JP2007021946A - Decorative plate - Google Patents
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- JP2007021946A JP2007021946A JP2005208835A JP2005208835A JP2007021946A JP 2007021946 A JP2007021946 A JP 2007021946A JP 2005208835 A JP2005208835 A JP 2005208835A JP 2005208835 A JP2005208835 A JP 2005208835A JP 2007021946 A JP2007021946 A JP 2007021946A
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Abstract
Description
本発明は、化粧板に関し、特に、台所、風呂場、駅舎、体育館等の壁材等の建築用内外装材として好適に使用することができる、表面にステンレス板を積層してなる化粧板に関するものである。 The present invention relates to a decorative board, and more particularly, to a decorative board formed by laminating a stainless steel plate on the surface, which can be suitably used as an interior / exterior material for a building such as a wall material such as a kitchen, a bathroom, a station building, and a gymnasium. Is.
従来、この種の建築用内外装材として使用する化粧板として、水酸化アルミニウム等の無機質骨材を主たる材料とし、これに熱硬化性樹脂を添加してなる基板の表面に印刷を施した熱硬化性樹脂を含浸させた化粧紙を積層、一体化したものが実用化されている（特許文献１参照）。 Conventionally, as a decorative board used as an interior / exterior material for this type of building, a heat produced by printing on the surface of a substrate made mainly of an inorganic aggregate such as aluminum hydroxide and adding a thermosetting resin thereto. A laminate of decorative paper impregnated with a curable resin and integrated is put into practical use (see Patent Document 1).
しかし、上記化粧板は強度が弱く、特に、不燃化のために基板の無機質骨材の含有率を高くすると、この傾向が一層顕著に現れるとともに、化粧紙と基板間の接着力が低下し、剥離を起こし易いという問題があった。
この問題に対処するために、本件出願人は、熱硬化性樹脂を含浸させたガラス不織布からなる不織布層と、無機質骨材及び熱硬化性樹脂からなる混合樹脂層とを積層してなる芯材シートを複数枚積層してなる芯材層の表面に、メラミン樹脂を含浸させた化粧紙からなる表面化粧層を積層した化粧板を提案した（特許文献２参照）。
However, the decorative board is weak in strength, and particularly when the content of the inorganic aggregate of the substrate is increased for non-combustibility, this tendency appears more prominently, and the adhesive force between the decorative paper and the substrate decreases, There was a problem that peeling was likely to occur.
In order to cope with this problem, the applicant of the present invention is a core material obtained by laminating a nonwoven fabric layer made of a glass nonwoven fabric impregnated with a thermosetting resin and a mixed resin layer made of an inorganic aggregate and a thermosetting resin. A decorative board has been proposed in which a surface decorative layer made of decorative paper impregnated with melamine resin is laminated on the surface of a core material layer formed by laminating a plurality of sheets (see Patent Document 2).
この技術により、上記問題点は解消されるに至ったが、反面、この化粧板では、表面化粧層にメラミン樹脂を含浸させた紙質のものを積層することから、例えば、台所のコンロの近くに設けるようにした場合は、コンロの熱や炎によって劣化したり、焦げたりするおそれがあった。
この問題に対処するために、本件出願人は、無機芯材、無機質骨材及び熱硬化性樹脂とよりなる芯材層の少なくとも一方の表面にステンレス板を積層してなる化粧板を提案した（特許文献３及び４参照）。
ところで、この表面にステンレス板を積層してなる化粧板は、通常の保存状況下では、一方の表面のみにステンレス板を積層してなる化粧板の場合、芯材層が吸湿することによって、化粧板に反り等の変形が生じ易く、このため、施工が困難となったり、施工後に不具合が発生する等の問題があった。
In order to deal with this problem, the present applicant has proposed a decorative board in which a stainless steel plate is laminated on at least one surface of a core material layer composed of an inorganic core material, an inorganic aggregate material, and a thermosetting resin. (See Patent Documents 3 and 4).
By the way, a decorative plate formed by laminating a stainless steel plate on this surface is a decorative plate made by laminating a stainless steel plate only on one surface under normal storage conditions. Deformation such as warpage is likely to occur in the plate, which causes problems such as difficulty in construction and occurrence of defects after construction.
本発明は、上記従来の表面にステンレス板を積層してなる化粧板の有する問題点に鑑み、倉庫などで保存しても、化粧板に反り等の変形が生ずることがなく保存でき、施工が困難となったり、施工後に不具合が発生する等の問題の発生がない、表面にステンレス板を積層してなる化粧板を提供することを目的とする。 In view of the problems of the decorative plate formed by laminating a stainless steel plate on the conventional surface, the present invention can be stored without deformation of the decorative plate even if stored in a warehouse or the like. It is an object of the present invention to provide a decorative board formed by laminating a stainless steel plate on the surface, which is difficult and does not cause problems such as problems after construction.
上記目的を達成するため、発明の化粧板は、無機芯材、無機質骨材及び熱硬化性樹脂とよりなる芯材層の表面にステンレス板を積層してなる化粧板において、芯材層の裏面に湿気を通過させない材料からなる保護層を積層し、施工時、該保護層を取り外して施工するようにしたことを特徴とする。 In order to achieve the above object, the decorative board of the invention is a decorative board in which a stainless steel plate is laminated on the surface of a core layer made of an inorganic core, an inorganic aggregate, and a thermosetting resin. A protective layer made of a material that does not allow moisture to pass through is laminated on the back surface, and the protective layer is removed during the construction.
