JP2012021102A - Flame retardant slurry, and fire-proofed decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative plate having a fire-proof capability, also excellent in strength, having a small dimensional change and further excellent in close adhesion by increasing the amount of an organic resin component contained in a prepreg used for a core layer up to an extent without causing interlayer peeling.SOLUTION: The flame retardant slurry containing the organic resin component as a binder component, an organic phosphorus compound and a non-water-containing inorganic material is used. The decorative sheet is obtained by using the prepreg obtained by impregnating a fiber sheet with the flame retardant slurry containing the organic resin component as the binder component, the organic phosphorus compound and the non-water-containing inorganic material and drying, as the core layer, arranging a thermosetting resin-impregnated paper obtained by impregnating decorative paper for the decorative plate with resin liquid consisting of the thermosetting resin and drying, at surface and reverse surface, and hot press-molding.

Description

  The present invention relates to a flame retardant slurry and an incombustible decorative board.

  Conventionally, a decorative board provided with functions such as fire prevention and non-flammability is known, and a resin-impregnated decorative paper in which a decorative liquid for a decorative board is impregnated with a resin liquid mainly composed of a thermosetting resin, and an inorganic fiber A prepreg impregnated with a slurry containing a metal hydroxide such as aluminum hydroxide or magnesium hydroxide as a binder component with phenol resin or melamine resin as a binder is used as a core layer, and both are laminated and hot-press molded.

JP-T-2004-51695 JP 2004-358814 A

  However, the prepreg used in the core layer for the nonflammable decorative board has a limit in the amount of the organic resin component as the binder component for the purpose of ensuring nonflammability, and the nonflammability is poor when the organic resin content is large. When the amount of the organic resin is small, adhesion between the prepregs is poor and delamination may occur.

  In addition, metal hydroxides such as aluminum hydroxide and magnesium hydroxide impart incombustibility due to the endothermic action when releasing crystal water, but since the incombustibility is small with a small amount of compounding, it is not suitable for organic resin components. Compared to this, a large amount must be blended, resulting in inferior machinability and workability, such as a decrease in the adhesion of the core layer and damage to the blade.

  Furthermore, the use of halogen-based flame retardants has been suppressed by recent regulations from the viewpoint of environmental protection.

  The present invention has been studied in view of such a situation, and is a non-combustible decorative board in which a decorative layer is formed on at least one side of a core layer, and the core layer includes an organic resin component as a binder component on a fiber sheet, A nonflammable decorative board, which is a prepreg impregnated and dried with a flame retardant composition containing an organic phosphorus compound and a non-hydrous inorganic substance. As a result, it has nonflammable performance, excellent strength, small dimensional change, and further increases the organic resin content contained in the prepreg used for the core layer to such an extent that delamination does not occur, thereby improving adhesion. It is something to try.

  The organophosphorus compound blended in the flame retardant composition of the present invention has a plasticizing effect, whereby the flowability of the binder component is improved, and a nonflammable decorative board having excellent interlayer adhesion even with a low amount of resin. Phosphoric acid esters also have a flame retardant effect and can impart incombustible performance. Hereinafter, the present invention will be described in detail.

  The flame retardant slurry of the present invention contains an organic resin component as a binder component, an organic phosphorus compound, and a non-hydrous inorganic substance. As organic resins, amino-formaldehyde resins, phenol-formaldehyde resins and other thermosetting resins can be suitably used because they have excellent physical properties such as heat resistance and dimensional changes. Also preferred are phenol-formaldehyde resins.

  The amino-formaldehyde resin is obtained by reacting an amino compound such as melamine, urea, benzoguanamine, acetoguanamine and formaldehyde.

  Phenol-formaldehyde resin is composed of 1 to 3 moles of formaldehyde with respect to 1 mole of phenolic hydroxyl groups of phenols such as phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, and bisphenol F. It can be obtained by reacting under a basic catalyst such as sodium oxide or triethylamine.

