JP2005335116A - Manufacturing method of decorative panel having embossed pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the destruction of a wet inorganic panel, which comprises a wet mat obtained from a slurry containing a mineral fiber, an inorganic powder and a binder as essential components by a wet papermaking process, by preventing the occurrence of cracks or the like in embossed protrusions caused by the evaporation of moisture due to a hot press when an embossed pattern is molded on the wet inorganic panel by hot pressing after drying and to develop the embossed pattern having a sharp shape. <P>SOLUTION: A B-type silica gel being a humidity absorbing and discharging material is added to at least one of the wet mat and a mixture of inorganic foam and the binder and the wet mats are used as a surface layer and a back layer to be integrally laminated to the mixture being a core layer to form the inorganic panel. After this inorganic panel is dried, it is hot-pressed by an embossing mold. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a decorative board having an embossed pattern, and more particularly to a method for forming an embossed pattern on a surface of an inorganic board made of a wet mat obtained by wet-making a slurry by hot pressing.

Conventionally, as a method for producing this kind of inorganic board, as shown in Patent Document 1, for example, wet obtained by wet-making a slurry containing mineral fiber, inorganic powder and binder as essential components There is known a method in which a wet inorganic plate made of a mat is formed, the wet inorganic plate is dried to a moisture content of 20% or less, and then hot pressed to completely cure the binder to obtain an inorganic plate. According to this manufacturing method, by reducing the moisture content of the wet inorganic plate to 20% or less, an inorganic plate having a hard surface excellent in smoothness can be obtained by suppressing spring back during hot pressing.
Japanese Patent Laid-Open No. 2003-251617

  However, even if the moisture content of the wet inorganic plate is lowered as in the above-mentioned conventional one, the distribution of water vapor accompanying the evaporation of moisture during hot pressing is not uniform inside the inorganic plate depending on the material. In particular, when forming an embossed pattern on the surface of an inorganic plate by hot-pressing with a mold material (embossed mold material), the embossed pattern in the embossed pattern pressed with high pressure by the convex part of the mold material is inorganic due to the heat of the press. The moisture inside the plate is prevented from abruptly evaporating to the outside, but more water evaporates from the convex part of the embossed pattern that is formed in the concave part of the mold material and is not pressed at high pressure compared to the concave part. It becomes like this. In addition, since the pressing pressure on the convex portion of the embossed pattern is lower than that of the concave portion, the strength is also weakened. As a result, a crack or the like is generated on the embossed convex portion, and the embossed convex portion is easily broken, resulting in a problem that productivity is lowered.

  In addition, high-pressure water vapor evaporated from the inorganic plate stays between the inorganic plate and the embossed mold material, and this pressure reduces the adhesion of the surface of the inorganic plate to the molding material surface, leading to the tip angle of the embossed pattern convex portion. There is a problem that an embossed pattern having a sharp shape with an edge standing on the surface of the inorganic plate is difficult to be exhibited as intended. This problem is particularly prominent in convex portions with low strength.

  The present invention has been made in view of such points, and the object thereof is from a wet mat obtained by wet-making a slurry containing mineral fiber, inorganic powder and binder as essential components as described above. In contrast to the method of forming an embossed pattern by drying the wet inorganic board after it is hot-pressed, cracks and the like are generated on the embossed protrusion due to evaporation of moisture by adding a predetermined component to the material of the inorganic board It is to prevent the destruction and prevent the appearance of a sharp embossed pattern.

  In order to achieve the above object, in the present invention, a moisture absorbing / releasing material is added to the material component of the wet mat so that water vapor generated by the heat pressure is adsorbed by the moisture absorbing / releasing material.

  Specifically, the manufacturing method of the decorative board having an embossed pattern of the invention of claim 1 includes a wet mat obtained by wet-making a slurry containing mineral fibers, inorganic powder and a binder as essential components; A mixture comprising an inorganic foam and a binder as essential components is laminated and integrated in a state where the wet mat is a front and back layer and the mixture is a core layer and a moisture absorbing / releasing material is added to at least one of the front and back layers or the core layer. An inorganic plate is formed, and after drying the inorganic plate, hot pressing is performed with a mold material having an embossed pattern.