この場合において、保護層に合成樹脂製の材料を用いることができる。 In this case, a synthetic resin material can be used for the protective layer.
また、芯材層の表層及び裏層に樹脂含浸紙を配することができる。 Moreover, resin impregnated paper can be arranged on the surface layer and the back layer of the core material layer.
本発明の化粧板によれば、芯材層の裏面に湿気を通過させない材料からなる保護層を積層し、施工時、該保護層を取り外して施工するので、化粧板は湿気を通過させない材料からなる保護層によって芯材層の裏面側からの吸湿量が抑制され（芯材層の裏面側からの吸湿量を、ステンレス板を積層した表面側からの吸湿量とバランスさせ）、化粧板に反り等の変形が生ずることを防止することができる。
そして、これにより、施工が困難となったり、施工後に不具合が発生する等の問題の発生を未然に防止することができる。
According to the decorative board of the present invention, since the protective layer made of a material that does not allow moisture to pass through is laminated on the back surface of the core material layer, and the protective layer is removed and applied at the time of construction, the decorative board is made of a material that does not allow moisture to pass through. The amount of moisture absorbed from the back side of the core material layer is suppressed by the protective layer (balances the amount of moisture absorbed from the back side of the core material layer with the amount of moisture absorbed from the surface side laminated with the stainless steel plate) and warps the decorative board It is possible to prevent such deformation.
Thus, it is possible to prevent the occurrence of problems such as difficulty in construction and occurrence of problems after construction.
また、保護層にポリエチレン樹脂等の合成樹脂製の材料を用いることにより、取り外した保護層を簡易に処理することができる。 Moreover, the removed protective layer can be easily processed by using a synthetic resin material such as polyethylene resin for the protective layer.
また、芯材層の表層及び裏層に樹脂含浸紙を配することにより、ステンレス板及び保護層を積層する前工程において、芯材層の表面側と裏面側との吸湿量をバランスさせ、芯材層に反り等の変形が生ずることを防止するとともに、芯材層とステンレス板及び保護層との密着性を高め、積層を確実に行うことができる。 Also, by arranging resin-impregnated paper on the surface layer and the back layer of the core material layer, in the previous step of laminating the stainless steel plate and the protective layer, the moisture absorption amount on the front surface side and the back surface side of the core material layer is balanced, and the core While preventing deformation such as warpage in the material layer, the adhesion between the core material layer, the stainless steel plate and the protective layer can be improved, and lamination can be performed reliably.
以下、本発明の化粧板の実施の形態を、図面に基づいて説明する。 Hereinafter, embodiments of the decorative board of the present invention will be described with reference to the drawings.
図１に、本発明の化粧板の一実施例を示す。
この化粧板Ｐは、その表面に設けられたステンレス板１と、無機芯材、無機質骨材及び熱硬化性樹脂とよりなる芯材層２と、芯材層２の裏面に設けられた湿気を通過させない材料からなる保護層３とからなり、施工時、保護層３を取り外して施工するようにしたものであり、必要に応じて、不燃性を備えるようにしたものである。
この化粧板Ｐの厚みは、特に限定されるものではないが、２〜６ｍｍ、特に、２〜５ｍｍの厚みであることが好ましい。この厚みであると、台所で使用される他の化粧板との段差をなくすことができ、台所周りを美しく仕上げることができる。
In FIG. 1, one Example of the decorative board of this invention is shown.
The decorative board P includes a stainless steel plate 1 provided on the surface thereof, a core material layer 2 made of an inorganic core material, an inorganic aggregate, and a thermosetting resin, and moisture provided on the back surface of the core material layer 2. The protective layer 3 is made of a material that does not pass through, and is constructed by removing the protective layer 3 at the time of construction, and is provided with nonflammability as necessary.
Although the thickness of this decorative board P is not specifically limited, It is preferable that it is 2-6 mm, especially 2-5 mm in thickness. With this thickness, it is possible to eliminate steps from other decorative plates used in the kitchen, and to finish the kitchen beautifully.
化粧板Ｐの表面に設けられているステンレス板１には、好ましくは、表面にヘアーライン処理を施したステンレス板を使用し、より好ましくは、さらにその表面に弗素系、シリカ系等の被膜層４を形成したものを使用することができる。 The stainless steel plate 1 provided on the surface of the decorative plate P is preferably a stainless steel plate with a hairline treatment on the surface, more preferably a fluorine-based or silica-based coating layer 4 on the surface. Can be used.
