JP2006336159A - Noncombustible board and noncombustible decorative laminate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a noncombustible board having high fireproofness and light weight, exhibiting high tensile strength perpendicular to the board surface and peeling strength as a building material such as decorative laminate and having sufficiently high surface smoothness. <P>SOLUTION: A noncombustible pressboard is produced by mixing sepiolite, an epoxy resin/phenolic resin, etc., in a material mixing step S1, adding a binder for consolidation/aggregation in an aggregation step S2 to prepare a slurry, forming a wet sheet having a thickness of about 0.8 mm and a water-content of 60-70% in a paper-making step S3 by forming the slurry containing aggregated flock, laminating several wet sheets in a lamination step S4 and hot-pressing in a hot-pressing step S5 to apply pressure and heat at the same time and cause thermosetting of the material in the case of using an epoxy resin, etc. A noncombustible board having smooth face on at least one surface is produced by cooling the noncombustible pressboard, applying a water-based organic-inorganic mixed binder to the surface in a water-based binder application step S6 and pressing and drying the product with a hot-press in a pressing and drying step S7. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a non-combustible board and a non-combustible decorative board that have both strength, non-combustibility, and smoothness and can be widely used for building materials such as wall coverings.

  In recent years, building materials such as wall coverings have been required to have fire resistance, flame resistance, and non-flammability from the viewpoint of fire prevention due to the strengthening of fire prevention standards in buildings and the improvement of consumer awareness of disaster prevention. . Conventionally, as non-combustible sheet materials that are versatile, those using asbestos (asbestos) fibers are typical, and they have been widely used because they are flame retardant, heat resistant, high strength, and inexpensive. . However, since asbestos fiber has been found to be a health-damaging substance and the use of asbestos has been regulated, the development of asbestos substitutes has been actively conducted.

  In particular, a thin incombustible board with a thickness of 3 mm or less is light and easy to process and has few restrictions on construction. Therefore, it is very popular for renovation and renovation including new houses. However, in the case of a conventional thin non-combustible board, there is a risk of breaking or breaking when handling in a standard size of 3 × 6, 4 × 8, and a glass cloth is pasted on the surface of aluminum hydroxide Etc., such as those that have been combined or that contain a large amount of organic resin.

Therefore, as disclosed in Patent Document 1, the present inventors made a slurry of hydrous magnesium silicate (sepiolite) as a main material and added inorganic fibers, binders, etc., and laminated pre-dried sheets. Has completed the patented invention of a non-combustible pressboard made by pressurizing and heating. This incombustible press board has been certified as a non-combustible material based on the provisions of the Building Standards Act by the Ministry of Land, Infrastructure, Transport and Tourism, and has a thin sheet multi-layer structure utilizing the caking properties of hydrous magnesium silicate and fiber entanglement. Therefore, it is not only highly fire-resistant and lightweight, but also has the advantage of high flexibility and handling strength.
Japanese Patent No. 3100243

  However, the non-combustible press board described in the above-mentioned Patent Document 1 has inorganic fibers such as glass fibers and pulp fixed by entanglement of those fibers and an organic binder, so that the tensile strength in the direction perpendicular to the surface, peeling strength However, since the surface smoothness is not sufficiently low, there has been a practical problem in applications such as decorative panels.

  Therefore, the present invention has high tensile strength and peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board, while taking advantage of the characteristics of non-combustible pressboard that is fire resistant and lightweight. It is an object of the present invention to provide a non-combustible board and a non-combustible decorative board that can obtain smooth surface smoothness.

  The nonflammable board according to the invention of claim 1 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, an inorganic fiber for reinforcement, and a binder for consolidation and aggregation. After forming the slurry and forming a sheet, a water-based organic-inorganic mixed binder is applied to a non-combustible pressboard obtained by laminating the sheet and pressurizing and heating, or the non-combustible pressboard is mixed with the water-based organic-inorganic mixed It is immersed in a binder and dried under pressure.

  The nonflammable board according to the invention of claim 2 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, a reinforcing inorganic fiber, and a binder for consolidation and aggregation. After forming a sheet containing slurry and forming a sheet, the sheet is laminated and water is applied to a non-combustible press board formed by pressurization and heating, or the non-combustible press board is immersed in water and press-dried. Later, a water-based organic / inorganic mixed binder is applied to the surface and dried.

  A nonflammable board according to a third aspect of the present invention is the nonflammable board according to the first or second aspect, wherein a water-based organic / inorganic mixed binder is applied to both surfaces of the non-combustible pressboard, or the non-combustible pressboard is mixed with the water-based organic / inorganic mixed board. After dipping in a binder, a plurality of sheets are laminated and dried under pressure.

  The nonflammable board according to the invention of claim 4 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, a reinforcing inorganic fiber, and a binder for consolidation and aggregation After forming the slurry and forming a sheet, a water-based organic / inorganic mixed binder is applied to one side of the non-combustible press board obtained by laminating the sheet and pressurizing and heating, and the pressure is reduced from the opposite side of the non-combustible press board. The water-based organic / inorganic mixed binder is infiltrated into the incombustible press board and then dried under pressure.

  The nonflammable board according to the invention of claim 5 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, an inorganic fiber for reinforcement, and a binder for consolidation and aggregation. After forming the slurry and forming a sheet, a water-based organic-inorganic mixed binder is applied to a non-combustible pressboard obtained by laminating the sheet and pressurizing and heating, or the non-combustible pressboard is mixed with the water-based organic-inorganic mixed After being immersed in a binder, the non-combustible pressboard is housed in a vacuum box and the inside of the non-combustible pressboard is infiltrated into the non-combustible pressboard by depressurizing the inside, followed by pressure drying. Is.

  The nonflammable board according to the invention of claim 6 is the structure according to any one of claims 1 to 5, wherein the water-based organic-inorganic mixed binder is a polyester emulsion or an acrylic emulsion in a solid content of 25 wt% to 50 wt%. And 50% by weight to 75% by weight of lithium silicate or potassium silicate as a solid content are uniformly dispersed and dissolved in water.

  A non-combustible decorative board according to a seventh aspect of the invention is obtained by embossing the non-combustible decorative board according to any one of the first to sixth aspects in the production of the non-combustible board according to any one of the first to sixth aspects.

  An incombustible decorative board according to an invention of claim 8 is subjected to bending processing during the pressure drying in the manufacture of the incombustible board or the incombustible decorative board according to any one of claims 1 to 7. It will be.

  A nonflammable board or a nonflammable decorative board according to the invention of claim 9 is obtained by applying a water-resistant sealant to the surface of the nonflammable board or the nonflammable decorative board according to any one of claims 1 to 8. It will be.

  A non-combustible decorative board according to a tenth aspect of the present invention is obtained by attaching a decorative sheet to the non-combustible board or the non-combustible decorative board according to any one of the first to ninth aspects.

  An incombustible decorative board according to an eleventh aspect of the invention is formed by dipping or applying a decorative coating to the surface of the incombustible board or the incombustible decorative board according to any one of claims 1 to 9. is there.

  A non-combustible board or a non-combustible decorative board according to the invention of claim 12 is obtained by applying an inorganic film agent to the front surface and / or the back surface in any one of the structures of claims 1 to 11.

