JP2010201697A - Material for plate material, decorative plate, and method of manufacturing material for plate material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To sufficiently restrain a heat generation amount, while using a resin raw material, and to exhibit incombustibility. <P>SOLUTION: This decorative plate 10 includes a material 12 for a plate material 12, and a surface layer 14 laminated on the material 12 for the plate material. The material 12 for the plate material comprises at least a laminate including an aluminum layer 16, and a nonflammable core layer 18 having a thermosetting resin such as a melamine resin and an inorganic flame retardant such as aluminum hydroxide. The aluminum layer 16 is arranged in an outside of the nonflammable core layer 18. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a decorative plate that can be used for wall materials, furniture, and the like, a material for a plate material that can be used for a plate material such as such a decorative plate, and an improvement of the manufacturing method thereof. The present invention relates to imparting flame retardancy or incombustibility while ensuring designability.

  In recent years, installation of materials requiring heat resistance such as incombustibility or flame retardance has been required at various locations. As a heat-resistant material having such incombustibility or flame retardancy, a metal material can be mentioned as a simple example. Among them, aluminum is relatively light and easy to process. Regarding heat resistance, it can be said that it is suitable as a material. However, when aluminum is used as it is, the cost increases, and as a result, there is a problem that the amount of use is limited.

  For this reason, attempts have recently been made to improve heat resistance in resin-based plate materials as an alternative to aluminum. As one of them, it has been proposed to add an inorganic flame retardant such as aluminum hydroxide to a thermoplastic resin such as an olefin resin (see, for example, Patent Document 1). However, in order to add an inorganic additive to a thermoplastic resin, it is necessary to load the thermoplastic resin with heat and shear force using a biaxial or uniaxial extruder or a batch kneader. There is. In this case, as the amount of the inorganic flame retardant added increases, the shearing force also increases. As a result, the heat generated by the shear increases and the inorganic flame retardant tends to decompose. For this reason, it is extremely difficult to add a large amount of an inorganic flame retardant to the thermoplastic resin, and as a result, the obtained plate material is not non-flammable but remains at a flame retardant level.

  On the other hand, as another method, in a thermosetting resin-based decorative board, it is also proposed to improve the heat resistance by adding an inorganic flame retardant such as aluminum hydroxide to a melamine resin or the like (for example, Patent Documents). 2 and 3). However, it is not always easy to disperse and mix aluminum hydroxide in a thermosetting resin or to apply or coat the obtained varnish. As a result, the resin is mainly applied to substrates such as nonwoven fabric and paper. In order to apply as a decorative board formed by laminating prepregs impregnated with bismuth and heating and pressurizing, advanced production techniques are required. For this reason, the present condition is that the board material which has a decorative external appearance as a decorative board, and also has sufficient heat resistance simultaneously is hardly provided.

  In addition, in particular, with regard to this heat resistance, the Building Standards Act was revised in 2000, and it is judged whether it conforms to the technical standards stipulated by the Cabinet Order for falling under the Article 2 item 9 The standard incombustible material test has been changed from the surface combustion test and the base material combustion test to the corn calorimeter exothermic test and the gas hazard test, and in order to use it as a noncombustible material, the calorific value must be suppressed. It has been requested. For this reason, with the resin-based heat-resistant decorative board as described above, it is difficult to suppress the amount of heat generation, and it is difficult to obtain the “non-combustible material” certification stipulated in Article 2-9 of the revised Building Standard Law. It has become.

Japanese Patent Laid-Open No. 7-207075 JP-A-1-56539 JP-A-1-56540

  In view of the above problems, the problem to be solved by the present invention is suitable for a decorative board having sufficient heat resistance while suppressing the amount of heat generated while using a resin-based material and such a decorative board. A plate material and a method for producing the same are provided.

  As a first means for solving the above-described problems, the present invention provides a plate material in which a surface layer is laminated on the surface to constitute a plate material. The plate material includes at least an aluminum layer and a nonflammable core layer. The non-flammable core layer has a melamine resin, a phenol resin and other thermosetting resins, and aluminum hydroxide, magnesium hydroxide and other inorganic flame retardants, and the aluminum layer is non-flammable. The present invention provides a plate material characterized by being disposed on the outer side of the conductive core layer.

  The present invention provides, as a second means for solving the above-mentioned problems, in the first solving means, wherein the aluminum layer is disposed on both sides of the incombustible core layer. Is to provide.