ステンレス板１の厚みは、特に限定されるものではないが、好ましくは、厚さ０．１〜０．６ｍｍ、さらに好ましくは０．２〜０．５ｍｍ程度の薄板からなり、芯材層２の表面に、例えば、シリコン系、エポキシ系、ポリウレタン系、アクリル系、ポリイミド系、ポリアミド系、合成ゴム系等の接着剤層５により接着されている。
なお、ステンレス板１の厚みが０．１ｍｍ以上であると、芯材層２の表面に凹凸があっても、これがステンレス板１の表面にまで影響することを防止できるので、ステンレス板１の表面が凹凸になることはなく、凹凸のない美しい表面状態を有する化粧板Ｐとすることができる。すなわち、芯材層２は無機質骨材や無機芯材等を含むので、これらの影響で表面が凹凸になる可能性があるし、後述の混合樹脂層２１の形成の際に凹凸となる可能性もあるので、ステンレス板１の厚みを０．１ｍｍ以上にしておくのが望ましい。一方、厚みを０．６ｍｍ以上にして耐熱性を向上させてもよいが、耐熱性は０．６ｍｍ厚で十分であり、かえって重さが重くなり取り扱い難くなるので、０．６ｍｍ以下が望ましい。そして、芯材層２として、後述の無機質骨材を含む熱硬化性樹脂が硬化したものを使用しているので、芯材層２自体がへこむことがなく、このため、比較的薄いステンレス板を使用してもステンレス板１が内側にへこむことがなく、化粧板Ｐの表面に凹凸が生じず、長期間に亘って美麗に保持することができる。
The thickness of the stainless steel plate 1 is not particularly limited, but is preferably a thin plate having a thickness of about 0.1 to 0.6 mm, more preferably about 0.2 to 0.5 mm. For example, it is bonded to the surface by an adhesive layer 5 such as silicon, epoxy, polyurethane, acrylic, polyimide, polyamide, or synthetic rubber.
If the thickness of the stainless steel plate 1 is 0.1 mm or more, even if the surface of the core material layer 2 is uneven, it can be prevented from affecting the surface of the stainless steel plate 1. Does not become uneven, and it can be a decorative board P having a beautiful surface state without unevenness. That is, since the core layer 2 includes an inorganic aggregate, an inorganic core, and the like, the surface may be uneven due to these effects, and may be uneven when the mixed resin layer 21 described later is formed. Therefore, it is desirable that the thickness of the stainless steel plate 1 be 0.1 mm or more. On the other hand, the heat resistance may be improved by setting the thickness to 0.6 mm or more, but 0.6 mm thickness is sufficient for the heat resistance, and on the other hand, the weight becomes heavier and difficult to handle, so 0.6 mm or less is desirable. And since the core material layer 2 uses what hardened the thermosetting resin containing the inorganic aggregate mentioned later, the core material layer 2 itself does not dent, For this reason, a comparatively thin stainless steel plate is used. Even if it is used, the stainless steel plate 1 does not dent inside, and the surface of the decorative plate P is not uneven, and can be held beautifully over a long period of time.
ステンレス板１の表面に形成する被膜層４のうち、弗素系被膜層に使用されるものとしては、熱可塑性弗素樹脂でも熱硬化性弗素樹脂でも使用可能であり、例えば、熱可塑性弗素樹脂としては、４弗化ポリエチレン樹脂、３弗化ポリエチレン樹脂、２弗化ポリエチレン樹脂、４弗化エチレン−パーフルオロアルコキシエチレン共重合体樹脂、４弗化エチレン−６弗化プロピレン共重合体樹脂、４弗化エチレン−エチレン共重合体樹脂などが用いられる。
この弗素被膜層４の厚みは、特に限定されるものではないが、１０〜１００μｍの厚さが好ましい。
Of the coating layer 4 formed on the surface of the stainless steel plate 1, as the fluorine-based coating layer, either a thermoplastic fluorine resin or a thermosetting fluorine resin can be used. For example, as the thermoplastic fluorine resin, 4 fluorinated polyethylene resin, 3 fluorinated polyethylene resin, 2 fluorinated polyethylene resin, 4 fluorinated ethylene-perfluoroalkoxyethylene copolymer resin, 4 fluorinated ethylene-6 fluorinated propylene copolymer resin, 4 fluorinated An ethylene-ethylene copolymer resin or the like is used.
The thickness of the fluorine coating layer 4 is not particularly limited, but a thickness of 10 to 100 μm is preferable.
また、シリカ系被膜層４に使用されるものとしては、シリカとバインダー樹脂とを混合したシリカ・樹脂混合物、シリカアルコキシドなどが使用される。シリカアルコキシドとしては、（Ｒ１）ｎＳｉ（ＯＲ２）４−ｎ（ここで、Ｒ１はメチル基、エチル基、フェニル基を表し、Ｒ２は炭素数が１〜４のアルキル基を表し、ｎは０、１又は２である。）で表される珪素化合物、（Ｒ３）ｍＳｉＸ４−ｍ（ここで、Ｒ３は炭素数１〜８の１価の炭化水素基を表し、Ｘは加水分解性基（アルコキシル基、アセトキシ基など）を表し、ｍは０、１、２又は３である。）で表される加水分解性オルガノシランなどが使用される。
このシリカ系被膜層４の厚みは、特に限定されるものではないが、１０〜１００μｍの厚さが好ましい。
Moreover, as what is used for the silica-type film layer 4, the silica * resin mixture which mixed silica and binder resin, a silica alkoxide, etc. are used. As the silica alkoxide, (R 1 ) n Si (OR 2 ) 4-n (where R 1 represents a methyl group, an ethyl group, or a phenyl group, and R 2 represents an alkyl group having 1 to 4 carbon atoms). , N is 0, 1 or 2.) (R 3 ) m SiX 4-m (wherein R 3 represents a monovalent hydrocarbon group having 1 to 8 carbon atoms, X represents a hydrolyzable group (alkoxyl group, acetoxy group, etc., and m is 0, 1, 2, or 3).
