Non-combustible decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a non-combustible decorative sheet keeping a non-combustibility, being excellent in strength, being small in dimensional change. <P>SOLUTION: A metal foil is interposed between a core layer comprising a prepreg made by impregnating an organic fiber base substrate with a slurry composed of an organic resin and an inorganic filler and a resin impregnated decorative paper made by impregnating the raw paper for the decorative sheet with a resin solution mainly comprising a thermosetting resin and drying it, and is formed under heated and pressurized conditions. The compounding ratio of the organic resin and the inorganic filler in the slurry are 5-50:95-50 as a solid ratio, and as this organic resin, a phenol resin and/or an amino-formaldehyde resin are used. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a non-combustible decorative board.

  Conventionally, a decorative board imparted with fireproofing and nonflammability has been known, and a prepreg impregnated with a slurry containing an inorganic filler and a phenol resin or melamine resin as a binder component in an inorganic fiber nonwoven fabric has been used for the core layer.

JP-A-8-216333 Japanese Utility Model Publication 59-75037 JP 2000-351177 A JP 2001-96702 A

  However, there are problems such as poor penetration of the slurry into the inorganic fiber base material and impregnation speed does not increase, and uneven penetration occurs. Further, when the prepreg is laminated, it may be damaged due to brittleness.

  The present invention has been studied in view of such circumstances, and aims to obtain a non-combustible decorative board having non-combustible performance, excellent strength, and small dimensional change, and is characterized by the following.

That is, in the invention described in claim 1, a metal foil is interposed between a core layer made of a prepreg in which an organic fiber base material is impregnated with a slurry made of an organic resin and an inorganic filler, and a decorative layer. It is a noncombustible decorative board characterized by becoming.
The invention according to claim 2 is characterized in that the blending ratio of the organic resin and the inorganic filler in the slurry is 5 to 50:95 to 50 in terms of solid content ratio. The incombustible makeup according to claim 1, wherein the makeup is makeup.
Furthermore, the invention according to claim 3 is the incombustible decorative board according to claim 1 or 2, wherein the organic resin is a phenol resin and / or an amino-formaldehyde resin.

The present invention uses a prepreg in which a core layer is impregnated with a slurry composed of an organic resin component and an inorganic filler in an organic fiber base material, and maintains a nonflammable performance by laminating a metal foil directly under the decorative layer, and Excellent strength and small dimensional change.
Hereinafter, the present invention will be described in detail.

  The incombustible decorative board of the present invention comprises a prepreg obtained by impregnating an organic fiber base material with a slurry comprising a resin component and an inorganic filler, a metal foil, and a decorative layer.

Examples of the organic fiber substrate include nonwoven fabrics and woven fabrics made of organic fibers, and the basis weight may be in the range of 10 to ²⁰⁰ g / m ² . Examples of organic fibers include polyethylene, polypropylene, vinylon, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyamide, polyester, polyurethane, etc., modified products thereof, and various copolymers typified by ethylene-vinyl acetate copolymer. Examples thereof include fibers made of polymers and mixtures thereof, and composite fibers made of these polymers.

The organic fiber base is impregnated with an organic resin as a binder component and a slurry containing an inorganic filler.
The impregnation rate (%) is a calculation method represented by Equation 1, and is preferably 500 to 3000%. If the upper limit is exceeded, the solid content will drop off, making it difficult to handle, and if the lower limit is not reached, delamination will easily occur.

  Examples of the resin component include a phenol resin and an amino-formaldehyde resin. By using both in combination, physical properties such as nonflammability, strength, and heat resistance are excellent.

  Products using prepregs with only phenolic resin as the binder component as the core layer have a limit to the amount of binder component added to ensure nonflammable performance, and the resulting nonflammable decorative board is somewhat inferior in strength. It becomes easy.

  In addition, prepregs containing melamine resin as a binder component as a core layer can ensure nonflammability even when the addition amount is about twice that of phenol resin, but the resin itself is hard and brittle, so it is nonflammable. The decorative board is inferior in strength, has a large dimensional change, and may warp due to changes over time.

Phenol resins are obtained by reacting phenols and aldehydes at a ratio of 1 to 3 moles of aldehydes with 1 mole of phenolic hydroxyl group under a basic catalyst or an acidic catalyst. Phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, bisphenol F and the like. Examples of aldehydes include formaldehyde, paraformaldehyde, glyoxal, trioxal and the like.
In addition, those modified with a modifying agent that promotes plasticization such as paratoluene sulfonamide, tung oil, phosphoric esters, glycols, etc. can be applied as necessary, and basic catalysts include alkali metals such as sodium and potassium, And oxides and hydroxides of alkaline earth metals such as magnesium and calcium, amines such as triethylamine and triethanolamine, and ammonia. Examples of acidic catalysts include paratoluenesulfonic acid and hydrochloric acid.