  According to the present invention, as a third means for solving the above problems, in the first or second solving means, the nonflammable core layer is impregnated with a thermosetting resin and an inorganic flame retardant. The thermosetting resin and the inorganic flame retardant are inorganic with respect to 10 to 30% by weight of the thermosetting resin when the total amount of the thermosetting resin and the inorganic flame retardant is 100% by weight. The present invention provides a plate material characterized by being blended at a ratio of 90 to 70% by weight of a flame retardant.

As a fourth means for solving the above-mentioned problems, the present invention provides a plate material characterized in that the basis weight of the glass fiber nonwoven fabric is 30 to 150 g / cm ² in the third solving means. It is to provide.

  According to the present invention, as a fifth means for solving the above-described problems, in any one of the first to fourth solving means, the nonflammable core layer is impregnated with a thermosetting resin and an inorganic flame retardant. The present invention provides a plate material characterized by being formed by laminating a plurality of non-woven glass fiber nonwoven fabrics.

  The present invention provides, as a sixth means for solving the above-mentioned problems, in any one of the first to fifth solving means, wherein the aluminum layer is made of an aluminum foil or an aluminum plate. The material is provided.

  The present invention provides, as a seventh means for solving the above-described problems, in any one of the first to sixth solving means, wherein the aluminum layer has a thickness of 0.1 mm to 0.3 mm. A material for a plate material is provided.

  In the present invention, as an eighth means for solving the above-mentioned problems, a decorative layer is heated and pressed as a surface layer on the design surface side of the plate material as any one of the first to seventh solving means. A decorative board characterized by being laminated is provided.

  According to the present invention, as a ninth means for solving the above-mentioned problems, in the eighth solving means, a core material layer is further laminated on the surface opposite to the design surface side of the plate material. The decorative board characterized by the above is provided.

  The present invention provides, as a tenth means for solving the above-mentioned problems, in a method for producing a plate material in which a surface layer is laminated on the surface to constitute a plate material. At least an aluminum layer, a melamine resin, a phenol resin, and the like And a non-flammable core layer having an inorganic flame retardant resin and aluminum hydroxide, magnesium hydroxide, and other inorganic flame retardant layers, laminated with the aluminum layer disposed outside the non-flammable core layer A method for manufacturing a material is provided.

  The present invention provides, as an eleventh means for solving the above-mentioned problems, in the tenth solution means, wherein an aluminum layer is disposed and laminated on both sides of a nonflammable core layer. A method for manufacturing a material is provided.

  As a twelfth means for solving the above-mentioned problems, the present invention provides a glass fiber nonwoven fabric as a base material, a thermosetting resin and an inorganic flame retardant in the tenth or eleventh solution means. When the total amount of the thermosetting resin and the inorganic flame retardant is 100% by weight, the thermosetting resin 10 to 30 is formed. The present invention provides a method for producing a plate material, characterized by blending in an amount of 90 to 70% by weight of an inorganic flame retardant with respect to weight%.

  As a thirteenth means for solving the above-mentioned problems, the present invention provides the above-mentioned twelfth solution means in which a thermosetting resin and an inorganic flame retardant are coated and impregnated on a glass fiber nonwoven fabric as a base material. The manufacturing method of the material for board | plate materials characterized by the above-mentioned is provided.

This invention uses the glass fiber nonwoven fabric whose basic weight is 30-150 g / cm < ² > in the said 12th or 13th solution means as a 14th means for solving said subject. The manufacturing method of the material for board | plate materials characterized by these is provided.

  The present invention provides, as a fifteenth means for solving the above problems, a plurality of glass fiber nonwoven fabrics impregnated with a thermosetting resin and an inorganic flame retardant in any one of the tenth to fourteenth solving means. The present invention provides a method for producing a plate material, which is formed by laminating to form a nonflammable core layer.

  The present invention provides, as a sixteenth means for solving the above-mentioned problems, in any one of the tenth to fifteenth solving means, wherein the aluminum layer is formed from an aluminum foil or an aluminum plate. The manufacturing method of the material for use is provided.

  According to the present invention, as a seventeenth means for solving the above-described problem, in any one of the tenth to sixteenth solving means, the aluminum layer is formed to a thickness of 0.1 mm to 0.3 mm. The manufacturing method of the board | plate material characterized by the above is provided.