  The method for producing a decorative board having an embossed pattern according to the invention of claim 2 is obtained by wet-making a slurry containing mineral fiber, inorganic powder, binder and hygroscopic material as essential components. An inorganic plate is formed by using a single wet mat or by laminating and integrating a plurality of wet mats, and after drying the inorganic plate, hot pressing is performed with a molding material having an embossed pattern.

  According to the structure of these inventions, at least one of the front and back layers or the core layer of the inorganic board in which the front and back layers made of the wet mat and the core layer made of the mixture are laminated and integrated, or the inorganic board made of one wet mat or Since the wet mats in the inorganic plates in which a plurality of wet mats are laminated and integrated each contain moisture absorbing and releasing materials, when these inorganic plates are hot-pressed for embossing, the moisture of the wet mats is reduced. Water vapor generated by heating is adsorbed by the hygroscopic material inside the inorganic plate. For this reason, it is suppressed that the water vapor evaporated from the inorganic board goes out to the part between the mold materials and stays in a high pressure state, and a sharp embossed pattern can be formed on the surface of the manufactured decorative board, and the strength Evaporation of water vapor from the weak embossed pattern of the embossed pattern is also suppressed, and cracks of the projecting part and the like can be effectively prevented from being broken, thereby improving the productivity of the decorative board. In addition, the manufactured decorative board has moisture absorption / release properties by the moisture absorption / release material, and can be used as a humidity control material.

  In the invention of claim 3, the hygroscopic material is B-type silica gel. This B-type silica gel has a very large moisture absorption / release capacity and can release moisture at room temperature, so that the water vapor absorbed by the silica gel at the time of hot pressure is desorbed at the room temperature and adsorbed in the substrate. The water vapor is not left as it is.

  As described above, according to the first aspect of the present invention, at least one of the wet mat having mineral fibers, the inorganic powder and the binder as components, and the mixture including the inorganic foam and the binder as components is absorbed and released. Wet materials were added, and the inorganic board in which these layers were laminated and integrated was dried and hot-pressed with an embossing mold material to produce a decorative board having an embossed pattern. In the invention of claim 2, an inorganic board is formed from one or a plurality of wet mats composed of mineral fiber, inorganic powder, binder and hygroscopic material, and the inorganic board is dried. A decorative sheet having an embossed pattern was manufactured by hot pressing with an embossing mold material. Therefore, according to these inventions, the water vapor generated when the inorganic plate is hot-pressed for embossing can be adsorbed by the moisture absorbing / releasing material inside the inorganic plate, and the evaporated water vapor is high-pressure between the mold material. It is possible to manufacture a decorative board having a sharp embossed pattern on the surface while preventing it from staying in the state, and effectively preventing the occurrence of cracks on the embossed convex parts with weak strength and the resulting damage. Productivity can be improved, and a decorative board for use as a humidity control material can be obtained.

  According to the invention of claim 3, the moisture-absorbing / releasing material is B-type silica gel that has an extremely large moisture-absorbing / releasing capacity and can dissipate moisture at room temperature. A decorative board having a stable moisture absorption and desorption performance can be obtained by preventing it from being left in the state.

Hereinafter, the best embodiment of the present invention will be described in detail with reference to the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its application, or its application.
(Embodiment 1)
FIG. 1 shows a decorative board A manufactured by the manufacturing method according to Embodiment 1 of the present invention, and this decorative board A has an embossed pattern 3 comprising concave portions 1, 1,... And convex portions 2, 2,. Have. The decorative board A has a three-layer structure of a surface layer 5, a core layer 7, and a back layer 6. The front and back layers 5 and 6 are the same as each other, and are formed of a wet mat obtained by wet-making a slurry containing mineral fiber, inorganic powder and binder as essential components. On the other hand, the core layer 7 is formed of a mixture containing an inorganic foam and a binder as essential components.