  Amino-formaldehyde resins include initial condensates obtained by reacting amino compounds such as melamine, urea, benzoguanamine, and acetoguanamine with formaldehyde, etherification with lower alcohols such as methyl alcohol and butyl alcohol, and paratoluene. Those modified with a reactive modifier that promotes plasticization such as sulfonamide can be applied, and among them, a melamine-formaldehyde resin excellent in durability is preferable.

  Examples of the inorganic filler contained in the slurry include aluminum hydroxide, magnesium hydroxide, calcium carbonate, silica, and the like, and those having an average particle size in the range of 0.5 to 500 μm impregnate the inorganic fiber nonwoven fabric. Among them, those containing crystal water such as aluminum hydroxide and magnesium hydroxide are excellent in water resistance and heat resistance.

The blending ratio of the phenol resin and the amino-formaldehyde resin as the organic resin component in the slurry is desirably a solid content ratio of 1: 0.1 to 5, and when the amino-formaldehyde resin is less than the phenol resin, Strength and adhesion tend to be inferior, and warping increases when there are many.
In addition, the blending ratio of the organic resin component and the inorganic filler is desirably 5 to 50:95 to 50. If the amount of the inorganic filler increases with respect to the organic resin component, the nonflammability is improved, but the adhesion is lowered. In addition, when the inorganic filler is reduced, the adhesion is improved, but the incombustibility is lowered, or the resin oozes out during hot pressing.

  A decorative layer is formed on at least one side of a core layer made of a prepreg in which slurry is impregnated with an organic fiber base material through a metal foil, and as a forming method, a method of applying, a method of using resin-impregnated decorative paper, A method of transferring a decorative layer using a transfer foil may be mentioned, but the use of a resin-impregnated decorative paper is particularly preferable from the viewpoints of productivity, adhesion to the core layer, and abrasion resistance. In the embodiment, the metal foil is laminated on only one side of the core layer and the decorative layer is applied. However, the decorative layer may be formed by arranging the metal foil on both sides of the core layer.

  By using a metal foil, it is considered that a thermal diffusion effect and a gas barrier effect are exhibited and no heat is generated in the corn calorie test. Examples of the material of the metal foil include iron, copper, aluminum, and stainless steel, and an adhesive paper, for example, a paper coated with phenol butyral is laminated to improve adhesion to the prepreg and the decorative layer. In terms of cost, it is preferable to use an aluminum foil.

  As the means for forming the decorative layer, means such as resin-impregnated paper or painting are employed. As a means for coating, a resin liquid containing an unsaturated polyester resin colored with a pigment, a curing agent such as methyl ethyl ketone peroxide, and a curing accelerator such as cobalt naphthenate is applied on the core molding. After coating, the coated surface is covered with a vinylon film, spread with a roller, and after the resin is cured, the vinylon film is peeled off.

  The unsaturated polyester resin contains an acid component containing an unsaturated dibasic acid and / or an acid anhydride thereof and other saturated acid and / or acid anhydride used as necessary, and a polyhydric alcohol. A dehydration-condensation reaction is carried out according to a conventional method at about 160 to 230 ° C., preferably 210 to 230 ° C. in an inert gas atmosphere such as argon, and a polymerizable monomer such as a styrene monomer is added.

The method using resin-impregnated decorative paper is a method in which a base resin for decorative board is impregnated with a resin liquid containing a thermosetting resin as a main component, dried resin-impregnated decorative paper is laminated, and hot pressing is performed. As a decorative paper, a resin liquid made of a thermosetting resin such as an amino-formaldehyde resin, a diallyl phthalate resin, or an unsaturated polyester resin is impregnated in 30 to 140 g / m ² of decorative paper for a decorative board expressed by the following equation (1). Those impregnated with a rate of 80 to 300% can be applied. Hot pressing may be performed with a press such as a flat plate press or a continuous press.