  According to the present invention, as described above, the plate material is composed of a laminate including at least an aluminum layer and a nonflammable core layer having a thermosetting resin and an inorganic flame retardant. In addition to being able to ensure sufficient heat resistance by the aluminum layer, while being a material for a plate material of the system, not only can ensure sufficient heat resistance by an incombustible core layer provided with an inorganic flame retardant, in particular Since the aluminum layer is located outside the nonflammable core layer and integrated, the aluminum layer blocks heat and does not affect the nonflammable core layer, reducing the amount of heat generated even when exposed to heat There is an actual benefit that can be obtained and can obtain non-combustible materials as stipulated in the Building Standard Law.

  In this case, according to the present invention, as described above, since the inorganic flame retardant is confused with the thermosetting resin and formed in a plate shape, the thickness and weight are sufficiently reduced to suppress the calorific value. At the same time, there is an advantage that fine powder is not scattered around during installation and processing.

  Similarly, according to the present invention, as described above, the aluminum layer is disposed on both sides of the nonflammable core layer, and is laminated in the order of the aluminum layer, the nonflammable core layer, and the aluminum layer. Unlike the case where the layer is disposed only on the outer side, the heat resistance can be surely exhibited, and as a result, there is an advantage that the calorific value can be sufficiently suppressed even during heating.

  In addition, according to the present invention, as described above, the nonflammable core layer is formed by impregnating the glass fiber nonwoven fabric as a base material with a melamine resin mixed with an inorganic flame retardant at an appropriate ratio. While ensuring sufficient bondability (interlaminar strength) to ensure strength and handleability as a material for plate materials, it is possible to apply and impregnate the base material without requiring advanced production technology, There is an actual advantage that the calorific value can be sufficiently suppressed while using the resin material.

  According to the present invention, as described above, a plurality of glass fiber nonwoven fabrics impregnated with an inorganic flame retardant and a melamine resin are laminated to form a nonflammable core layer. Unlike the case where it is easy to sufficiently impregnate each glass fiber nonwoven fabric that is a base material using a resin, and it is easy to impregnate an inorganic flame retardant into one thick base material, With multiple prepregs that are fully penetrated by the inorganic flame retardant, it is possible to disperse the inorganic flame retardant evenly in almost all cross sections of the non-flammable core layer. There is.

  According to the present invention, as described above, since the aluminum layer made of an aluminum foil or an aluminum plate is formed to a thickness of at least 0.1 mm or more, there is an advantage that sufficient heat resistance can be ensured.

  Furthermore, according to the present invention, as described above, the decorative layer is heated and pressed as a surface layer on the design surface (one surface or both surfaces that require decoration) side of the material for plate material, so that it is nonflammable. While having the functionality of the above, at the same time, there is an advantage that a decorative appearance can be secured and it can be appropriately installed in various places.

It is a conceptual diagram of the decorative board of this invention.

  DETAILED DESCRIPTION OF THE INVENTION Embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 shows a decorative board 10 of the present invention, and the decorative board 10 is a plate material according to the present invention as shown in FIG. 12 and a surface layer 14 laminated on the surface of the plate material 12.

  In the illustrated embodiment, the surface layer 14 is a decorative layer 14A, and this decorative layer 14A is disposed on the design surface side of the plate material 12 of the present invention. In the illustrated embodiment, it is shown that a decorative layer 14A, which is a surface layer 14, is laminated on both surfaces of the plate material 12, but when a design surface that requires decoration is set to only one surface. Unlike the illustrated embodiment, the decorative layer 14A can be laminated only on the design surface (one surface) side.

  In this case, when the design surface is set to only one surface, a core material layer (not shown) can be further laminated on the surface opposite to the design surface. The decorative board 10 is formed by forming the plate material 12, the decorative layer as the surface layer 14, etc., and then superposing them and heating and pressing to laminate each layer as shown in FIG. 1. Can be manufactured.

  In addition, the surface layer 14 laminated | stacked on the board | plate material 12 of this invention is not necessarily limited to the decorative layer 14A, When using as an internal material which does not need a decoration in particular, as the surface layer 14 For example, veneer can be laminated, and metal materials can be laminated when it is necessary to ensure strength.

<1. Material for plate>
The board | plate material 12 of this invention consists of the laminated body provided with the aluminum layer 16 and the nonflammable core layer 18 which has a thermosetting resin and an inorganic flame retardant, as shown in FIG.

<1-1. Aluminum layer>
The aluminum layer 16 is made of an aluminum foil or an aluminum plate, and has a function of mainly imparting heat resistance to the plate material 12. The aluminum layer 16 is desirably set to a thickness of at least 0.1 mm. This is because if the thickness is less than 0.1 mm, non-flammability cannot be secured sufficiently. The upper limit is not particularly limited, and the greater the thickness, the better the incombustibility. However, the thickness and weight of the plate material 12 and thus the decorative board 10 as a whole increase, and the cost increases. It is preferable to set within an allowable range in terms of design in a simple product, and when used as the decorative board 10, it is preferable to set it to 0.3 mm or less.