  For example, rock wool, mineral wool, glass wool or the like is used as the mineral fiber in the front and back layers 5 and 6. The composition ratio of the mineral fiber is 20 to 60 wt% in each of the front and back layers 5 and 6.

  As the inorganic powder, for example, calcium carbonate, aluminum hydroxide, microsilica, slag and the like are used. The composition ratio of the inorganic powder is about 30 to 70 wt% in the front and back layers 5 and 6. This inorganic powder improves the fire resistance and hardness of the decorative board A and improves the screwing performance. The inorganic powder also functions as a bulking agent.

  Further, as the binder, for example, melamine resin, phenol resin, poval, epoxy resin, starch or the like is used. The composition ratio of this binder is about 7 to 15 wt%.

  In addition, as auxiliary additives in the front and back layers 5 and 6, for example, synthetic fibers such as polypropylene, polyester and vinylon, plant fibers such as hemp and flax, and wood fibers are added. Moreover, you may add an aggregating agent, a size agent, an antifoamer, an admixture, etc. as needed.

  On the other hand, as the inorganic foam in the core layer 7, for example, pearlite, shirasu foam, silica flour, glass foam or the like is used. The composition ratio of the inorganic foam is about 40 to 90 wt% in the core layer 7.

  As the binder, for example, melamine resin, phenol resin, poval, epoxy resin, starch or the like is used. The composition ratio of this binder is about 7 to 15 wt% in the core layer 7.

  In addition, for example, mineral fibers such as rock wool, mineral wool, and glass wool, synthetic fibers such as polypropylene, polyester, and vinylon, plant fibers such as hemp and flax, and wood fibers may be added to the core layer 7. In addition, an inorganic powder such as calcium carbonate may be added.

  In addition, B-type silica gel as a moisture absorbing / releasing material is added to at least one of the core layer 7 and the front and back layers 5 and 6. Since this B-type silica gel is powdery and its particle size affects the surface properties of the decorative board A, those having a mesh size of 20 mesh or more (passing through a 20-mesh sieve) are preferable. The composition ratio of the B type silica gel is about 5 to 36 wt%.

  When the manufacturing method of the said decorative board A based on Embodiment 1 of this invention is demonstrated, each material (Mineral fiber, an inorganic powder, and a binder are essential) of the said front and back layers 5 and 6 is stirred in water. And agglomerated by adding an auxiliary additive such as an agglomerate to obtain a slurry. When B-type silica gel is added to the front and back layers 5 and 6, it is added to each material for the front and back layers. Then, the slurry is made with a paper making machine to prepare two wet mats for the front and back layers.

  On the other hand, each material of the core layer 7 (inorganic foam and binder are essential) is mixed while spraying water to obtain a mixture. When B-type silica gel is added to the core layer 7, it is added when the materials for the core layer are mixed.

  And among the two wet mats for the front and back layers, the mixture for the core layer is uniformly sprayed and deposited on the surface of one wet mat that becomes the front layer 5, and then the other wet mat that becomes the back layer 6 Wet mats are stacked to obtain an inorganic plate made of a three-layer laminate.

  In order to obtain sufficient shape retention and handling strength, the inorganic plate is temporarily clamped at a predetermined pressure and temperature (for example, 80 to 180 ° C.). This temporary pressing can be performed by a heating roll or a continuous press. Some springback occurs after this temporary pressing, but since the hot pressing is performed in the final process, the physical properties of the final product are not affected.

  Next, the temporarily pressed inorganic plate is dried with a hot air dryer or the like at a temperature of 80 to 250 ° C. until the moisture content becomes 20% or less.

  The dried inorganic plate is pressed at a predetermined pressure, temperature, and time by hot press using a press. At that time, an embossed pattern (molding material) having an embossed pattern such as a mold or an embossed plate for forming the embossed pattern 3 is interposed between the hot plate and the inorganic plate of the press machine, thereby embossing pattern. Is molded. The binder is cured by this hot press, and the decorative board A having the embossed pattern 3 on the surface is manufactured.