  The nonflammable decorative board according to the invention of claim 13 is provided with an organic flame retardant foam board, a flame retardant rubber board or a wood board on the front or back surface of a nonflammable board coated with an inorganic film agent on the front and / or back. It is bonded with an adhesive.

  A nonflammable decorative board according to the invention of claim 14 is the structure of claim 12 or claim 13, wherein the inorganic film agent is a hydrous aluminum silicate (vermiculite) in a range of 60% to 100% by weight, a polyether. The resin or polyester resin is contained in the range of 0 to 40% by weight, more preferably 1 to 40% by weight.

  The non-combustible board according to the invention of claim 1 is made of a slurry containing sepiolite as a main material, wood pulp as an organic extender, inorganic fibers for reinforcement, and a binder for consolidation and aggregation, After forming the sheet, apply a water-based organic / inorganic mixed binder to a non-combustible pressboard formed by laminating and pressing and heating the sheet, or immerse the non-combustible pressboard in a water-based organic / inorganic mixed binder and press dry. Become.

  Here, as the reinforcing inorganic fiber, rock wool, glass fiber or the like can be used. Moreover, as a method of applying the water-based organic / inorganic mixed binder, methods such as spray coating, roll coating, and flow coating can be used. Further, a hot press or the like is generally used as a method of pressure drying.

  A wet sheet is formed by making a slurry containing sepiolite and reinforcing inorganic fibers as the main material and reinforcing material, and further comprising a wood pulp as an organic extender and a binder for consolidation / aggregation. Since the non-combustible press board is formed by doing this, since it is sufficient to produce a thin wet sheet in paper making, paper making can be performed in a short time, and pressurization and heating can also be performed in a short time.

  The hydrous magnesium silicate (sepiolite) is an incombustible material having a melting point of about 1550 ° C. and extremely excellent heat resistance, and rock wool, glass fiber, etc. can be used as the reinforcing inorganic fiber. Although it has a melting point of 1000 ° C. or higher, glass fiber is an incombustible material having extremely high heat resistance, for example, a melting point of 840 ° C., depending on the type. Since these materials are mainly constituted, a non-combustible press board having high non-combustibility and high strength can be obtained.

  By applying a water-based organic / inorganic mixed binder to this non-combustible pressboard or immersing the non-combustible pressboard in the water-based organic / inorganic mixed binder, the water-based organic / inorganic mixed binder penetrates from the surface layer of the non-combustible pressboard to the inside. By pressure drying, the vicinity of the surface layer is hardened and strengthened with the organic-inorganic mixed binder, and the interlayer strength and peeling strength are greatly improved. In addition, fine irregularities on the surface of the incombustible press board are filled with the organic / inorganic mixed binder to make the surface smooth, and further, the surface becomes smoother by pressurizing and drying.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a nonflammable board which can obtain the smoothness of the surface.

  In addition, you may mix thermoplastic resins, such as thermosetting resins, such as an epoxy resin and a phenol resin, and an acrylic resin, in the slurry for making an incombustible press board. By mixing these thermosetting resins and thermoplastic resins, a stronger non-combustible board can be obtained.

  The nonflammable board according to the invention of claim 2 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, a reinforcing inorganic fiber, and a binder for consolidation and aggregation. After forming the slurry and forming the sheet, water is applied to the non-combustible press board formed by laminating the sheets and pressurizing and heating, or the non-combustible press board is immersed in water and dried under pressure, and then the aqueous system. An organic / inorganic mixed binder is applied to the surface and dried.

  Here, as the reinforcing inorganic fiber, rock wool, glass fiber or the like can be used. Moreover, as a method of applying the water-based organic / inorganic mixed binder, methods such as spray coating, roll coating, and flow coating can be used.

  A wet sheet is formed by making a slurry containing sepiolite and reinforcing inorganic fibers as the main material and reinforcing material, and further comprising a wood pulp as an organic extender and a binder for consolidation / aggregation. Since the non-combustible press board is formed by doing this, since it is sufficient to produce a thin wet sheet in paper making, paper making can be performed in a short time, and pressurization and heating can also be performed in a short time.

  The hydrous magnesium silicate (sepiolite) is an incombustible material having a melting point of about 1550 ° C. and extremely excellent heat resistance, and rock wool, glass fiber, etc. can be used as the reinforcing inorganic fiber. Although it has a melting point of 1000 ° C. or higher, glass fiber is an incombustible material having extremely high heat resistance, for example, a melting point of 840 ° C., depending on the type. Since these materials are mainly constituted, a non-combustible press board having high non-combustibility and high strength can be obtained.

  By applying water to this incombustible pressboard or immersing the incombustible pressboard in water, water penetrates from the surface layer of the incombustible pressboard and pressurizes it to make the surface smooth, and the interlayer Strength and peeling strength are greatly improved. Further, by applying an organic / inorganic mixed binder to the surface, the vicinity of the surface layer is hardened and strengthened, and fine irregularities on the surface of the non-combustible press board are filled with the organic / inorganic mixed binder, so that the surface becomes smoother.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a nonflammable board which can obtain the smoothness of the surface.

  In addition, you may mix thermoplastic resins, such as thermosetting resins, such as an epoxy resin and a phenol resin, and an acrylic resin, in the slurry for making an incombustible press board. By mixing these thermosetting resins and thermoplastic resins, a stronger non-combustible board can be obtained.

  The non-combustible board according to the invention of claim 3 is formed by applying a water-based organic / inorganic mixed binder on both sides of the non-combustible press board, or immersing the non-combustible press board in the water-based organic / inorganic mixed binder, and then laminating a plurality of sheets and pressing. It is dried.

  As a result, a plurality of incombustible press boards are brought into close contact with each other by being pressurized, and are firmly bonded by a water-based organic-inorganic mixed binder applied or immersed on the surface, thereby obtaining a non-combustible board having a predetermined thickness. It is done. And since the water-based organic / inorganic mixed binder is applied or immersed on both sides of the non-combustible board having the predetermined thickness, the water-based organic / inorganic mixed binder penetrates into the inside, and by drying it, the vicinity of the surface layer becomes organic. It is hardened and strengthened with an inorganic mixed binder, and interlayer strength and peeling strength are greatly improved. Moreover, the surface becomes sufficiently smooth by being dried under pressure.

  In this way, the tensile strength and peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of a non-combustible press board that is fire resistant and lightweight, and the necessary thickness In addition, the non-combustible board can be formed, and sufficient surface smoothness can be obtained.

  The nonflammable board according to the invention of claim 4 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, a reinforcing inorganic fiber, and a binder for consolidation and aggregation After forming a sheet containing slurry and forming a sheet, a water-based organic / inorganic mixed binder is applied to one side of a non-combustible pressboard that is laminated and pressurized and heated, and suctioned under reduced pressure from the opposite side of the non-combustible pressboard. Then, the water-based organic / inorganic mixed binder is infiltrated into the inside of the non-combustible press board, followed by pressure drying.