<1-2. Nonflammable core layer>
Specifically, the nonflammable core layer 18 is made of a glass fiber nonwoven fabric impregnated with an inorganic flame retardant such as aluminum hydroxide or magnesium hydroxide and a thermosetting resin such as melamine resin or phenol resin. The nonflammable core layer 18 can be formed by producing a blend of an inorganic flame retardant and a thermosetting resin and impregnating the blend into a glass fiber nonwoven fabric as a base material.

In this case, the glass fiber nonwoven fabric is used as the base material because it is suitable for allowing the blend of the inorganic flame retardant and the thermosetting resin to penetrate inside. Specifically, it is desirable to use a glass fiber nonwoven fabric having a basis weight of 30 to 150 g / cm ² . A glass fiber nonwoven fabric having a basis weight of less than 30 g / cm ² is insufficient in strength and self-retaining properties, and therefore, a glass fiber nonwoven fabric as a base material is coated with a blend of an inorganic flame retardant and a thermosetting resin. In some cases, the glass fiber nonwoven fabric having a basis weight of more than 150 g / cm ² may have insufficient adhesion between the layers when being molded by lamination. Because there is.

  On the other hand, examples of the thermosetting resin that contains an inorganic flame retardant such as aluminum hydroxide or magnesium hydroxide having flame retardancy include melamine resin or phenol resin. It is most desirable to add it to the resin. This is because when melamine resin is used, it is possible to sufficiently secure the viscosity necessary for appropriately holding the inorganic flame retardant than when using other thermosetting resins such as phenol resin, This is because when this melamine resin is used as a binder, it can be applied to a glass fiber nonwoven fabric by a comma coater or the like, and good handleability can be secured. However, even when a phenol resin is used, as shown in the examples described later, the certification test as a non-combustible material intended by the present invention can be passed.

  In this case, the inorganic flame retardant and the thermosetting resin have an inorganic flame retardant 90 of 10 to 30% by weight of the thermosetting resin when the total amount of the inorganic flame retardant and the thermosetting resin is 100% by weight. It is desirable to blend at a ratio of ˜70% by weight. That is, for example, when the thermosetting resin is set to 10% by weight, the inorganic flame retardant is 90% by weight, and when the thermosetting resin is set to 20% by weight, the inorganic flame retardant is 80% by weight. When the functional resin is set to 30% by weight, the inorganic flame retardant is desirably set to 70% by weight. In this case, the compounding ratio of the inorganic flame retardant is set higher in order to ensure sufficient incombustibility, and the thermosetting resin has a role as a binder for the inorganic flame retardant. .

  This is because if the thermosetting resin is less than 10% by weight, the thermosetting resin cannot sufficiently function as a binder, and the binding force is insufficient at the time of handling as the plate material 12 as a core material. This is because handling may be difficult, and as a result, the interlayer adhesive strength may become insufficient in the decorative board 10 after molding. In addition, it is necessary to use an expensive and special mixer to prevent the viscosity from rising or remaining in the state, or it is necessary to lower the viscosity with a solvent or water. Further, in the coating process, a high viscosity resin liquid is applied. When technology is required, or when the viscosity is lowered with a large amount of solvent or water, environmental pollution such as increase of carbon dioxide gas due to solvent combustion, and energy and process for drying become enormous. This increases the cost, which is not preferable. On the other hand, when the thermosetting resin exceeds 30% by weight (when the inorganic flame retardant is less than 70% by weight), the incombustible effect is lowered, which is not preferable.

  In addition, when blending these aluminum hydroxides or magnesium hydroxide and thermosetting resin, if inorganic fillers such as carbon are added in addition to aluminum hydroxide or magnesium hydroxide, the dispersibility of aluminum hydroxide or magnesium hydroxide Is preferable. In addition, melamine resin, phenol resin, aluminum hydroxide, or magnesium hydroxide may be partially replaced with other resin or inorganic flame retardant within the range that does not impair the object and effect of the present invention. It is included in the scope of the present invention.