  Regarding the above embossing die, it is necessary to use a material that has good heat resistance and heat shrinkability with respect to a predetermined temperature at the time of hot press, and if it is a metal die, a material such as aluminum or an aluminum alloy, or a resin die If so, materials such as FRP and unsaturated polyester are used.

In addition, you may apply | coat aqueous or oil-based liquid substance to the front-and-back surface or single side | surface of a laminated body before making it harden | cure with a hot press. Thereby, the flow of the binder is promoted, and the surface smoothness and the surface hardness are improved. In addition to fresh water, vinyl acetate emulsion, PVA, and the like can be used as the aqueous liquid, and isocyanate-based and epoxy-based alcohol-diluted products can be used as the oil-based liquid. The coating amount is preferably ²⁰ to 100 g / m ^{2 on} one side.

  When the embossed pattern 3 is formed on the surface by pressing the inorganic plate with a hot press using a press in this way, at least one of the front and back layers 5 and 6 or the core layer 7 has B as a moisture absorbing / releasing material. Since the type silica gel is contained, the water vapor generated when the moisture in the inorganic plate is heated is adsorbed by the B type silica gel inside the inorganic plate. For this reason, it is possible to prevent the water vapor evaporated from the inorganic board from coming out between the embossing mold and stay in a high-pressure state, thereby forming the sharp embossed pattern 3 on the surface of the manufactured decorative board A. it can.

  Further, the adsorption of water vapor by the B-type silica gel suppresses the evaporation of water vapor from the convex portion 2 of the embossed pattern 3 having a low strength, and the occurrence of cracks in the convex portion 2 and the decorative board A (inorganic Can be effectively prevented and the productivity of the decorative board A is improved.

  Furthermore, since B-type silica gel is contained in the manufactured decorative board A, the decorative board A has moisture absorption / release properties and can be used as a humidity control material.

  The B-type silica gel has a very large moisture absorption / release capacity and can release moisture at room temperature, so that the water vapor absorbed by the silica gel at the time of hot pressure is dehumidified at the subsequent room temperature. The water vapor adsorbed inside is not left as it is.

Therefore, as the decorative board A, a surface having a sharp embossed pattern 3 with no damage due to cracks or the like of the convex part 2 is obtained.
(Embodiment 2)
FIG. 2 shows a decorative board A manufactured by the manufacturing method according to Embodiment 2 of the present invention, and this decorative board A also has an embossed pattern 3 comprising concave portions 1, 1,... And convex portions 2, 3,. Have. The difference between this decorative board A and that of the first embodiment is that, in the first embodiment, the decorative board A is obtained from a mixture of the front and back layers 5 and 6 obtained from a wet mat, an inorganic foam and a binder. In this embodiment, an inorganic board is formed by laminating and integrating two wet mats obtained by wet papermaking of the slurry, and this inorganic board. Therefore, the decorative sheet A has a two-layer structure having front and back layers 5 and 6.

  Similar to the first embodiment, the wet mat contains mineral fibers, inorganic powder, and a binder as essential components, and further includes B-type silica gel as a moisture absorbing / releasing material. Other material components are the same as those in the first embodiment.

  And when manufacturing the decorative board A of this embodiment, it is the same as the method of Embodiment 1 except making the mixture for core layers. That is, a material that requires mineral fiber, inorganic powder, binder and hygroscopic material (B-type silica gel) is agitated in water and agglomerated by adding an auxiliary additive such as an agglomerate to obtain a slurry. Then, the slurry is made with a paper making machine to make a wet mat.

  Then, the two wet mats are stacked to obtain an inorganic plate made of a laminate having a two-layer structure. The two-layer inorganic plate is temporarily pressed and dried to a moisture content of 20% or less, and then pressed. An embossed pattern is formed on the surface by pressing with a hot-pressing machine. By the above, the decorative board A which has the front and back layers 5 and 6 which have the embossed pattern 3 on the surface is manufactured.

