JP2012210794A - Non-combustible decorative plate - Google Patents
Non-combustible decorative plate Download PDFInfo
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Abstract
Description
本発明は、熱圧成型により表面凹凸形状を施した不燃化粧板に関する。 The present invention relates to a non-combustible decorative board having a surface uneven shape formed by hot pressing.
浮造り調等の表面凹凸形状を施した化粧板は、光線により陰影が発生することから視覚的な意匠性に優れるうえ、物理的な凹凸による触感も楽しめることから、建築物の内装用途に広く用いられている。 A decorative board with surface irregularities, such as a float-like tone, has excellent visual design due to the occurrence of shadows due to light rays, and can also be enjoyed by physical irregularities, so it is widely used for interior decoration of buildings. It is used.
近年、建築物の壁面や天井等の住宅内装等に使用される化粧板には、火災等が生じた際の安全性確保のため不燃性の要請が高まっており、浮造り調の化粧板においても不燃性の確保が求められている。浮造り調の不燃性化粧板としては、例えば、オレフィン系シートを基材とした化粧シート（特許文献１参照）を無機基材にラミネートした化粧板が存在している。しかし、当該不燃化粧板は、表層の化粧シートに樹脂フィルム基材が使用されていることから、高度な不燃性の確保が得られにくく、また、凹凸が浅いことから意匠性も劣るものであった。 In recent years, there has been an increasing demand for non-combustible decorative panels used for interior decorations such as wall surfaces and ceilings of buildings to ensure safety in the event of a fire. However, ensuring nonflammability is also required. As a non-combustible decorative board having a floating tone, for example, there is a decorative board obtained by laminating a decorative sheet (see Patent Document 1) having an olefin-based sheet as a base material on an inorganic base material. However, since the non-combustible decorative board uses a resin film substrate for the decorative sheet of the surface layer, it is difficult to ensure a high degree of non-combustibility, and the design is poor because the unevenness is shallow. It was.
化粧シートに樹脂フィルム基材を使用せず、紙質基材を使用した浮造り調化粧板としては、例えば、印刷を施した薄紙を合板に接着後、エンボスロールにより凹凸を形成した化粧板が開示されている（特許文献２参照）。しかし、当該化粧板は耐汚染性に劣り、特に表面凹凸が設けられた浮造り調の化粧板とすると当該汚染性の問題が顕著に生じるものであった。また、紙質基材のみからなる化粧シートを使用すると、熱圧プレスによる凹凸形成の際に凹凸形状への追従性に難があり、表面の意匠層として木目模様等の印刷柄を施した場合などには、当該印刷柄が凹凸形状に追従し難い場合があった。 As a decorative decorative board that uses a paper base material without using a resin film base material for the decorative sheet, for example, a decorative board in which unevenness is formed by embossing rolls after bonding printed thin paper to plywood is disclosed. (See Patent Document 2). However, the decorative board is inferior in stain resistance. In particular, the problem of contamination is prominent when it is made of a float-like decorative board provided with surface irregularities. In addition, if a decorative sheet consisting only of a paper-based substrate is used, it is difficult to follow the uneven shape when forming unevenness by hot-pressing, and when a printed pattern such as a wood grain pattern is applied as a design layer on the surface, etc. In some cases, the printed pattern is difficult to follow the uneven shape.
本発明が解決しようとする課題は、良好な不燃性と意匠性を有し、かつ凹凸加工時のシート折れや屈曲部への汚染物質残留により汚染の生じやすい凹凸表面の耐汚染性に優れた不燃化粧板を提供することにある。 The problem to be solved by the present invention has excellent non-flammability and design, and excellent anti-contamination resistance of the uneven surface, which is likely to be contaminated due to sheet folding during uneven processing and residual contaminants on the bent portion. It is to provide a non-combustible decorative board.
本発明においては、金属薄膜層を有する不燃性基材の一面に化粧シートが設けられた不燃化粧板の化粧シート側表面に、熱圧成型により凹凸形状を施した不燃化粧板であって、前記不燃性基材が、化粧シートが設けられる表層に金属薄膜層を有する不燃性基材であり、前記化粧シートが、紙質層とポリオレフィン系樹脂フィルム層とを有する積層シート上に意匠層が設けられた化粧シートであり、前記不燃性基材上の有機物の総量が１８０ｇ／ｍ２以下である不燃化粧板により、上記課題を解決できる。 In the present invention, the non-combustible decorative board is provided with a concave-convex shape by hot pressing on the decorative sheet side surface of the non-combustible decorative board provided with a decorative sheet on one surface of the non-combustible base material having a metal thin film layer, The non-combustible substrate is a non-combustible substrate having a metal thin film layer on a surface layer on which a decorative sheet is provided, and the decorative sheet is provided with a design layer on a laminated sheet having a paper layer and a polyolefin resin film layer. The above-mentioned problem can be solved by a non-combustible decorative sheet that is a decorative sheet and has a total amount of organic matter on the non-combustible substrate of 180 g / m 2 or less.