  The blend of the inorganic flame retardant and the thermosetting resin is used as it is or diluted with a solvent such as water or alcohol. In this blend, when the ratio of water, alcohol and other solvents (including those originally contained in the resin) is the dilution ratio, the dilution ratio depends on the ratio of the resin in the blend. Usually, it is about 0.05 to 0.5, preferably about 0.1 to 0.3. If it is smaller than this range, the viscosity of the blend may be high and coating may be difficult. On the other hand, if it is larger than this range, the viscosity may be low and the coated blend may be difficult to hold on the glass fiber nonwoven fabric.

  Next, the non-flammable core layer 18 is formed by impregnating the glass fiber nonwoven fabric, which is a base material, by coating the glass fiber nonwoven fabric with the diluted inorganic flame retardant and thermosetting resin blend. Is done. In this case, as this coating, for example, by applying with various ordinary coater devices such as a comma coater or a die coater, or by spraying with a spray device such as a spray or a nozzle, a shearing force is applied to the inorganic flame retardant. The substrate can be impregnated without loading. In the present invention, this is possible because, as described above, the inorganic flame retardant is blended with an appropriate material such as a melamine resin at an appropriate blending ratio, so that good handleability is ensured. That is.

  In this case, if the ratio of the inorganic flame retardant and thermosetting resin compound (solid content) to the glass fiber nonwoven fabric during coating is the impregnation rate, the impregnation rate depends on the basis weight of the glass fiber nonwoven fabric, but the weight The ratio is usually about 5 to 100 times, preferably about 10 to 60 times. This is because if it is less than the above lower limit value, it is difficult to maintain the required thickness and the surface finish may not be sufficient. Furthermore, the flame resistance decreases and the cost increases. On the other hand, if the above upper limit is exceeded, the flame resistance is good, but disadvantages such as being easily broken when handling the material before lamination are caused.

  In addition, the melamine resin which is a suitable example as a thermosetting resin is usually used in a molar ratio of formaldehyde to melamine (hereinafter simply referred to as a molar ratio) of 1.0 to 4.0. It is not limited to the range. However, from the viewpoint of storage stability as a resin varnish, it is preferably in the range of 1.0 to 2.0, and an acidic curing agent can be appropriately blended.

  On the other hand, aluminum hydroxide or magnesium hydroxide as an inorganic flame retardant is not particularly limited, but those having an average particle diameter of 1 to 100 μm can be preferably used. In addition, you may mix and use what has a large particle diameter and a small thing, and may close-pack.

  The nonflammable core layer 18 is formed by laminating a plurality of glass fiber nonwoven fabrics impregnated with the inorganic flame retardant and melamine resin formed as described above, as shown in FIG. For this reason, each glass fiber nonwoven fabric can be thinly formed, and it becomes easy to sufficiently impregnate each glass fiber nonwoven fabric, which is a base material, with a resin, using a resin. Unlike the case where it is infiltrated into a thick base material, it is possible to disperse the inorganic flame retardant thoroughly and uniformly in almost all cross sections of the non-combustible core layer by using a plurality of prepregs in which the inorganic flame retardant has sufficiently penetrated to the inside. Therefore, the incombustible effect can be enhanced. In addition, this nonflammable core layer 18 may also be provided with a reinforcing layer or the like as long as it has at least a glass fiber nonwoven fabric impregnated with a thermosetting resin blended with an inorganic flame retardant.

<2. Makeup layer>
On the other hand, the original material of the decorative layer 14 laminated on the plate material 12 as the surface layer 14 is not particularly limited. Also in the present invention, as with the normal decorative layer, thermosetting such as melamine resin is performed. After preparing a liquid varnish containing an adhesive resin and impregnating it into a sheet substrate such as gravure printing paper, the solvent is removed by heating and drying at about 50 ° C. to 60 ° C. to obtain a thermosetting resin. A semi-cured prepreg can be used. In this case, the method for impregnating the varnish into the paper substrate is not particularly limited, and a method using a kiss coater which is usually performed can be employed, and a method by dipping can also be employed.

In this case, the sheet substrate is not particularly limited, but preferably pulp, linter, synthetic fiber, glass fiber or the like can be used, and a basis weight of 40 to 150 g containing a pigment such as titanium oxide as necessary. / M ² sheet or paper.

  On the other hand, the thermosetting resin impregnated in the sheet substrate is not particularly limited. For example, the melamine resin can be used alone, but in order to further improve the heat resistance, the melamine resins 60 to 95 are used. It is possible to use impregnated sheets or paper impregnated with a formulation consisting of 40% by weight of aluminum hydroxide or magnesium hydroxide or silica by weight of 5 to 5%. The impregnation rate of this melamine resin or compound is usually 50 to 80% by weight with respect to the sheet or paper. As the melamine resin, a resin to which an ordinary modifier (for example, glycols) is added in an amount of 0.1 to 20% by weight can be used, and an acidic curing agent can be appropriately blended.