The thickness of the silica-based coating layer 4 is not particularly limited, but a thickness of 10 to 100 μm is preferable.
これらの被膜層４は、上記弗素樹脂やシリカ・樹脂混合物やシリカアルコキシドなどをフィルム化してステンレス板１に熱圧着などの方法で接合一体化してもよいし、塗料化してステンレス板１に塗布・固化して一体化（例えば、焼付塗装）してもよい。 These coating layers 4 may be formed by film-forming the above fluororesin, silica / resin mixture, silica alkoxide, etc., and joined and integrated with the stainless steel plate 1 by a method such as thermocompression bonding. You may solidify and integrate (for example, baking painting).
そして、ステンレス板１の表面に被膜層４を形成することによって、ステンレス板１に傷が付くことを防止できる上に、台所の油などの汚れが付着しても簡単に拭き取ることができる。
特に、シリカ系被膜層は、弗素系被膜層と比べても表面硬度が高く、鉛筆硬度で５以上の硬度、好ましくは８前後の硬度を有しているので、鍋などで擦っても傷が付くことがなく、台所に使用する場合においてはシリカ系被膜層が好ましく採用される。
Further, by forming the coating layer 4 on the surface of the stainless steel plate 1, it is possible to prevent the stainless steel plate 1 from being damaged, and it is possible to easily wipe it off even if dirt such as kitchen oil adheres.
In particular, the silica-based coating layer has a surface hardness higher than that of the fluorine-based coating layer, and has a pencil hardness of 5 or more, and preferably a hardness of around 8. A silica-based coating layer is preferably employed for use in a kitchen without sticking.
一方、化粧板Ｐの芯材層２は、無機芯材と無機質骨材と熱硬化性樹脂とよりなるものである。具体的には、無機芯材に無機質骨材と熱硬化性樹脂とを含浸、塗布若しくは積層させた複数の芯材シート２０を積層して熱硬化させた層によって構成されている。この芯材層２の厚さは、特に限定されるものではないが、１．５〜５ｍｍの厚さであることが好ましい。 On the other hand, the core material layer 2 of the decorative board P is made of an inorganic core material, an inorganic aggregate, and a thermosetting resin. Specifically, it is constituted by a layer obtained by laminating and thermosetting a plurality of core material sheets 20 impregnated, coated or laminated with an inorganic aggregate and a thermosetting resin. The thickness of the core material layer 2 is not particularly limited, but is preferably 1.5 to 5 mm.
無機芯材としては、例えば、ガラス不織布や織布などが使用される。
また、無機質骨材としては、水酸化アルミニウム、水酸化マグネシウム等の含水無機化合物や炭酸カルシウム、タルク等の充填剤が使用される。
また、熱硬化性樹脂としては、メラミン樹脂、フェノール樹脂等が使用される。
As the inorganic core material, for example, a glass nonwoven fabric or a woven fabric is used.
Further, as the inorganic aggregate, water-containing inorganic compounds such as aluminum hydroxide and magnesium hydroxide, and fillers such as calcium carbonate and talc are used.
Moreover, as a thermosetting resin, a melamine resin, a phenol resin, etc. are used.
そして、より具体的には、図２（Ａ）に示すように、無機芯材として秤量３０〜１００ｇ／ｍ２程度のガラス不織布を使用し、この無機芯材にメラミン樹脂、フェノール樹脂等の熱硬化性樹脂を含浸させた後、この含浸無機芯材２２の片面に、水酸化アルミニウム、水酸化マグネシウム等の含水無機化合物や炭酸カルシウム、タルク等の無機充填剤などの無機質骨材、及びメラミン樹脂、フェノール樹脂等の熱硬化性樹脂（さらに、必要に応じて他の添加剤）を混合した混合物（本明細書において、「混合樹脂」という。）を塗布して混合樹脂層２１を形成し、２層構造とした芯材シート２０Ａを用いることができる。
また、図２（Ｂ）に示すように、ガラス不織布に熱硬化性樹脂を含浸させた含浸無機芯材２２の両面に、無機質骨材及び熱硬化性樹脂（さらに、必要に応じて添加剤）を混合した混合樹脂を塗布して混合樹脂層２１を形成し、３層構造とした芯材シート２０Ｂを用いることができる。
さらに、図２（Ｃ）に示すように、ガラス不織布に無機質骨材及び熱硬化性樹脂（さらに、必要に応じて他の添加剤）を混合した混合樹脂を含浸させた含浸無機芯材２２の両面に、該混合樹脂を塗布して混合樹脂層２１を形成した芯材シート２０Ｃ（この場合、図示の３層構造のほか、２層構造とすることもできる。）を用いることもできる。
また、図２（Ｄ）に示すように、ガラス不織布に無機質骨材及び熱硬化性樹脂（さらに、必要に応じて他の添加剤）を混合した混合樹脂を含浸させ、１層構造とした芯材シート２０Ｄを用いたり、図２（Ｅ）に示すように、無機質骨材及び熱硬化性樹脂を含浸させた含浸ガラス不織布（含浸無機芯材２３）と、前記熱硬化性樹脂に無機骨材を混合した混合樹脂シート２４とを適宜選択し、必要に応じて、組み合わせた芯材シート２０Ｅ用いることができる。
More specifically, as shown in FIG. 2 (A), a glass nonwoven fabric having a weight of about 30 to 100 g / m 2 is used as the inorganic core material, and melamine resin, phenol resin, etc. are used for this inorganic core material. After impregnating the thermosetting resin, an inorganic aggregate such as a water-containing inorganic compound such as aluminum hydroxide or magnesium hydroxide, or an inorganic filler such as calcium carbonate or talc, The mixture resin layer 21 is applied by applying a mixture (referred to as “mixed resin” in this specification) in which a thermosetting resin such as melamine resin or phenol resin (and other additives as necessary) is mixed. The core sheet 20A that is formed and has a two-layer structure can be used.