  Thus, in the present invention, the water-based organic / inorganic mixed binder is soaked into the incombustible press board by the suction impregnation method, so even with a high concentration water-based organic / inorganic mixed binder that could not be permeated by the natural permeation method, It can be soaked to the inside. Not only can it be applied to only one side of the non-combustible press board, but the water-based organic / inorganic mixed binder can be infiltrated to the opposite side, so the same effect as when applied to both sides can be obtained and the process is greatly improved. It will be shortened. Furthermore, when the water-based organic / inorganic mixed binder is spread over the entire non-combustible press board, it is possible to obtain a strength improvement effect that cannot be compared with the case where it is infiltrated only in the vicinity of the coating surface.

  In this way, higher tensile strength and peeling strength in the vertical direction for use as a building material such as a decorative board can be obtained while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a nonflammable board which can obtain the smoothness of the surface and shorten the manufacturing process.

  The nonflammable board according to the invention of claim 5 is a hydrous magnesium silicate (sepiolite) as a main material, a wood pulp as an organic extender, an inorganic fiber for reinforcement, and a binder for consolidation and aggregation. After forming a slurry containing a sheet, forming a sheet, and then applying a water-based organic / inorganic mixed binder to a non-combustible pressboard that is laminated and pressurized and heated, or after immersing the non-combustible pressboard in a water-based organic / inorganic mixed binder The incombustible pressboard is housed in a decompression box and the inside is decompressed to infiltrate the water-based organic / inorganic mixed binder into the incombustible pressboard, followed by pressure drying.

  Here, a vacuum desiccator or the like can be used as the decompression box.

  Thus, in the present invention, since the water-based organic-inorganic mixed binder is immersed in the incombustible press board by the reduced pressure impregnation method, even in the high concentration water-based organic-inorganic mixed binder that could not be permeated by the natural infiltration method, It can be soaked to the inside. Not only can it be applied to only one side of the non-combustible press board, but the water-based organic / inorganic mixed binder can be infiltrated to the opposite side, so the same effect as when applied to both sides can be obtained and the process is greatly improved. It will be shortened. Furthermore, when the water-based organic / inorganic mixed binder is spread over the entire non-combustible press board, it is possible to obtain a strength improvement effect that cannot be compared with the case where it is infiltrated only in the vicinity of the coating surface.

  In this way, higher tensile strength and peeling strength in the vertical direction for use as a building material such as a decorative board can be obtained while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a nonflammable board which can obtain the smoothness of the surface and shorten the manufacturing process.

  The nonflammable board according to the invention of claim 6 is a water-based organic / inorganic mixed binder comprising a polyester emulsion or an acrylic emulsion in a solid content of 25 wt% to 50 wt% and a lithium silicate or potassium silicate in a solid content of 50 wt% to 75% by weight is uniformly dispersed and dissolved in water.

  About the composition of the water-based organic-inorganic mixed binder used in the non-combustible board according to the present invention, the present inventors have conducted extensive experimental studies. As a result, the organic binder is a polyester emulsion or acrylic emulsion, the inorganic binder is lithium silicate or By using potassium silicate, the ratio of the organic binder is 25% to 50% by weight in terms of solid content and the inorganic binder is 50% to 75% by weight in terms of solid content, thereby greatly improving the surface strength. The present invention has been found based on this finding.

  That is, as the inorganic binder, alkali silicate is excellent, but from the viewpoint of permeability, lithium silicate or potassium silicate is preferable, and if the organic binder exceeds 50% by weight in solid content, nonflammability decreases. The composition is as described above.

  And since water is used as a solvent, the working environment of the worker is not deteriorated, and since only water vapor is volatilized during drying, problems due to harmful volatile organic compounds (VOC) occur. There is no need to do.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. Surface smoothness is obtained, and it becomes an incombustible board friendly to the environment.

  The non-combustible decorative board according to the invention of claim 7 is formed by embossing at the time of pressure drying in the manufacture of the non-combustible board according to any one of claims 1 to 6. In a press such as a hot press used for pressure drying, an incombustible decorative board having an embossed pattern on the surface at the same time as pressure drying is manufactured by providing an embossed protrusion on at least one of the press surfaces. The

  In this way, while taking advantage of the characteristics of non-combustible pressboards that are high in fire resistance and light weight, the tensile strength and peeling strength in the direction perpendicular to the surface for use as a decorative board are high, and further excellent in design. It becomes an incombustible decorative board with an embossed pattern.

  The non-combustible decorative board according to the invention of claim 8 is formed by bending during pressure drying in the manufacture of the non-combustible board or the non-combustible decorative board according to any one of claims 1 to 7. . In a press machine such as a hot press used for pressure drying, a non-combustible decorative board with a curve according to the application can be easily manufactured by attaching R to the press surface.

  In this way, while taking advantage of the characteristics of non-combustible pressboards that are high in fire resistance and light weight, the tensile strength and peeling strength in the direction perpendicular to the surface for use as a decorative board are high, and further excellent in design. It becomes a noncombustible decorative board with a curve according to the application.

  A nonflammable board or a nonflammable decorative board according to the invention of claim 9 is obtained by applying a water-resistant sealant to the surface of the nonflammable board or the nonflammable decorative board according to any one of claims 1 to 8. Become. Here, as the water-resistant sealant, specifically, for example, an alkali silicate and polyurethane emulsion dissolved and dispersed in water can be used. Thereby, water repellency, water resistance and dimensional stability can be imparted to the surface of the non-combustible board, and the non-combustible board is more preferable as a building material.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a non-combustible board or a non-combustible decorative board having surface smoothness and water resistance.

  A non-combustible decorative board according to a tenth aspect of the present invention is formed by laminating a decorative sheet on the non-combustible board or the non-combustible decorative board according to any one of the first to ninth aspects. Here, specifically, for example, a decorative sheet in which a wood grain pattern is printed on a film layer of an olefin resin can be used. As a result, it is possible to manufacture a non-combustible decorative board with a high design and having a woodgrain surface.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a non-combustible decorative board having surface smoothness and excellent design.

  An incombustible decorative board according to an eleventh aspect of the present invention is formed by dipping or applying a decorative coating to the surface of the incombustible board or the noncombustible decorative board according to any one of the first to ninth aspects. Here, as the decorative coating, urethane coating is common, but there are also epoxy coating, UV coating, and the like. By dipping, it becomes a non-combustible decorative board with a wood-grained design on the surface of the non-combustible board, and by applying a decorative paint such as urethane paint, the non-combustible decorative board has high design characteristics while maintaining non-combustibility. It becomes.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. It becomes a non-combustible decorative board having surface smoothness and excellent design.

  The nonflammable board or the nonflammable decorative board according to the invention of claim 12 is obtained by applying an inorganic film agent to the front surface and / or the back surface. Here, specific examples of the inorganic film agent include an inorganic coating agent containing hydrous aluminum silicate (vermiculite) as a main component, and vermiculite is a scaly crystal having a high aspect ratio. Cover the front or back without any gaps. Therefore, since gas is not permeated, flammable gas does not permeate through the non-combustible board or non-combustible decorative board in the event of a fire to prevent ignition and ignition, preventing the fire from spreading and serving as a gas barrier. Fulfill.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. The smoothness of the surface is obtained, and the nonflammable board or the nonflammable decorative board is more excellent in fire resistance.