In addition, a sheet or paper having a basis weight of 10 to 50 g / m ² was impregnated with a melamine resin alone or a composition comprising melamine resin 60 to 95% by weight, aluminum hydroxide, magnesium hydroxide or silica 40 to 5% by weight. A combination of overlay impregnated papers can be laminated. The impregnation ratio of the melamine resin or the blend of this overlay impregnated paper is 50 to 80% by weight with respect to a normal sheet or paper. Moreover, this overlay impregnated paper can be combined with the surface of a decorative sheet or decorative paper not impregnated with resin.

The decorative layer 14A is laminated and integrated on the surface of the plate material, but it is also preferable to install it on the back side in order to prevent warpage. Both of these decorative layers 14A desirably have a thickness of 0.5 mm or less and an organic substance amount of 360 g / m ² or less.

<3. Processing to decorative board>
The plate material 12 and the decorative layer 14 </ b> A which is the surface layer 14 can be made into the decorative plate 10 by laminating and heating and pressing each layer, as in the case of the normal high-pressure resin decorative plate 10. . In this case, however, in the present invention, as shown in FIG. 1, the aluminum layer 16 is disposed outside the nonflammable core layer 18. Furthermore, as shown in FIG. 1, the aluminum layer 16 is desirably disposed on both sides of the nonflammable core layer 18.

  That is, in the present invention, as shown in FIG. 1, a plurality of aluminum layers 16 are stacked, and a plurality of nonflammable core layers 18 are inserted therebetween (in the order of the aluminum layer 16, the nonflammable core layer 18, and the aluminum layer 16). ), The surface layer 14 is superimposed on the surface side or both sides thereof, and these are heated and pressed to form the decorative board 10.

  In this case, since the fire is interrupted by the aluminum layer 16 located outside and the fire is prevented from being transmitted to the incombustible core layer 18, a sufficient amount of heat is generated from the incombustible core layer 18 even during heating. Can be suppressed. Similarly, even though the aluminum layer 16 and the nonflammable core layer 18 are provided, if the nonflammable core layer 18 is located outside, the outer nonflammable core layer 18 is ignited to increase the heat generation amount. Therefore, the X-ray shielding function cannot be exhibited. In addition, in this invention, if the aluminum layer 16 is arrange | positioned also on the outer side of the nonflammable core layer 18, the layer for providing another function can also be installed among these.

In addition, at the time of the heating and pressing molding as the decorative board 10, the plate material 12 and the decorative layer 14 are pressurized at about 60 to 100 kg / cm ² while being heated at a temperature at which the thermosetting resin is cured. It is preferable. At the time of molding, a mirror-finished plate, an embossed plate, an embossed film, or the like can be stacked to finish a surface such as a mirror finished or embossed finish.

  Next, an example of the decorative board 10 of the present invention and a comparative example for verifying the effect will be described. About the blend of the inorganic flame retardant and the thermosetting resin constituting the non-flammable core layer 18, the ratio of the thermosetting resin to the total amount of 100 wt% of the inorganic flame retardant and the thermosetting resin is 30 in Example 1. % By weight, 10% by weight in Example 2, 8% by weight in Comparative Example 1, and 32% by weight in Comparative Example 2, respectively. As thermosetting resins, melamine resin was used for Example 1 and Comparative Example 2, and phenol resin was used for Example 2 and Comparative Example 1. On the other hand, as the inorganic flame retardant, magnesium hydroxide was used for Example 1 and Comparative Example 2, and aluminum hydroxide was used for Example 2 and Comparative Example 1.

Example 1
A glass fiber nonwoven fabric having a basis weight of 75 g / m ² , a specific gravity of 0.23 g / cm ³ , and an organic binder amount of 11%, magnesium hydroxide (average particle diameter 10 μm) 70% by weight, melamine resin (molar ratio 1.5, resin) (B) Nonflammable core layer 18 having an impregnation rate of 20 times was obtained by coating a composition comprising 30 wt% (solid content: 50 wt%) (solid content conversion, hereinafter the same) and 15 parts by weight of water and alcohol. . On the other hand, (a) aluminum foil having a thickness of 0.3 mm was used as the aluminum layer 16. Then, (a) one sheet, (b) four sheets, and (a) one sheet are laminated in this order, followed by heating and pressing under conditions of 140 ° C. and 80 kg / cm ² for 20 minutes. A 1 mm sample (1) was obtained.