Moreover, as shown in FIG. 2 (B), an inorganic aggregate and a thermosetting resin (additional additives as necessary) are provided on both surfaces of the impregnated inorganic core material 22 in which a glass nonwoven fabric is impregnated with a thermosetting resin. ) Can be applied to form a mixed resin layer 21 to use a core sheet 20B having a three-layer structure.
Furthermore, as shown in FIG. 2 (C), an impregnated inorganic core material 22 in which a glass nonwoven fabric is impregnated with a mixed resin obtained by mixing an inorganic aggregate and a thermosetting resin (and other additives as required). It is also possible to use a core material sheet 20C (in this case, a two-layer structure can be used in addition to the three-layer structure shown in the figure) in which the mixed resin is applied to both surfaces to form the mixed resin layer 21.
Further, as shown in FIG. 2D, a core having a one-layer structure is obtained by impregnating a glass non-woven fabric with a mixed resin in which an inorganic aggregate and a thermosetting resin (and other additives as necessary) are mixed. As shown in FIG. 2E, an impregnated glass nonwoven fabric (impregnated inorganic core material 23) impregnated with an inorganic aggregate and a thermosetting resin, and an inorganic bone is added to the thermosetting resin. The mixed resin sheet 24 mixed with materials can be selected as appropriate, and the combined core sheet 20E can be used as necessary.
この場合、無機芯材には、熱硬化性樹脂が８０〜１５０重量％程度含浸されるようにする。
また、無機質骨材には、含水した水酸化アルミニウム等の無機化合物の粉末を、さらに、無機芯材２１内に浸入、含浸されるようにする場合には、粒径５０μｍ以下のものを用いるのが好ましい。
さらに、この含水水酸化アルミニウム等の無機化合物と炭酸カルシウム等の充填剤を３０〜１０：７０〜９０の割合で混合したものも好ましく用いることができる。
なお、無機芯材に水酸化アルミニウム等の無機質骨材を含浸させる場合、無機質骨材の含有率は、層間の界面の接着性を考慮して、１０重量％未満とすることが望ましい。
In this case, the inorganic core is impregnated with about 80 to 150% by weight of a thermosetting resin.
In addition, as the inorganic aggregate, in the case where the powder of an inorganic compound such as water-containing aluminum hydroxide is further infiltrated and impregnated into the inorganic core 21, one having a particle size of 50 μm or less is used. Is preferred.
Furthermore, what mixed this inorganic compound, such as a water-containing aluminum hydroxide, and fillers, such as a calcium carbonate in the ratio of 30-10: 70-90, can also be used preferably.
When the inorganic core material is impregnated with an inorganic aggregate such as aluminum hydroxide, the content of the inorganic aggregate is preferably less than 10% by weight in consideration of adhesion at the interface between layers.
そして、芯材シート２０全体として、熱硬化性樹脂が１０〜２０重量％含有されるようにする。
熱硬化性樹脂の含有量が、２０重量％より多いと、所期の不燃性の性質が得にくくなり、反対に、１０重量％より少ないと、結合力（接着力）が小さく、成形性が悪くなる。
一方、芯材シート２０全体には、無機質骨材が９０〜８０重量％含有されることとなるので、芯材シート２０を含む本実施例の化粧板Ｐを不燃性にすることができる。
And it is made for thermosetting resin to contain 10 to 20weight% as the core material sheet 20 whole.
If the content of the thermosetting resin is more than 20% by weight, it is difficult to obtain the desired non-flammable properties. Conversely, if the content is less than 10% by weight, the bonding strength (adhesive strength) is small and the moldability is low. Deteriorate.
On the other hand, since 90-80% by weight of the inorganic aggregate is contained in the entire core sheet 20, the decorative board P of the present embodiment including the core sheet 20 can be made nonflammable.
ところで、本実施例においては、芯材層２の表層及び裏層に、芯材シート２０に使用したのと同じメラミン樹脂、フェノール樹脂等の熱硬化性樹脂をクラフト紙などに含浸させた樹脂含浸紙２５、２６を配するようにする。
クラフト紙には、１００〜２５０ｇ／ｍ２のクラフト紙を好適に用いることができる。
そして、このクラフト紙に、熱硬化性樹脂を、例えば、２０〜１００重量％程度含浸させることにより、樹脂含浸紙２５、２６を得ることができる。
これにより、ステンレス板１及び保護層３を積層する前工程において、芯材層２の表面側と裏面側との吸湿量をバランスさせ、芯材層２に反り等の変形が生ずることを防止するとともに、芯材層２とステンレス板１及び保護層３との密着性を高め、積層を確実に行うことができる。
By the way, in this embodiment, the resin layer impregnated with kraft paper or the like impregnated with thermosetting resin such as melamine resin, phenol resin or the like used for the core material sheet 20 on the surface layer and the back layer of the core material layer 2. Paper 25 and 26 are arranged.