  Therefore, also in this embodiment, the same effect as that of the first embodiment can be obtained. Three or more wet mats are stacked to form an inorganic plate made of a multi-layered laminate or an inorganic plate made of only one wet mat, and these are temporarily pressed and dried, followed by hot pressing. And it is good also as a decorative board.

  Next, specific examples will be described.

(1) Example 1
A decorative board was obtained from a three-layered inorganic board having front and back layers and a core layer by the manufacturing method of the first embodiment. The respective materials and composition ratios of the front and back layers and the core layer of the decorative board of Example 1 are as follows.
(Front and back layers)
Mineral wet fiber: Rock wool 50wt%
Inorganic powder: Aluminum hydroxide 21wt%, calcium carbonate 12wt%
Binder (starch, phenol): 9wt%
Organic fiber: 0.5 wt%
Admixture: 7.5wt%
(Core layer)
Inorganic foam: Shirasu foam 45wt%
Absorbent / release material: B-type silica gel 36wt%
Inorganic powder: Calcium carbonate 7wt%
Binder (starch, phenol): 10wt%
Admixture: 2wt%
(2) Example 2
Moreover, the decorative board was obtained from the inorganic board which has a front and back layer (2 layers) with the manufacturing method of Embodiment 2. FIG. The materials and composition ratios of the front and back layers of the decorative board of Example 2 are as follows.
(Front and back layers)
Mineral wet fiber: (Rock wool) 45wt%,
Inorganic powder: Aluminum hydroxide 21wt%, calcium carbonate 10wt%
Binder (starch, phenol): 8wt%
Absorbent / release material: B-type silica gel 10wt%
Organic fiber: 2wt%
Admixture: 4 wt%
(3) Comparative Example In addition, a material obtained by removing B-type silica gel from the core layer material in Example 1 (not added) was used as Comparative Example 1, and B-type silica gel was similarly removed from the material of the front and back layers in Example 2. One (not added) was designated as Comparative Example 2.

  When Example 1 and Comparative Example 1 were compared, and Example 2 and Comparative Example 2 were respectively compared, a difference was found in the embossed pattern of the decorative board. In the first and second embodiments, such a phenomenon does not occur, and the embossed pattern is sharp with no cracks. It was a shape. This proves that the present invention is effective.

  The present invention, from a wet mat obtained by wet-making a slurry containing mineral fiber, inorganic powder and binder as components, when the embossed pattern of the decorative board is formed by hot pressing after drying, A sharp embossed pattern can be secured, cracks can be prevented, and productivity can be improved, so it is extremely useful and has high industrial applicability.

It is a schematic sectional drawing of the decorative board manufactured by the manufacturing method which concerns on Embodiment 1 of this invention. 6 is a schematic cross-sectional view of a decorative board manufactured by a manufacturing method according to Embodiment 2. FIG.

Explanation of symbols

A decorative board 1 concave part 2 convex part 3 embossed pattern 5 surface layer 6 back layer 7 core layer

Claims (3)

A wet mat obtained by wet-making a slurry containing mineral fibers, inorganic powder and a binder as essential components, and a mixture containing inorganic foam and a binder as essential components, the wet mat is a front and back layer. The mixture becomes a core layer and is laminated and integrated with a hygroscopic material added to at least one of the front and back layers or the core layer to form an inorganic plate,
A method for producing a decorative board having an embossed pattern, wherein the inorganic board is dried and then hot-pressed with a molding material having an embossed pattern. An inorganic board made of one wet mat obtained by wet-making a slurry containing mineral fiber, inorganic powder, binder and moisture-absorbing / releasing material, or by laminating and integrating multiple wet mats Form the
A method for producing a decorative board having an embossed pattern, wherein the inorganic board is dried and then hot-pressed with a molding material having an embossed pattern. In the manufacturing method of the decorative board which has an embossed pattern of Claim 1 or 2,
A method for producing a decorative board having an embossed pattern, wherein the hygroscopic material is B-type silica gel.

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