(Example 2)
In the same glass fiber nonwoven fabric as used in Example 1, 90% by weight of aluminum hydroxide (average particle size 10 μm) and 10% by weight of phenol resin (molar ratio 1.5, resin solid content 50% by weight) (solid content) (Conversion, the same applies hereinafter) and a composition comprising 15 parts by weight of water and alcohol was applied to obtain (b) an incombustible core layer 18 having an impregnation rate of 20 times. On the other hand, (a) aluminum foil having a thickness of 0.1 mm was used as the aluminum layer 16. And these were laminated | stacked in order of (a) 1 sheet, (b) 4 sheets, (a) 1 sheet | seat in the same way as Example 1, and heat-pressed for 20 minutes under the conditions of 140 degreeC and 80 kg / cm < ² >. Molding was performed to obtain a sample (2) having a thickness of 3.6 mm.

(Comparative Example 1)
The same glass fiber nonwoven fabric as used in Example 1, 92% by weight of aluminum hydroxide (average particle size 10 μm), 8% by weight of the same phenolic resin as used in Example 2, and 15 parts by weight of water and alcohol (B) Incombustible core layer 18 having an impregnation rate of 20 times was obtained. On the other hand, (a) aluminum foil having a thickness of 0.1 mm was used as the aluminum layer 16. And these are laminated | stacked in order of (a) 1 sheet, (b) 4 sheets, (a) 1 sheet | seat, and it shape | molds for 20 minutes on the conditions of 140 degreeC and 80 kg / cm < ² >, and thickness 3.7mm Sample (3) was obtained. That is, this Comparative Example 1 is a comparative example in which the weight percentage of the thermosetting resin is lower than the lower limit in the present invention, different from Example 2 only in the blending ratio of aluminum hydroxide and phenol resin.

(Comparative Example 2)
The same glass fiber nonwoven fabric as used in Example 1, 68% by weight of magnesium hydroxide (average particle size 10 μm), 32% by weight of the same melamine resin used in Example 1, and 15 parts by weight of water and alcohol (B) Incombustible core layer 18 having an impregnation rate of 20 times was obtained. On the other hand, (a) aluminum foil having a thickness of 0.3 mm was used as the aluminum layer 16. And these are laminated | stacked in order of (a) 1 sheet, (b) 4 sheets, (a) 1 sheet | seat, and it shape | molds for 20 minutes on the conditions of 140 degreeC and 80 kg / cm < ² >, and thickness 4.0mm Sample (4) was obtained. That is, this comparative example 2 is a comparative example in which the weight percentage of the thermosetting resin exceeds the upper limit in the present invention, differing from the first example only in the blending ratio of magnesium hydroxide and melamine resin.

  The characteristics of the samples (1) to (4) obtained in the above examples were evaluated, and the results are shown in Table 1.

(Test method)
1. Non-combustibility test The Japanese Standard Building Laboratory's Operation Standards “Fireproof and Fireproof Performance Test / Evaluation Procedure Method” 4.10 (2) ii) 4.10.2 Exothermic test / evaluation method and 4.10. The gas toxicity test / evaluation method of 3 was used. The above items of the business standard "Fireproof and Fireproof Performance Test / Evaluation Business Method" describe performance evaluation methods related to certification based on the provisions of Article 2, Item 9 (non-combustible materials) of the Building Standards Act.
2. Interlaminar strength Conforms to the JAS plane tensile test.

  As is clear from the results shown in Table 1 above, the samples (1) and (2) obtained in Examples 1 and 2 are appropriately equipped so that the nonflammability meets the standards and the like. On the other hand, the sample (3) obtained in Comparative Example 1 has sufficient incombustibility but low interlaminar strength, and there is a problem in terms of strength when the blending ratio of the thermosetting resin is less than the range of the present invention. Is proven to remain. Moreover, the sample (4) obtained in Comparative Example 2 could not clear the standard for nonflammability. From this, it was confirmed that when the blending ratio of the inorganic flame retardant is less than the range of the present invention, the incombustibility cannot be cleared.

  The decorative board according to the present invention has both sufficient nonflammability and interlayer strength. Furthermore, since the decorative layer can use the same decorative layer sheet material as a conventional decorative plate, it can be freely selected from abundant color patterns and is subject to restrictions on nonflammable materials in public facilities, etc. It can be widely applied to applications.