  The nonflammable decorative board according to the invention of claim 13 is provided with an organic flame retardant foam board, a flame retardant rubber board or a wood board on the front or back surface of a nonflammable board coated with an inorganic film agent on the front and / or back. It is bonded with an adhesive. Even organic foam boards have flame retardant materials such as flame retardant urethane foam, and rubber boards that are usually considered to be easily flammable have flame retardant materials such as chloroprene flame retardant rubber boards. Moreover, since the wood board is carbonized by flame but is difficult to ignite, it can be used as a decorative board without substantially impairing the incombustibility of the incombustible board. In addition, the nonflammable board is coated with an inorganic film agent, so that it does not allow gas to pass through, and in the event of a fire, the flammable gas does not permeate through the nonflammable decorative plate and ignite / ignite, thus spreading the fire. It serves as a gas barrier.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. Smoothness of the surface is obtained, and the nonflammable decorative board is more excellent in fire resistance.

  A nonflammable decorative board according to the invention of claim 14 is the structure of claim 12 or claim 13, wherein the inorganic film agent is a hydrous aluminum silicate (vermiculite) in a range of 60% to 100% by weight, a polyether. The resin or polyester resin is contained in the range of 0 to 40% by weight, more preferably 1 to 40% by weight.

  Since hydrous aluminum silicate (vermiculite) is a scaly crystal having a high aspect ratio, it covers the front or back surface without any gaps when applied. Furthermore, by including a polyether resin or a polyester resin, a resin gas-impermeable film is formed. Therefore, since the gas is not permeated, the flammable gas does not pass through the non-combustible decorative plate and does not ignite / ignite at the time of a fire, so that it is possible to prevent the fire from spreading and serve as a gas barrier.

  The polyether resin or polyester resin is 0% by weight, that is, even if it is not contained, a sufficient gas-impermeable film can be formed only by vermiculite, but the polyether resin or polyester resin is 1% by weight to 40% by weight. When the content is within the range, a resin gas-impermeable film is formed, and the gas barrier characteristics are further improved, which is more preferable.

  In this way, the tensile strength and the peeling strength in the direction perpendicular to the surface for use as a building material such as a decorative board are high, while taking advantage of the characteristics of non-combustible pressboard that is high in fire resistance and lightweight. Smoothness of the surface is obtained, and the nonflammable decorative board is more excellent in fire resistance.

  Embodiments of the present invention will be described below with reference to the drawings.

Embodiment 1
First, the nonflammable board according to the first embodiment of the present invention will be described with reference to FIGS. 1 to 3. FIG. 1 is a flowchart showing an outline of a method for manufacturing a non-combustible board according to Embodiment 1 of the present invention. FIG. 2 is an explanatory view showing a test method for a vertical tensile strength test of the nonflammable board according to the first embodiment of the present invention. FIG. 3 is an explanatory diagram showing a test method for a peel strength test of the noncombustible board according to the first embodiment of the present invention.

  Initially, the manufacturing method of the nonflammable board concerning this Embodiment 1 is demonstrated with reference to FIG. In the nonflammable board manufacturing method according to the first embodiment, first, in the raw material mixing step S1, hydrated magnesium silicate (sepiolite) fiber and glass fiber as reinforcing inorganic fiber are put into a defibrator such as a pulper. Then, the fibers were disentangled by stirring to improve the dispersibility of the fibers. Moreover, the wood pulp as an organic extender was put into a beater and beaten. Then, the defibrated sepiolite, glass fiber, and beaten wood pulp were placed in a mixing tank and mixed. In addition, you may mix thermoplastic resins, such as thermosetting resins, such as an epoxy resin and a phenol resin, and an acrylic resin here.

  The mixed solution prepared in the raw material mixing step S1 was subjected to an agglomeration process suitable for papermaking. Therefore, in the aggregation step S2, a binder for consolidation / aggregation was added to prepare a slurry. As binders for consolidation and agglomeration, PAA (polyacrylamide) for increasing paper strength, EPA (polyamide polyamine epichlorohydrin) for imparting agglomeration and water resistance, and AA (acrylamide acrylic acid co-polymerization) for agglomeration Coalescence) and DMAEM (dimethylaminoethyl methacrylate) for aggregation.

  The mixed solution to which the binder for consolidation / aggregation was added was focused by a focusing reactor, and the concentration of the slurry at this time was adjusted to about 0.5%. And the slurry maintained uniformly was pumped up to the fixed quantity hopper with the fixed quantity pump, and the slurry measured with the fixed quantity hopper was led to papermaking process S3. In the paper making step S3, using a long net-type wet machine, the slurry in which the aggregated flocs are formed is caused to flow from above to the paperwork provided with the netted nets, and water is quickly allowed to flow down from the papermaking nets through the aggregated flocs. A wet sheet having a thickness of 60% to 70% and a thickness of about 0.8 mm was obtained.

  Next, in the stacking step S4, a plurality of wet sheets having a thickness of about 0.8 mm are stacked. Sepiolite, epoxy resin / phenolic resin, etc. can secure the interlaminar bonding strength of the completed sheet, but in order to prevent delamination more reliably, heat such as acrylic resin on the surface of the wet sheet before lamination A plastic resin may be applied as an adhesive.

The plurality of wet sheets stacked in the stacking step S4 are simultaneously pressed and heated by hot pressing in the pressure heating step S5. Hot pressing, pressure ^{15kgf / cm 2 ~80kgf / cm 2} , under the conditions of heating temperature of 130 ° C. to 180 ° C., was carried out for 3 minutes to 10 minutes. By this hot pressing, the laminated wet sheets are formed in a board shape while being dehydrated, and the internal moisture is evaporated and solidified by heating. Under this heating condition, when epoxy resin is mixed inside, it melts, so the bonding strength between the fibers increases, and the epoxy resin is thermally cured to become insoluble and infusible, thereby causing interlaminar strength. Is improved, and a non-combustible press board is formed.

  In Embodiment 1, hydrous magnesium silicate (sepiolite) is 70% to 90% by weight, glass fiber is 5% to 10% by weight, and wood pulp is 0% to 10% by weight, preferably 1%. % To 10% by weight, 3% to 5% by weight of acrylic resin, and 2% to 5% by weight of epoxy resin were mixed to form a non-combustible press board. The bulk specific gravity of the formed noncombustible press board was in the range of 0.7 to 1.2. Here, the wood pulp may be 0% by weight, that is, it may not be mixed, but the strength is further improved by mixing the wood pulp within the range of up to 10% by weight. Is more preferable.

  In this way, an incombustible press board is formed in the processes from step S1 to S5. In the water-based binder application step S6, a water-based organic / inorganic mixed binder is applied to the surface (one side or both sides) of the non-combustible press board. In the first embodiment, as a water-based organic / inorganic mixed binder, about 50% by weight of a polyester emulsion and about 50% by weight of lithium silicate are uniformly dispersed and dissolved in water. Used approximately 8%.

  As a method of applying a water-based organic / inorganic mixed binder to the surface of a non-combustible press board, spray coating using a spray gun, brush coating using a brush, roll coating using a coating roll, water-based organic on the surface of a non-combustible press board Although there are methods such as flow coating in which an inorganic mixed binder is flowed and dipping in which an incombustible press board is immersed in a water-based organic / inorganic mixed binder liquid, in Embodiment 1, after performing flow coating, roll coating is performed. The coating was performed by a two-stage coating method.