As the kraft paper, a kraft paper of 100 to 250 g / m 2 can be suitably used.
Then, by impregnating the kraft paper with a thermosetting resin, for example, about 20 to 100% by weight, the resin-impregnated papers 25 and 26 can be obtained.
Thereby, in the pre-process which laminates | stacks the stainless steel plate 1 and the protective layer 3, the moisture absorption amount of the surface side of the core material layer 2 and a back surface side is balanced, and deformation, such as curvature, arises in the core material layer 2. At the same time, the adhesion between the core material layer 2 and the stainless steel plate 1 and the protective layer 3 can be improved, and lamination can be performed reliably.
また、芯材層２の裏面に設けられる保護層３には、湿気を通過させない材料、具体的には、ポリエチレン樹脂等の合成樹脂フィルム（通常、２０〜１５０μｍ、より好ましくは、４０〜１００μｍ程度の厚みの合成樹脂フィルム）やポリエチレン樹脂等の合成樹脂をラミネート加工した紙などのシート状材料を好適に用いることができる。
なお、保護層３は、芯材層２の裏面側からの吸湿量を抑制し（芯材層２の裏面側からの吸湿量を、ステンレス板１を積層した表面側からの吸湿量とバランスさせ）、化粧板Ｐに反り等の変形が生ずることを防止することを目的とするものである（後述のステンレス板１の表面に形成した被膜層４の表面に設けられる保護層６と異なり、芯材層２の裏面側に傷が付くことを防止することを目的とするものではない）ことから、芯材層２の裏面全体に貼り付けられている。そして、取り外した保護層を簡易に処理することができるように、保護層６と比較して、厚みの薄い合成樹脂フィルムを好適に用いることができる。
The protective layer 3 provided on the back surface of the core layer 2 is made of a material that does not allow moisture to pass through, specifically, a synthetic resin film such as polyethylene resin (usually about 20 to 150 μm, more preferably about 40 to 100 μm. Sheet-like material such as paper laminated with a synthetic resin such as a polyethylene resin or a synthetic resin such as polyethylene resin.
The protective layer 3 suppresses the amount of moisture absorbed from the back side of the core material layer 2 (balances the amount of moisture absorbed from the back surface side of the core material layer 2 with the amount of moisture absorbed from the surface side on which the stainless steel plate 1 is laminated). ), Which is intended to prevent the decorative plate P from undergoing deformation such as warping (unlike the protective layer 6 provided on the surface of the coating layer 4 formed on the surface of the stainless plate 1 described later, the core). It is not intended to prevent the back surface side of the material layer 2 from being scratched), and is thus attached to the entire back surface of the core material layer 2. And the synthetic resin film with a thin thickness can be used suitably compared with the protective layer 6 so that the removed protective layer can be processed easily.
また、ステンレス板１の表面に形成した被膜層４の表面に保護層６を積層し、施工後、この保護層６を取り外すようにする。
この保護層６は、化粧板Ｐの製造、保管及び施工時にステンレス板１の表面に形成した被膜層４（及びステンレス板１）の表面に傷が付くことを防止するためのもので、保護層６には、具体的には、シート状材料、より具体的には、ポリエチレン樹脂等の合成樹脂フィルム（通常、５０〜２００μｍ、より好ましくは、７０〜１５０μｍ程度の厚みの合成樹脂フィルム）やポリエチレン樹脂等の合成樹脂をラミネート加工した紙などのシート状材料を好適に用いることができる。
Moreover, the protective layer 6 is laminated | stacked on the surface of the film layer 4 formed in the surface of the stainless steel plate 1, and this protective layer 6 is removed after construction.
The protective layer 6 is for preventing the surface of the coating layer 4 (and the stainless steel plate 1) formed on the surface of the stainless steel plate 1 from being damaged during the manufacture, storage and construction of the decorative plate P. 6, specifically, a sheet-like material, more specifically, a synthetic resin film such as a polyethylene resin (usually a synthetic resin film having a thickness of about 50 to 200 μm, more preferably about 70 to 150 μm) or polyethylene. A sheet-like material such as paper laminated with a synthetic resin such as a resin can be suitably used.
次に、上記の構成からなる本実施例の化粧板Ｐと、従来の化粧板とについて、反りの状態を確認するため、以下の試験条件により強制反り試験を行った結果を表１に示す。
［試験条件］
・温度：５℃〜６０℃／５時間／１サイクル
・繰り返し数：１０回
・サンプル：
サンプルＡ（本実施例）；ステンレス板１（有）、保護層３（有）
サンプルＢ（参考例）；ステンレス板１（有）、保護層３（無）
サンプルＣ（参考例）；ステンレス板１（無）、保護層３（無）、表面の樹脂含浸紙としてチタン含有化粧紙を使用
・サンプルサイズ：９１０×１２１０ｍｍ
［試験方法］
・サンプルを平面上に平置きし、上記試験条件でヒートサイクルをかける。
・ヒートサイクルをかけた後、サンプルを平面上にステンレス板１又は化粧紙を上面側及び下面側となるようにして平置きして、表１に示す８個の測定位置について反り量［ｍｍ］を測定する。
［試験の評価基準］
・○（良）：反り量が１０ｍｍ未満
・×（不良）：反り量が１０ｍｍ以上
Next, Table 1 shows the results of a forced warp test performed under the following test conditions in order to confirm the state of warping of the decorative board P of the present example having the above-described configuration and the conventional decorative board.