  The organophosphorus compound has a plasticizing effect and a flame retardant effect, and is an extremely important constituent in the present invention. When the organophosphorus compound receives heat from combustion, it undergoes a dehydration action by phosphorous and becomes a carbonized layer. In addition, it reacts with the generated self-condensed water in a heated environment to generate gas, and acts as a dehydration catalyst, and also has a function of forming an incombustible inorganic phosphate coating.

  Specific examples of the compound include trimethyl phosphate, triethyl phosphate, tripropyl phosphate, tributyl phosphate, tripentyl phosphate, trihexyl phosphate, tricyclohexyl phosphate, triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate. Phosphophenanthrene compounds such as phosphate esters such as dimethyl ethyl phosphate, methyl dibutyl phosphate, ethyl dipropyl phosphate, hydroxyphenyl diphenyl phosphate, and 9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide Etc. Among these, the flame retardant effect of phosphate esters such as triphenyl phosphate, tricresyl phosphate and various aromatic condensed phosphates having a phosphorus content of 7 to 30% by weight is remarkable. The organophosphorus compound is blended in an amount of 0.14 to 0.5 parts by weight based on 1 part by weight of the solid content of the organic resin component. If the lower limit is not reached, the flame retardancy and plasticizing effect are small, and if the upper limit is exceeded, the solubility in the slurry is limited and the resin tends to aggregate.

  Examples of the non-hydrated inorganic substance include calcium carbonate, talc, fly ash, silica and the like, and calcium carbonate is particularly preferable. There is no restriction | limiting in particular as calcium carbonate, Heavy calcium carbonate, light calcium carbonate (precipitation calcium carbonate), etc. can be used. Heavy calcium carbonate having an average particle size of 0.05 to 20 μm, more preferably 1 to 10 μm is preferable. If the lower limit is not reached, secondary agglomeration tends to occur and agglomeration tends to occur, and the impregnation suitability tends to deteriorate. The surface of the decorative resin decorative board is not smooth, resulting in poor appearance. Light calcium carbonate refers to calcium carbonate that is chemically produced by firing limestone, and heavy calcium carbonate refers to finely powdered calcium carbonate prepared by dry or wet pulverization of white crystalline limestone.

  The blending ratio of the organic resin component and calcium carbonate is preferably 1:18 to 26 in terms of solid content. If the calcium carbonate is less than the lower limit, the nonflammability is not satisfied, and further the warp of the decorative board increases. If the upper limit is exceeded, the water resistance and strength of the decorative board will decrease.

The base material of the core layer impregnated with the flame retardant slurry containing the organic resin component, the organic phosphorus compound, and the non-hydrous inorganic substance as the binder component is a woven or non-woven fabric of inorganic fibers, , Glass fiber, rock wool, carbon fiber, etc., and the basis weight of the substrate is preferably in the range of 10 to ²⁰⁰ g / m ² , and in particular, it is preferable to use a glass fiber nonwoven fabric excellent in slurry impregnation. .

The impregnation rate of the slurry to the base material is preferably 500 to 3000% by the calculation method represented by the formula 1, and when the impregnation rate exceeds the upper limit, the solid content drops off and is difficult to handle, and if the lower limit is not reached Delamination easily occurs.

The content of the organic resin component in the prepreg is preferably 3 to 5% by the calculation method shown in Formula 2, and if the lower limit is not reached, the strength and adhesion tend to be inferior, and if the upper limit is exceeded, nonflammability is satisfied. Absent.

The incombustible decorative board of the present invention is a flat plate in which a plurality of prepregs obtained by impregnating a slurry into a substrate and drying, a resin-impregnated decorative paper as a decorative layer, and a resin-impregnated surface paper as necessary are laminated. It can be obtained by hot pressing with a press or continuous press. The hot pressure conditions may be a temperature of 120 to 140 ° C. and a pressure of 40 to 70 kgf / cm ² .

The resin-impregnated decorative paper is obtained by impregnating a decorative liquid for decorative board of 80 to 160 g / m ^{2 with} a resin liquid composed of a thermosetting resin and drying it. As the thermosetting resin, the amino-formaldehyde described above is used. Resins are preferably used because of their excellent heat resistance and wear resistance.