That is, first, while moving the non-combustible press board on the belt conveyor, the above-mentioned water-based organic / inorganic mixed binder is flowed from the basket provided on the belt conveyor to flow coat the surface of the non-combustible press board. Subsequently, the above-described aqueous organic / inorganic mixed binder is roll-coated on the surface of the non-combustible press board using an application roll. As a result, a sufficient amount of the water-based organic / inorganic mixed binder penetrates into the incombustible press board. The total coating amount of the water-based organic / inorganic mixed binder was about 400 g / m ² . Thereby, a nonflammable board containing about 32 g / m ² of solid content of the water-based organic / inorganic mixed binder after pressure drying can be obtained.

After this process is performed on both sides of the non-combustible press board, pressure drying is performed by hot pressing in the pressure drying process S7. First, after pre-drying at room temperature or 40 ° C. to 60 ° C. without evaporation and evaporating about 80% of water, hot press (at least one side) at a pressure of 11 kgf / cm ² and a heating temperature of 150 ° C. Pressure-dried by using a mirror-finished press plate) to obtain a nonflammable board having a thickness of about 2.5 mm and smooth on at least one side.

  The non-combustible board according to the first embodiment thus obtained is subjected to a vertical tensile strength test and a peeling strength test as compared with the non-combustible press board manufactured up to the pressure heating step S5 in FIG. It was. A method for performing the vertical tensile strength test and the peeling strength test will be described with reference to FIGS.

As shown in FIG. 2, 50 mm × 50 mm × 2.5 mm cut out from the non-combustible board according to the first embodiment between a pair of 50 mm × 50 mm square steel jigs 2A, 2B. The test piece S of ^t is firmly fixed with an adhesive, and between the disc-shaped tension jigs 3A and 3B fixed to the ends of a pair of tension shafts 4A and 4B of the tensile tester 1, The square plate-like steel jigs 2A and 2B are fixed with bolts. Then, the tensile tester 1 was operated and a tensile force was applied in the direction of the arrow by a pair of tensile shafts 4A and 4B, and the tensile strength when the test piece S was separated and separated between layers was measured.

As a result, the vertical tensile strength was 2.34 kgf / cm ² for the non-combustible press board, which was an untreated product, whereas the non-combustible board according to the first embodiment was 4.21 kgf / cm ² . It was found to be sufficiently strong. Thereby, the application method of the water-based organic / inorganic mixed binder according to the first embodiment, that is, the application by two steps of flow coating and roll coating effectively infiltrate the water-based organic / inorganic mixed binder from the surface of the non-combustible board to the inside. I can see that

  Further, the water-based organic / inorganic mixed binder according to the first embodiment, that is, a polyester emulsion having a solid content of about 50% by weight and lithium silicate of about 50% by weight of a solid content are uniformly dispersed and dissolved in water. It can be seen that a concentration of about 8% is suitable as a water-based organic / inorganic mixed binder.

  Next, a method for measuring the peeling strength will be described with reference to FIG. As shown in FIG. 3, a measurement sheet (thickness 150 μm) 5 mainly composed of an olefin resin is attached to the surface of the non-combustible board 9 according to the first embodiment with a urethane adhesive 6, The peel strength required to peel the olefin sheet 5 to a length of 1 inch was measured by pulling in the direction (180 degree direction).

  As a result, the peeling strength is 0.25 kgf / inch for the non-combustible press board which is an untreated product, whereas the non-flammable board 9 according to the first embodiment is 3.75 kgf / inch, which is large. It was improved and the surface smoothness was found to be excellent. Thus, it became clear that the tensile strength and the peeling strength in the vertical direction of the incombustible board 9 according to the first embodiment are both at a practical level.

Furthermore, the nonflammability of the nonflammable board 9 according to the first embodiment was compared with the nonflammable press board, and a combustion experiment was performed. As a result, the total calorific value of the non-combustible press board as an untreated product was 5.1 MJ / m ² , whereas the total calorific value of the non-combustible board 9 according to the first embodiment was 5.2 MJ / m ^2. There was almost no change with m ^2, and both met the standards of nonflammability.

  Thus, in the incombustible board according to the first embodiment, the tensile strength in the vertical direction for use as a building material such as a decorative board while taking advantage of the characteristics of the incombustible press board having high fire resistance and light weight. The peeling strength is high, and sufficient surface smoothness can be obtained.

Embodiment 2
Next, a nonflammable board according to a second embodiment of the present invention will be described with reference to FIGS. 1 and 4. 4 (a), 4 (b), and 4 (c) are longitudinal sectional views showing a part of the manufacturing process of the non-combustible board according to the second embodiment of the present invention.

  As shown in FIG. 4, the non-combustible board 9A according to the second embodiment is manufactured by immersing the water-based organic / inorganic mixed binder 8 in the entire non-combustible press board 7 by a suction impregnation method. . That is, the non-combustible press board 7 manufactured up to the heating and pressurizing step S5 of FIG. 1 is placed on the suction box 21 having a large number of small suction holes 21a formed on the upper surface as shown in FIG. Then, the water-based organic / inorganic mixed binder 8 is applied to the upper surface of the non-combustible press board 7 and sucked under reduced pressure by the suction pump 22.

  Then, the water-based organic / inorganic mixed binder 8 sucked and penetrated into the inside from the upper surface of the incombustible press board 7, and the water-based organic / inorganic mixed binder 8 was impregnated throughout the incombustible press board 7 as shown in FIG. It becomes nonflammable board 9A. When the suction pump 22 is depressurized for a predetermined time, as shown in FIG. 4 (c), the suction pump 22 is operated in reverse to suck air from outside and send it into the suction box 21 to obtain a number of suction holes 21a. The non-combustible board 9 </ b> A is pushed up by the air blown out from the upper surface of the suction box 21.

After completing the aqueous binder coating step S6 of FIG. 1 as described above, the pressure drying step S7 by hot pressing is performed in the same manner as in the first embodiment, and the nonflammable board 9A according to the second embodiment is performed. Is completed. Here, as will be described later, since the aqueous organic / inorganic mixed binder 8 having a higher concentration than in the first embodiment can be applied, there is no need for preliminary drying, and hot pressing can be performed immediately. Can be shortened. That is, pressure drying is performed by hot pressing (using a press plate with at least one side mirror-finished) at a pressure of 11 kgf / cm ² and a heating temperature of 150 ° C. for about 10 minutes, and at least one side having a thickness of about 2.5 mm is smooth. Incombustible board 9A was obtained.

  As described above, in the second embodiment, the water-based organic / inorganic mixed binder 8 is soaked into the incombustible press board 7 by the suction impregnation method, so that it can be permeated by the natural infiltration method as in the first embodiment. Even the high-concentration water-based organic / inorganic mixed binder 8 that has not existed can be soaked into the inside.