EXAMPLES Hereinafter, although an Example is given and demonstrated in detail, this invention is shown more concretely and is not specifically limited.
Example 1
Core layer 50 g / m ² Polyester fiber nonwoven fabric A slurry in which 7 parts of amino-formaldehyde resin and 85 parts of aluminum hydroxide are blended with 8 parts of phenol resin has a slurry solid content fixing ratio of 1400% shown in Equation 1. A prepreg (A ₁ ) was obtained by impregnation.
Decorative layer A plain pattern decorative paper having a basis weight of 100 g / m ² was impregnated with a melamine-formaldehyde resin so that the impregnation ratio represented by the formula 1 was 100% to obtain a melamine resin-impregnated decorative paper (B ₁ ).
Non-combustible decorative plate In order from the bottom, 4 sheets of prepreg (A ₁ ), 40 μm thick aluminum foil coated with phenolol butyral on both sides, ₁ sheet of melamine resin-impregnated decorative paper (B ₁ ) are laminated and flat finished plate Was subjected to hot-press molding under the conditions of 130 ° C., 100 kg / cm ² , and 90 minutes to obtain a noncombustible decorative board of Example 1.

Example 2
In Example 1, instead of the 40 μm-thick aluminum foil coated with phenol butylal on both sides, a 40 μm-thick paper-aluminum sheet laminated on both sides was used, and the nonflammable of Example 2 was used. A decorative board was obtained.

Comparative example 1 (when there are few inorganic fillers with respect to a resin component)
In Example 1, it carried out similarly except having used the slurry which mix | blended 11 parts of amino-formaldehyde resin and 59 parts of aluminum hydroxide with respect to 30 parts of phenol resins, and obtained the decorative board of the comparative example 1.

Comparative example 2 (when there are many inorganic fillers with respect to the resin component)
A decorative board of Comparative Example 2 was obtained in the same manner as in Example 1 except that a slurry in which 1 part of amino-formaldehyde resin and 96 parts of aluminum hydroxide were blended with 3 parts of phenol resin was used.

Comparative Example 3 (when melamine-formaldehyde resin is less than phenol resin)
In Example 1, it carried out similarly except having used the slurry which mix | blended 1 part of amino-formaldehyde resin and 85 parts of aluminum hydroxide with respect to 14 parts of phenol resins, and obtained the decorative board of the comparative example 3.

Comparative Example 4 (when melamine-formaldehyde resin is more than phenolic resin)
In Example 1, it carried out similarly except having used the slurry which mix | blended 14 parts of melamine-formaldehyde resins, and 85 parts of aluminum hydroxide with respect to 1 part of phenol resins, and obtained the decorative board of the comparative example 4.

Comparative Example 5 (when the impregnation rate of the slurry is less than the lower limit)
The decorative plate of Comparative Example 5 was obtained in the same manner as in Example 1 except that the slurry solid content fixing rate was 450%.

Comparative Example 6 (when the slurry fixing rate exceeds the upper limit)
The decorative plate of Comparative Example 6 was obtained in the same manner as in Example 1 except that the slurry solid content fixing rate was 3200%.

Comparative Example 7 (when aluminum foil is not used)
A decorative board of Comparative Example 7 was obtained in the same manner as in Example 1 except that a 40 μm thick aluminum foil coated with phenolol butyral on both sides was not used.

Comparative Example 8 (when glass fiber nonwoven fabric is used)
In Example 1, it implemented similarly except having used the glass fiber nonwoven fabric instead of the polyester fiber nonwoven fabric, and obtained the decorative board of the comparative example 8. FIG.

The evaluation results are shown in Table 1.

The test method was as follows.
Nonflammability: JIS A 1321 “Evaluation based on building interior materials and flame retardancy test method of construction method. (Cone calorimeter test)
Dimensional change rate: JIS K 6902
Bending strength; JIS K 6902
Breaking deflection; JIS K 6902
Permeability of slurry: “O” indicates that the slurry has permeated;
Handling of prepreg: “O” indicates that there is no problem, “Δ” indicates that the powder of the slurry slightly dances during the lamination, and “x” indicates that the powder dances during the lamination because the slurry does not permeate.

1 is a configuration cross-sectional view of a non-combustible decorative board of Example 1.

Explanation of symbols

1 Metal foil 2 Prepreg 3 Melamine resin impregnated paper 6 Non-combustible decorative board

Claims (3)

A nonflammable decorative board, wherein a metal foil is interposed between a core layer made of a prepreg in which an organic fiber base material is impregnated with a slurry made of an organic resin and an inorganic filler, and a decorative layer. The incombustible decorative board according to claim 1, wherein the mixing ratio of the organic resin and the inorganic filler in the slurry is 5 to 50:95 to 50 in terms of solid content. The incombustible decorative board according to claim 1 or 2, wherein the organic resin is a phenol resin and / or an amino-formaldehyde resin.