The resin-impregnated surface paper is used for the purpose of improving the abrasion resistance when printing paper is used as decorative paper, and is made of a thermosetting resin on the surface paper that becomes transparent after impregnation of 20 to 40 g / m ^2. As the thermosetting resin, an amino-formaldehyde resin is preferably used as in the case of decorative paper.

  EXAMPLES Hereinafter, although an Example is given and demonstrated in detail, this invention is shown more concretely and is not specifically limited. In addition, the part in an Example and a comparative example shows solid content.

An impregnation ratio shown in Equation 1 is obtained by blending 1300 parts of calcium carbonate having an average particle diameter of 8 μm and 10 parts of triphenyl phosphate with 50 parts of phenol-formaldehyde resin into a glass fiber nonwoven fabric having a core layer of 80 g / m ^2. A prepreg was obtained by impregnation to 1200%.
In this case, the weight of the solid content after impregnation with the slurry is 1040 g / m ² from Equation ¹ , and the slurry content is 960 g / m ² by subtracting the weight of the glass fiber nonwoven fabric from 1040 g / m ² .
Further, 960 g / ^{m 2,} the phenol - 50 parts formaldehyde resin, 1300 parts of calcium carbonate, than to include triphenyl phosphate, 10 parts of the organic resin component is 35 g / ^{m 2,} calcium carbonate is 915 g / ^{m 2.}
Therefore, the content (%) of the organic resin component in the prepreg calculated from Equation 2 is 3.4% by 35 / (80 + 35 + 915) × 100.
A plain pattern decorative paper having a decorative layer basis weight of 80 g / m ² was impregnated with a melamine-formaldehyde resin so that the impregnation ratio represented by Formula 1 was 130% to obtain a melamine resin-impregnated decorative paper.
Laminate one sheet of melamine resin impregnated decorative paper, four sheets of prepreg, and one sheet of melamine resin impregnated decorative paper in order from the bottom of the thermosetting resin decorative board, and use a flat finish plate at 140 ° C., 70 kg / cm ² , The incombustible decorative board of Example 1 was obtained by hot pressing under the condition of 90 minutes.

  The flame retardant slurry shown in Table 1 was impregnated and dried in the same manner as in Example 1, laminated, and hot-pressed.

  The flame retardant slurry shown in Table 1 was impregnated and dried in the same manner as in Example 1, laminated, and hot-pressed.

Comparative Example 1
The composition shown in Table 1 was impregnated and dried in the same manner as in Example 1, laminated, and hot-pressed.

Comparative Example 2
The composition shown in Table 1 was impregnated and dried in the same manner as in Example 1, laminated, and hot-pressed.

Comparative Example 3
The composition shown in Table 1 was impregnated and dried in the same manner as in Example 1, laminated, and hot-pressed.

The evaluation method was as follows.
Non-flammability: The total calorific value is 8 MJ / m ² or less and the maximum heat generation rate does not exceed 200 kW / m ² for 10 seconds or more in the exothermic test / evaluation method of a 20 minute test using a corn calorimeter according to ISO 5660. The case is marked with ○.
Adhesiveness: After immersion in boiling water for 2 hours, the case where there was no peeling of the decorative layer and no significant crack between the core layer and the decorative layer was accepted, and the case where there was peeling and cracking was rejected. The above tests were performed, and those that passed both were marked with ◯, and those that were not, with x.

FIG. 2 is a structural cross-sectional view of the incombustible decorative board of the present invention.

2 Resin-impregnated decorative paper layer 3 Prepreg 6 Non-combustible decorative board

Claims (2)

A flame retardant slurry containing an organic resin component as a binder component, an organic phosphorus compound, and a non-hydrous inorganic substance. A non-combustible decorative board having a decorative layer formed on at least one side of a core layer, wherein the core layer is a prepreg impregnated with the slurry according to claim 1 and dried. Board.