[Test conditions]
-Temperature: 5 ° C to 60 ° C / 5 hours / 1 cycle-Number of repetitions: 10 times-Sample:
Sample A (this example); stainless steel plate 1 (with), protective layer 3 (with)
Sample B (reference example); stainless steel plate 1 (with), protective layer 3 (without)
Sample C (reference example): Stainless steel plate 1 (no), protective layer 3 (no), and titanium-containing decorative paper used as the resin-impregnated paper on the surface. Sample size: 910 × 1210 mm
[Test method]
-Place the sample flat on a flat surface and heat cycle under the above test conditions.
-After heat cycle, the sample was placed flat on a flat surface with the stainless steel plate 1 or decorative paper on the upper surface side and lower surface side, and the amount of warping [mm] at the 8 measurement positions shown in Table 1 Measure.
[Test Evaluation Criteria]
・ ○ (good): warpage amount is less than 10 mm ・ × (defective): warpage amount is 10 mm or more
表１に示す強制反り試験の結果からも明らかなとおり、本実施例の化粧板Ｐは、各測定位置について反り量が、強制反り試験の評価基準が○（良）の１０ｍｍ以下であり、反り等の変形が生ずることを防止することができることを確認できた。
一方、保護層３を設けていないサンプルＢ（参考例）は、評価基準の１０ｍｍ以上であり、反り変形を生じる化粧板となった。
これらのことにより、保護層３が反り防止に著しい効果を発揮することがわかった。
なお、ステンレス板を積層していないサンプルＣ（参考例）は、反りがほとんどないことを確認した。
As is apparent from the results of the forced warpage test shown in Table 1, the decorative board P of this example has a warpage amount at each measurement position, and the evaluation standard of the forced warpage test is 10 mm or less, which is ○ (good). It has been confirmed that it is possible to prevent such deformation.
On the other hand, Sample B (reference example) in which the protective layer 3 was not provided was an evaluation standard of 10 mm or more, and became a decorative board that caused warping deformation.
From these, it was found that the protective layer 3 exhibits a remarkable effect in preventing warpage.
In addition, it was confirmed that Sample C (reference example) in which the stainless steel plate was not laminated had almost no warpage.
次に、上記の構成からなる本実施例の化粧板Ｐについて、施工後の耐久性能を確認するため、以下の試験条件により耐久試験を行った。
［試験条件］
・温度：５℃〜６０℃／５時間／１サイクル（ここで、防火予防条例に規定される距離でコンロを使用した場合に、化粧板Ｐの表面温度が６０℃に達するため、温度を５℃〜６０℃に設定した。）
・繰り返し数：２５０回
・サンプル：ステンレス板１（有）、保護層３（有）
・サンプルサイズ：９１０×１８２０ｍｍ
［試験方法］
・サンプルの化粧板Ｐから保護層３を取り外し、化粧板Ｐの裏面を構成する樹脂含浸紙２６の表面に、図３に示すように、仮止め用の両面接着テープ７及びウレタン樹脂系接着剤（製品名：タキロン社製タキボンド５）８を施した後、鉛直面からなる下地材（石膏ボード）上に接着し、上記試験条件でヒートサイクルをかける。
・ヒートサイクルをかけた後、下地材（石膏ボード）上に接着されたサンプルの剥がれ、浮き、膨れ、亀裂、その他不具合を検証する。
［試験の評価基準］
・○（良）：剥がれ、浮き、膨れ、亀裂、その他不具合のいずれもなし
・×（不良）：剥がれ、浮き、膨れ、亀裂、その他不具合のいずれかが有る
Next, in order to confirm the durability performance after construction, the durability test was performed under the following test conditions for the decorative board P of the present example having the above-described configuration.
[Test conditions]
・ Temperature: 5 ° C. to 60 ° C./5 hours / 1 cycle (Here, the surface temperature of the decorative board P reaches 60 ° C. when the stove is used at the distance specified in the fire prevention regulations) ℃ -60 ℃ was set.)
-Number of repetitions: 250 times-Sample: Stainless steel plate 1 (with), protective layer 3 (with)
・ Sample size: 910 × 1820mm
[Test method]
The protective layer 3 is removed from the decorative plate P of the sample, and the double-sided adhesive tape 7 and urethane resin adhesive for temporary fixing are applied to the surface of the resin-impregnated paper 26 constituting the back surface of the decorative plate P as shown in FIG. (Product name: Takiron 5 manufactured by Takiron Co., Ltd.) After 8 application, the product is adhered onto a base material (gypsum board) composed of a vertical surface and subjected to a heat cycle under the above test conditions.
・ After heat cycle, verify the peeling, floating, swelling, cracking, and other defects of the sample adhered on the base material (gypsum board).
[Test Evaluation Criteria]
・ ○ (good): No peeling, floating, swelling, cracking, or other defects ・ × (defect): There are peeling, floating, swelling, cracks, or other defects
耐久試験の結果、剥がれ、浮き、膨れ、亀裂、その他不具合のいずれもなく、通常の使用による耐久性には問題がないことを確認できた。 As a result of the durability test, it was confirmed that there was no peeling, floating, swelling, cracking, and other problems, and that there was no problem in durability under normal use.