For example, in the first embodiment, as a water-based organic / inorganic mixed binder, a polyester emulsion having a solid content of about 50% by weight and lithium silicate having a solid content of about 50% by weight are uniformly dispersed and dissolved in water. Although There is obtained a non-combustible board 9 aqueous organic-inorganic mixed binder is about 32 g / m ² coating impregnated with solids resulting in about 400 g / m ² coated of about 8%, of the embodiment 2 In which about 50% by weight of a polyester emulsion having a concentration of 1.5 times and about 50% by weight of lithium silicate are uniformly dispersed and dissolved in water, and the concentration is about 12%. the coating amount requires only 267g in order also to obtain since it is possible to permeate an aqueous organic-inorganic mixed binder of about 32 g / m ² coated impregnated incombustible board 9A at a solids intended It made.

  Not only that, but only on one side of the non-combustible press board 7, the water-based organic-inorganic mixed binder 8 penetrates to the opposite side, so the same effect as when applied on both sides can be obtained and the process is greatly shortened. It becomes. Furthermore, by spreading the water-based organic / inorganic mixed binder 8 over the entire non-combustible press board 7, it is possible to obtain a strength improvement effect that is not comparable to the case where it is penetrated only in the vicinity of the coating surface.

  In this way, in the nonflammable board 9A according to the second embodiment, the vertical direction for use as a building material such as a decorative board while taking advantage of the characteristics of the nonflammable pressboard 7 that is fireproof and lightweight. Higher tensile strength and peeling strength can be obtained, and furthermore, sufficient surface smoothness can be obtained, and the manufacturing process can be shortened.

  In the second embodiment, a suction impregnation method in which a water-based organic / inorganic mixed binder is applied to one side of the non-combustible press board 7 and sucked from the opposite surface is used. As a similar method, a non-combustible press is used. Apply a water-based organic / inorganic mixed binder on one or both sides of the board 7 or immerse (dipping) the non-combustible press board 7 in the water-based organic / inorganic mixed binder, and then put the pressure in a vacuum box such as a vacuum desiccator to reduce the pressure inside. By this, the water-based organic / inorganic mixed binder spreads over the entire incombustible press board 7 and the strength is further improved, and an effect that a high-concentration water-based organic / inorganic mixed binder can also be used can be obtained.

Embodiment 3
Next, a nonflammable decorative board according to Embodiment 3 of the present invention will be described with reference to FIG. FIG. 5: is a perspective view which shows the whole structure of the nonflammable decorative board concerning Embodiment 3 of this invention.

  As shown in FIG. 5, the nonflammable decorative board 10 according to the third embodiment has a decorative sheet 11 attached to the surface of the nonflammable board 9 according to the first embodiment with a vinyl acetate adhesive 12. It will be. Here, the decorative sheet 11 is obtained by applying a woodgrain print 11b on one side of the transparent synthetic resin sheet 11a, and is attached to the surface of the incombustible board 9 with the woodgrain print 11b side down. Through the synthetic resin sheet 11a, the woodgrain print 11b can be seen from the front, and the woodgrain print 11b does not appear on the surface, so there is no risk of being damaged.

As described above, the non-combustible decorative board 10 according to the third embodiment is a decorative board excellent in design that allows the surface to look like a wood grain. As a result of performing a combustion test on the incombustibility of the obtained incombustible decorative board 10, the total calorific value is 5.2 MJ / m ² , and the total calorific value is 8 MJ / m ² or less, which is a standard for incombustibility. It turns out to be nonflammable. Although the decorative sheet 11 itself is not incombustible, since it is a thin material, it is affixed to the incombustible board 9 that is completely incombustible, so that the incombustible decorative board 10 as a whole clears the standard of incombustibility. It becomes.

  Thus, in the nonflammable decorative board 10 according to the third embodiment, while taking advantage of the characteristics of the noncombustible press board that is fire resistant and lightweight, the surface of the nonflammable decorative board 10 in the direction perpendicular to the surface for use as a decorative board is used. The tensile strength and peeling strength are high, and sufficient surface smoothness is obtained, and the design properties as a decorative board are excellent.

  In addition, in the nonflammable decorative board 10 according to the third embodiment, a water-resistant sealant can be applied to the surface and / or the back surface of the nonflammable board 9 before the adhesive 12 is applied. Here, as the water-resistant sealant, for example, an alkali silicate and polyurethane emulsion dissolved and dispersed in water can be used. Since this water-resistant sealant reacts with sepiolite to form a strong water-resistant layer, it imparts water repellency, water resistance and dimensional stability to the front and / or back surface of the non-combustible board 9 mainly composed of sepiolite. It becomes a nonflammable decorative board more preferable as a decorative board.

Embodiment 4
Next, a noncombustible decorative board according to a fourth embodiment of the present invention and a noncombustible decorative board as a modification thereof will be described with reference to FIG. The non-combustible decorative board according to the fourth embodiment and the non-combustible decorative board serving as a modified non-combustible decorative board according to the fourth embodiment basically follow the steps shown in FIG. Manufactured. The difference is that the number of pre-dried wet sheets to be laminated in the lamination step S4 in FIG. 1 is first reduced, and the thickness of the non-combustible board obtained in the pressure drying step S7 is reduced to about 1.0 mm. . Therefore, the total coating amount of the water-based organic / inorganic mixed binder applied to the incombustible press board in the water-based binder coating step S6 is also reduced to about 150 g / m ² .

Next, on the surface of the non-combustible board having a thickness of about 1.0 mm obtained in this manner, urethane coating is applied so as to have an application amount of about 50 g / m ² , and the non-combustibility according to the fourth embodiment is dried. A decorative board was obtained. The incombustibility of this incombustible decorative board was measured in comparison with an incombustible board having a thickness of about 1.0 mm that had not been subjected to urethane coating. As a result, the total calorific value of the incombustible board was 2.1 MJ / m ² , whereas the total calorific value of the incombustible decorative board according to the fourth embodiment was 3.3 MJ / m ² , The total calorific value, which is regarded as a measure of nonflammability, was 8 MJ / m ² or less and satisfied the nonflammability standard.

In addition, a non-combustible decorative board according to a modification of the fourth embodiment is applied to the surface of a non-combustible board having a thickness of about 1.0 mm by applying UV coating so as to have an application amount of about 50 g / m ² and drying. Got. As a result of measuring the incombustibility of this incombustible decorative board, the total calorific value is 3.9 MJ / m ² , the total calorific value is 8 MJ / m ² or less, which is a standard for incombustibility, and the standard of incombustibility is Satisfied.

  Thus, in the non-combustible decorative board according to the fourth embodiment and the non-combustible decorative board as a modification thereof, it is used as a decorative board while taking advantage of the characteristics of the non-combustible press board that is fire-resistant and lightweight. Therefore, the tensile strength and the peeling strength in the direction perpendicular to the surface are high, and sufficient surface smoothness is obtained, and the design as a decorative board is excellent.

  In the non-combustible decorative board according to the fourth embodiment and the non-combustible decorative board as a modified example thereof, a water-resistant sealant is applied to the front and / or back of the non-combustible board before urethane coating or UV coating is applied. You can also. Here, as the water-resistant sealant, for example, an alkali silicate and polyurethane emulsion dissolved and dispersed in water can be used. Since this water-resistant sealant reacts with sepiolite to form a strong water-resistant layer, it imparts water repellency, water resistance and dimensional stability to the front and / or back surface of non-combustible boards mainly composed of sepiolite. It becomes a nonflammable decorative board more preferable as a decorative board.