DESCRIPTION OF SYMBOLS 10 Decorative plate 12 Material for plate material 14 Surface layer 14A Decorative layer 16 Aluminum layer 18 Nonflammable core layer

Claims (17)

In the plate material comprising a surface layer laminated on the surface to constitute a plate material, the plate material is composed of a laminate including at least an aluminum layer and a nonflammable core layer, and the nonflammable core layer is a melamine resin. And a thermosetting resin such as phenol resin and aluminum hydroxide, magnesium hydroxide or other inorganic flame retardant, wherein the aluminum layer is disposed outside the nonflammable core layer. Material for board. It is a board | plate material as described in Claim 1, Comprising: The said aluminum layer is arrange | positioned at the both surfaces side of the said nonflammable core layer, The board | plate material characterized by the above-mentioned. It is the material for board | plate materials as described in any one of Claim 1 or Claim 2, Comprising: The said nonflammable core layer consists of the glass fiber nonwoven fabric impregnated with the said thermosetting resin and the said inorganic flame retardant, The said When the total amount of the thermosetting resin and the inorganic flame retardant is 100% by weight, the thermosetting resin and the inorganic flame retardant 90 to 90% of the inorganic flame retardant with respect to 10 to 30% by weight of the thermosetting resin. A board material characterized by being blended in a proportion of 70% by weight. It is a board | plate material as described in Claim 3, Comprising: The basic weight of the said glass fiber nonwoven fabric is 30-150 g / cm < ² >, The board | plate material characterized by the above-mentioned. The plate material according to any one of claims 1 to 4, wherein the non-combustible core layer is formed by laminating a plurality of glass fiber nonwoven fabrics impregnated with the thermosetting resin and the inorganic flame retardant. A plate material characterized by being formed. The plate material according to any one of claims 1 to 5, wherein the aluminum layer is made of an aluminum foil or an aluminum plate. It is a board | plate material as described in any one of Claims 1 thru | or 6, Comprising: The said aluminum layer has thickness of 0.1 mm-0.3 mm, The board | plate material characterized by the above-mentioned. A decorative board, wherein a decorative layer as a surface layer is laminated by heating and pressing on the design surface side of the material for a plate material according to any one of claims 1 to 7. The decorative board according to claim 8, wherein a core material layer is further laminated on a surface opposite to the design surface side of the plate material. In a method for producing a plate material comprising a surface layer laminated on the surface, at least an aluminum layer, a melamine resin, a phenol resin or other thermosetting resin, and aluminum hydroxide, magnesium hydroxide or other inorganic flame retardant A non-combustible core layer comprising: an aluminum layer disposed outside the non-combustible core layer, and laminated. It is a manufacturing method of the board | plate material as described in Claim 10, Comprising: The said aluminum layer is arrange | positioned and laminated | stacked on the both surfaces side of the said nonflammable core layer, The manufacturing method of the board | plate material. The method for producing a plate material according to claim 10 or 11, wherein the non-combustible material is impregnated with the thermosetting resin and the inorganic flame retardant in a glass fiber nonwoven fabric as a base material. When the total amount of the thermosetting resin and the inorganic flame retardant is 100% by weight, the thermosetting resin 10 to 30 is formed. The manufacturing method of the material for board | plate materials characterized by mix | blending in the ratio of said inorganic flame retardant 90 to 70 weight% with respect to weight%. It is a manufacturing method of the material for board | plate materials described in Claim 12, Comprising: The board | plate material characterized by apply | coating and impregnating the said thermosetting resin and the said inorganic flame retardant to the glass fiber nonwoven fabric which is the said base material. Method of manufacturing materials. It is a manufacturing method of the board | plate material as described in any one of Claim 12 or Claim 13, Comprising: Glass fiber nonwoven fabric whose basis weight is 30-150 g / cm < ² > is used, The board | plate material of the board | substrate material characterized by the above-mentioned Production method. The method for producing a plate material according to any one of claims 10 to 14, wherein a plurality of glass fiber nonwoven fabrics impregnated with the thermosetting resin and the inorganic flame retardant are laminated to form the nonflammable material. A method for producing a plate material, comprising forming a core layer. The method for producing a plate material according to any one of claims 10 to 15, wherein the aluminum layer is formed from an aluminum foil or an aluminum plate. The method for manufacturing a plate material according to any one of claims 10 to 16, wherein the aluminum layer is formed to a thickness of 0.1 mm to 0.3 mm. Production method.

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