かくして、本実施例の化粧板Ｐは、無機芯材、無機質骨材及び熱硬化性樹脂とよりなる芯材層２の表面にステンレス板１を積層してなることから、ステンレス板１により熱や炎を遮断することができ、これにより、台所のコンロの近くなどで化粧板Ｐを設けるようにした場合でも、コンロの熱や炎によって化粧板、特にその表面が、劣化したり焦げたりすることを防止し、さらには、これ以外の用途を含め、長期に亘り表面を平滑に美麗に保つことができるという利点を有しながら、芯材層２の裏面に湿気を通過させない材料からなる保護層３を積層し、施工時、この保護層３を取り外して施工することにより、湿気を通過させない材料からなる保護層３によって、芯材層２の裏面側からの吸湿量を抑制し（芯材層２の裏面側からの吸湿量を、ステンレス板１を積層した表面側からの吸湿量とバランスさせ）、化粧板Ｐに反り等の変形が生ずることを防止することができる。
そして、これにより、施工が困難となったり、施工後に不具合が発生する等の問題の発生を未然に防止することができる。
Thus, the decorative board P of the present embodiment is formed by laminating the stainless steel plate 1 on the surface of the core material layer 2 made of the inorganic core material, the inorganic aggregate material, and the thermosetting resin. Even when the decorative board P is provided near the stove in the kitchen, the decorative board, particularly its surface, deteriorates or burns due to the heat or flame of the stove. In addition to this, the protection made of a material that does not allow moisture to pass through the back surface of the core material layer 2 while having the advantage that the surface can be kept smooth and beautiful for a long period of time including other uses. The layer 3 is laminated, and the protective layer 3 is removed during the construction, so that the moisture absorption from the back side of the core material layer 2 is suppressed by the protective layer 3 made of a material that does not allow moisture to pass through (core material). Moisture absorption from the back side of layer 2 Stainless steel plate 1 moisture absorption and are balanced from laminated surface side), it is possible to prevent deformation such as warp occurs in the veneer P.
Thus, it is possible to prevent the occurrence of problems such as difficulty in construction and occurrence of problems after construction.
以上、本発明の化粧板について、その実施形態に基づいて説明したが、本発明は上記実施形態に記載した構成に限定されるものではなく、その趣旨を逸脱しない範囲において適宜その構成を変更することが可能である。 As mentioned above, although the decorative board of this invention was demonstrated based on the embodiment, this invention is not limited to the structure described in the said embodiment, In the range which does not deviate from the meaning, the structure is changed suitably. It is possible.
本発明の化粧板は、化粧板に反り等の変形が生ずることがなく、施工が困難となったり、施工後に不具合が発生する等の問題の発生がないことから、台所、風呂場、駅舎、体育館等の壁材等の建築用内外装材の用途に好適に用いることができる。 Since the decorative board of the present invention does not cause deformation such as warping on the decorative board, there is no occurrence of problems such as difficulty in construction or occurrence of problems after construction, so the kitchen, bathroom, station building, It can be suitably used for interior and exterior materials for buildings such as wall materials such as gymnasiums.
Ｐ 化粧板
１ ステンレス板
２ 芯材層
２０、２０Ａ、２０Ｂ、２０Ｃ、２０Ｄ、２０Ｅ 芯材シート
２１ 混合樹脂層
２２ 含浸無機芯材
２３ 含浸ガラス不織布
２４ 混合樹脂シート
２５、２６ 樹脂含浸紙
３ 保護層
４ 被膜層
５ 接着剤層
６ 保護層
P decorative plate 1 stainless steel plate 2 core material layer 20, 20A, 20B, 20C, 20D, 20E core material sheet 21 mixed resin layer 22 impregnated inorganic core material 23 impregnated glass nonwoven fabric 24 mixed resin sheet 25, 26 resin impregnated paper 3 protection Layer 4 Coating layer 5 Adhesive layer 6 Protective layer
Claims (3)
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| JP2005208835A JP4680705B2 (en) | 2005-07-19 | 2005-07-19 | Veneer |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107938978A (en) * | 2017-12-29 | 2018-04-20 | 东祥麟(江苏)实业有限公司 | A kind of indoor moisture proof decorative panel with high degree of comfort |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH07269062A (en) * | 1994-03-28 | 1995-10-17 | Kikusui Kagaku Kogyo Kk | Surface decorative building material |
| JPH09112004A (en) * | 1995-10-16 | 1997-04-28 | Tadahiro Akita | Decorative panel and manufacture thereof |
| JPH10138401A (en) * | 1996-11-14 | 1998-05-26 | Hitachi Chem Co Ltd | Metallic plate base decorative plate and manufacture of the same |
| JP2003103741A (en) * | 2001-07-25 | 2003-04-09 | Tokuyama Corp | Decorative sheet |
| JP2004009718A (en) * | 2002-06-12 | 2004-01-15 | Takiron Co Ltd | Incombustible decorative laminated sheet |
| JP2004351750A (en) * | 2003-05-29 | 2004-12-16 | Takiron Co Ltd | Non-combustible decorative laminated sheet |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107938978A (en) * | 2017-12-29 | 2018-04-20 | 东祥麟(江苏)实业有限公司 | A kind of indoor moisture proof decorative panel with high degree of comfort |
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