Embodiment 5
Next, a nonflammable decorative board according to a fifth embodiment of the present invention will be described with reference to FIG. FIG. 6 is a partial cross-sectional view showing the structure of a non-combustible decorative board according to Embodiment 5 of the present invention. The non-combustible board 19 serving as the substrate of the non-combustible decorative board 15 according to the fifth embodiment is manufactured according to the same procedure as in the third embodiment.

That is, the number of pre-dried wet sheets to be laminated in the lamination step S4 of FIG. 1 is reduced, and the thickness of the non-combustible board 19 obtained in the pressure drying step S7 is reduced to about 1.0 mm, so that an aqueous binder is applied. The total coating amount of the water-based organic / inorganic mixed binder applied to the noncombustible press board in step S6 is also reduced to about 150 g / m ² . About 150 g / m ² of the two-pack type epoxy adhesive 18 is applied to the surface of the non-combustible board 19 having a thickness of about 1.0 mm thus obtained, and a flame-retardant urethane having a thickness of 30 mm as a core material. The foam 17 is firmly attached, and the inorganic film agent 13 is applied to the back surface of the non-combustible board 19 from about 100 g / m ² to about 200 g / m ² .

  Here, as the inorganic film agent 13, one having a solid content of 12% containing 80% by weight of hydrous aluminum silicate (vermiculite) and 20% by weight of a polyether resin is used. Since hydrous aluminum silicate (vermiculite) is a scaly crystal having a high aspect ratio, it covers the front or back surface without any gaps when applied. Furthermore, by including a polyether resin, a gas-impermeable film of the polyether resin is formed. Therefore, since the gas is not permeated, the flammable gas does not pass through the non-combustible decorative plate and does not ignite / ignite at the time of a fire, so that it is possible to prevent the fire from spreading and serve as a gas barrier.

The nonflammability of the nonflammable decorative board 15 according to the fifth embodiment is as follows. For comparison, the inorganic film agent 13 is not applied at all, the inorganic film agent 13 is applied at 100 g / m ² , and 150 g / m ^2. Combustion tests were performed on the coated and 200 g / m ² coated samples. As a result, those without the inorganic film agent 13 completely applied is the total calorific value is 13.4MJ / m ^2, and greatly exceeds the total calorific value 8 MJ / m ^2, which is a measure of non-flammable, and non-flammable It turned out not to be certified.

In contrast, those coated with an inorganic film agent 13, 100 g / m ² obtained by coating the total calorific value ^{7.1MJ / m 2, 150g / m} 2 obtained by coating the total calorific value 6.6MJ / m ² , 200 g / m ^{2 was} applied, and the total calorific value was 6.9 MJ / m ² , and the total calorific value was 8 MJ / m ² or less, which was regarded as a standard for incombustibility, and met the incombustibility standard. . In the combustion test, a considerable amount of organic gas is generated from the flame retardant urethane foam 17 and the two-pack type epoxy adhesive 18, but these organic gases are blocked by the gas barrier effect of the inorganic film agent 13, thereby suppressing combustion. I understand that.

  Thus, the nonflammable decorative board 15 according to the fifth embodiment is perpendicular to the surface for use as a building material such as a decorative board while taking advantage of the nonflammable press board having high fire resistance and light weight. The tensile strength and peeling strength in the direction are high, and a sufficient surface smoothness is obtained. The design as a decorative board is also high, and the nonflammable decorative board is more excellent in fire resistance.

Embodiment 6
Next, a nonflammable decorative board according to Embodiment 6 of the present invention will be described. The same non-combustible board manufactured according to the same procedure as that of the above-described fifth embodiment is also used for the non-combustible board serving as the non-combustible decorative board according to the sixth embodiment. About 100 g / m ^{2 of} vinyl acetate adhesive is applied to the surface of the non-combustible board having a thickness of about 1.0 mm, and wood MDF (Medium Density Fiberboard) having a thickness of 20 mm is firmly used as a core material. The inorganic film agent is applied to the back surface of the non-combustible board at about 100 g / m ² to about 200 g / m ² .

  Here, as the inorganic film agent 13, one having a solid content of 12% containing 90% by weight of hydrous aluminum silicate (vermiculite) and 10% by weight of a polyester resin is used. Since hydrous aluminum silicate (vermiculite) is a scaly crystal having a high aspect ratio, it covers the front or back surface without any gaps when applied. Furthermore, a polyester resin gas-impermeable film is formed by containing a polyester resin. Therefore, since the gas is not permeated, the flammable gas does not pass through the non-combustible decorative plate and does not ignite / ignite at the time of a fire, so that it is possible to prevent the fire from spreading and serve as a gas barrier.

The incombustible incombustible decorative plate according to the sixth embodiment, and which do not at all coated with the inorganic film agent for comparison, the inorganic film agent to that 100 g / m ² coating, those 150 g / m ² coating And the combustion test was done about what applied 200 g / m < ² >, respectively. As a result, those that do not inorganic film agent entirely coating the gross calorific value is 12.5 mJ / m ^2, and greatly exceeds the total calorific value 8 MJ / m ^2, which is a measure of non-flammable, certification nonflammable Turned out not to be.

In contrast, inorganic film agent that is applied is, 100 g / m ² obtained by coating the total calorific value ^{6.2MJ / m 2, 150g / m} 2 obtained by coating the total calorific value 5.9MJ / m ^2, 200 g / m ² was obtained by coating the total calorific value 5.6MJ / m ^2, both equal to or less than the total heating value 8 MJ / m ^2, which is a measure of non-flammable, have met the criteria for non-combustible. In the combustion test, considerable organic gas is generated from wood MDF (medium density compressed plywood) and vinyl acetate adhesive, but these organic gases are blocked by the gas barrier effect of the inorganic film agent, and combustion can be suppressed. I understand.

  Thus, the non-combustible decorative board according to the sixth embodiment is perpendicular to the surface for use as a building material such as a decorative board while taking advantage of the characteristics of the non-combustible press board that is fire resistant and lightweight. The non-combustible decorative board has high tensile strength and peeling strength, and sufficient surface smoothness, high design as a decorative board, and excellent fire resistance.

Embodiment 7
Next, a nonflammable decorative board according to Embodiment 7 of the present invention will be described with reference to FIG. FIG. 7: is a fragmentary sectional view which shows the structure of the nonflammable decorative board concerning Embodiment 7 of this invention.

  As shown in FIG. 7, the nonflammable decorative board 16 according to the seventh embodiment was dried and solidified by applying the inorganic film agent 20 to the back surface of the nonflammable decorative board 10 of the above-described third embodiment. Is. Here, as the inorganic film agent 20, the inorganic film agent which has a hydrous aluminum silicate (vermiculite) as a main component is used. Since hydrous aluminum silicate (vermiculite) is a scaly crystal having a high aspect ratio, it covers the back surface of the nonflammable decorative board 16 without any gaps when applied. Therefore, since no gas is allowed to pass through, the flammable gas does not pass through the non-flammable decorative plate 16 in the event of a fire, so it is possible to prevent the fire from spreading, and the non-flammable decorative plate 16 serves as a gas barrier. To fulfill the role of

  In this way, in the non-combustible decorative board 16 according to the seventh embodiment, it is perpendicular to the surface to be used as a building material such as a decorative board while taking advantage of the characteristics of the non-combustible press board that is fire resistant and lightweight. The tensile strength and peeling strength in any direction are high, sufficient surface smoothness is obtained, and the nonflammable decorative board is more excellent in fire resistance.

  In each of the above fifth, sixth, and seventh embodiments, an inorganic film agent mainly composed of hydrated aluminum silicate (vermiculite) is used as the inorganic film agent, but a gas barrier layer that does not allow gas to permeate can be formed. Any inorganic film agent may be used as long as it is. Moreover, in this Embodiment 7, although the example which apply | coated the inorganic film agent 20 to the back surface of the nonflammable decorative board 10 of Embodiment 3 was demonstrated, the surface of the nonflammable board 9 of Embodiment 1 and / or A nonflammable board having gas barrier properties can also be produced by applying an inorganic film agent to the back surface.

  In each of the above embodiments, the case where a non-combustible board and a non-combustible decorative board are manufactured by applying a water-based organic / inorganic mixed binder on both sides of a single incombustible press board has been described. It is also possible to produce a nonflammable board and a nonflammable decorative board having a desired thickness by applying a water-based organic / inorganic mixed binder on both sides and applying pressure to form a single body.

  In each of the above embodiments, the case where hot pressing is performed with a smooth press plate in the pressure drying step S7 has been described. However, pressure drying is performed using at least one of the press plates provided with an emboss protrusion. You can also. This makes it possible to easily manufacture a non-combustible decorative board that is embossed on at least one side. Further, an appropriate R can be attached to a press plate of a hot press, and bending can be performed simultaneously with pressure drying. Thereby, a non-combustible decorative board having a curve having a size corresponding to the application can be easily manufactured.

  In carrying out the present invention, the configuration, shape, quantity, material, size, connection relationship, manufacturing method, and the like of the other parts of the non-combustible board and non-combustible decorative board are also limited to the above-described embodiments. It is not a thing.

FIG. 1 is a flowchart showing an outline of a method for manufacturing a non-combustible board according to Embodiment 1 of the present invention. FIG. 2 is an explanatory view showing a test method for a vertical tensile strength test of the nonflammable board according to the first embodiment of the present invention. FIG. 3 is an explanatory diagram showing a test method for a peel strength test of the noncombustible board according to the first embodiment of the present invention. 4 (a), 4 (b), and 4 (c) are longitudinal sectional views showing a part of the manufacturing process of the non-combustible board according to the second embodiment of the present invention. FIG. 5: is a perspective view which shows the whole structure of the nonflammable decorative board concerning Embodiment 3 of this invention. FIG. 6 is a partial cross-sectional view showing the structure of a non-combustible decorative board according to Embodiment 5 of the present invention. FIG. 7: is a fragmentary sectional view which shows the structure of the nonflammable decorative board concerning Embodiment 7 of this invention.

Explanation of symbols

7 Non-combustible press board 8 Water-based organic / inorganic mixed binder 9, 9A, 19 Non-combustible board 10, 15, 16 Non-combustible decorative board 11 Cosmetic sheet 13, 20 Inorganic film agent S Test piece

Claims (14)

After forming a sheet by making a slurry containing hydrous magnesium silicate (sepiolite) as the main material, wood pulp as the organic extender, inorganic fibers for reinforcement, and binder for consolidation and aggregation ,
Applying a water-based organic / inorganic mixed binder to a non-combustible pressboard formed by laminating and pressing and heating the sheet, or immersing the non-combustible pressboard in the water-based organic / inorganic mixed binder, followed by pressure drying. Features non-combustible board. After forming a sheet by making a slurry containing hydrous magnesium silicate (sepiolite) as the main material, wood pulp as the organic extender, inorganic fibers for reinforcement, and binder for consolidation and aggregation ,
Water is applied to a non-combustible press board formed by laminating the sheet and pressurized and heated, or the non-combustible press board is immersed in water and dried under pressure, and then a water-based organic / inorganic mixed binder is applied to the surface and dried. A non-combustible board characterized by   A water-based organic / inorganic mixed binder is applied to both surfaces of the non-combustible pressboard, or the non-combustible pressboard is immersed in the water-based organic / inorganic mixed binder, and a plurality of sheets are stacked and dried under pressure. The noncombustible board according to claim 1 or 2. After forming a sheet by making a slurry containing hydrous magnesium silicate (sepiolite) as the main material, wood pulp as the organic extender, inorganic fibers for reinforcement, and binder for consolidation and aggregation ,
A water-based organic / inorganic mixed binder is applied to one side of a non-combustible pressboard obtained by laminating and pressurizing and heating the sheet, and the water-based organic is sucked from the opposite surface of the non-combustible pressboard to the inside of the non-combustible pressboard. An incombustible board obtained by impregnating an inorganic mixed binder and then drying under pressure. After forming a sheet by making a slurry containing hydrous magnesium silicate (sepiolite) as the main material, wood pulp as the organic extender, inorganic fibers for reinforcement, and binder for consolidation and aggregation ,
A water-based organic / inorganic mixed binder is applied to a non-combustible pressboard obtained by laminating and pressing and heating the sheet, or the non-combustible pressboard is immersed in a water-based organic / inorganic mixed binder, and the noncombustible pressboard is placed in a vacuum box. The incombustible board is characterized in that the water-based organic / inorganic mixed binder is infiltrated into the inside of the incombustible press board by depressurizing the inside thereof and then dried under pressure.   The water-based organic / inorganic mixed binder uniformly disperses and dissolves polyester emulsion or acrylic emulsion in solid content of 25 wt% to 50 wt% and lithium silicate or potassium silicate in solid content of 50 wt% to 75 wt% in water. The noncombustible board according to any one of claims 1 to 5, wherein the nonflammable board is formed.   An incombustible decorative board, which is embossed during the pressure drying in the manufacture of the incombustible board according to any one of claims 1 to 6.   A nonflammable decorative board obtained by bending during the pressure drying in the production of a nonflammable board or a nonflammable decorative board according to any one of claims 1 to 7.   A nonflammable board or a nonflammable decorative board, wherein a water-resistant sealant is applied to the surface of the nonflammable board or nonflammable decorative board according to any one of claims 1 to 8.   A non-combustible decorative board, comprising a decorative sheet bonded to the non-combustible board or non-combustible decorative board according to any one of claims 1 to 9.   A nonflammable decorative board, wherein the surface of the nonflammable board or the nonflammable decorative board according to claim 1 is dipped or painted.   The nonflammable board or the nonflammable decorative board according to any one of claims 1 to 11, wherein an inorganic film agent is applied to the front surface and / or the back surface.   An organic flame retardant foam board, flame retardant rubber board, flame retardant plastic or wood board is bonded to the front or back of a non-flammable board with an inorganic film agent applied to the front and / or back. Characteristic non-combustible decorative board. The inorganic film agent contains hydrous aluminum silicate (vermiculite) in a range of 60% to 100% by weight and a polyether resin or a polyester resin in a range of 0% to 40% by weight. The nonflammable decorative board according to claim 12 or 13.

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