本発明の不燃化粧板は、凹凸加工に際しても凹凸形状への好適な追従性を有し、高い意匠性を備えながら、汚染物質の滞留しやすい凹凸加工部でも十分な耐汚染性を保持できる。また、良好な不燃性を有することから建築基準法の定める不燃建材に適用できる。 The incombustible decorative board of the present invention has a suitable followability to the uneven shape even during uneven processing, and can maintain sufficient stain resistance even in an uneven processed portion where contaminants tend to stay while having high design properties. Moreover, since it has good nonflammability, it can be applied to nonflammable building materials defined by the Building Standards Act.
本発明の不燃化粧板は、不燃性基材の一面に化粧シートが設けられた不燃化粧板の化粧シート側表面に、熱圧成型により凹凸形状を施した表面凹凸形状を有する不燃化粧板であり、不燃性基材として表層に金属薄膜層を有する不燃性基材を使用し、化粧シートが、紙質層と樹脂フィルム層とを有する積層シート上に意匠層が設けられた化粧シートであり、有機物の総量が１８０ｇ／ｍ２以下の不燃化粧板である。 The non-combustible decorative board of the present invention is a non-combustible decorative board having a concavo-convex shape obtained by applying a concavo-convex shape by hot-pressure molding on the decorative sheet side surface of the non-combustible decorative board provided with a decorative sheet on one surface of the non-combustible substrate. The decorative sheet is a decorative sheet provided with a design layer on a laminated sheet having a paper layer and a resin film layer, using a non-combustible base material having a metal thin film layer as a non-combustible base material. Is a non-combustible decorative board having a total amount of 180 g / m 2 or less.
［化粧シート］
本発明に使用する化粧シートは、基材となる紙質層と、汚染物質からの保護層である樹脂フィルム層と、意匠性を担う意匠層とを有する。
[Decorative sheet]
The decorative sheet used in the present invention has a paper layer as a base material, a resin film layer that is a protective layer from contaminants, and a design layer that bears design properties.
紙質層としては、壁紙等の化粧シートに一般的に使用される紙質基材を適宜使用でき、例えば、上質紙、薄用紙、強化紙、樹脂含浸紙等を例示できる。また、上記の紙に、水性ラテックス・水性アクリル等の樹脂を含浸させたラテックス含浸紙であってもよい。これらのなかでもラテックス含浸紙は、紙間強度や耐水性に優れ、また湿気にも強いため好ましく使用できる。 As the paper layer, a paper base generally used for decorative sheets such as wallpaper can be used as appropriate, and examples thereof include fine paper, thin paper, reinforced paper, and resin-impregnated paper. Further, it may be a latex-impregnated paper obtained by impregnating the above paper with a resin such as aqueous latex or aqueous acrylic. Among these, latex-impregnated paper can be preferably used because it is excellent in inter-paper strength and water resistance and is also resistant to moisture.
また、湿度に対する寸法安定性を向上させるために、ガラスファイバーやカーボン繊維等の無機質繊維や疎水性の合成繊維を含有するものや、難燃性を向上させるために、スルファミン酸グアニジン、リン酸グアジニン等の難燃剤を含有するものも好ましく使用できる。 In addition, those containing inorganic fibers such as glass fibers and carbon fibers and hydrophobic synthetic fibers to improve dimensional stability against humidity, and guanidine sulfamate and guanidine phosphate to improve flame retardancy Those containing a flame retardant such as can also be preferably used.
本発明に使用する樹脂フィルム層には紙質層と積層できる各種樹脂を使用することができ、意匠層の印刷に適した樹脂を好適に用いることができる。樹脂フィルムに使用できる樹脂としては、例えば、ポリエチレン、ポリプロピレン等のポリオレフィン系樹脂、ポリエチレンテレフタレート等のポリエステル系樹脂、ポリエチレンとポリプロピレンの共重合樹脂、ＡＢＳ樹脂（アクリロニトリル−ブタジエン−スチレン共重合樹脂）等を好ましく例示できる。なかでも、印刷時に高温にさらされる場合には、比較的耐熱性の高いポリエチレン系樹脂を好ましく使用でき、ポリエチレンテレフタレートがより好ましい。これら樹脂フィルムには他の層との密着性を向上させるため、プライマー処理やコロナ処理などの表面処理が施されていてもよい。 Various resins that can be laminated with the paper layer can be used for the resin film layer used in the present invention, and a resin suitable for printing on the design layer can be suitably used. Examples of the resin that can be used for the resin film include polyolefin resins such as polyethylene and polypropylene, polyester resins such as polyethylene terephthalate, copolymer resins of polyethylene and polypropylene, and ABS resins (acrylonitrile-butadiene-styrene copolymer resins). Preferred examples can be given. Especially, when exposed to high temperature at the time of printing, a polyethylene-type resin with comparatively high heat resistance can be used preferably, and a polyethylene terephthalate is more preferable. These resin films may be subjected to surface treatment such as primer treatment or corona treatment in order to improve adhesion with other layers.
本発明に使用する化粧シートは、使用する態様に応じて各種の着色や模様の意匠層が設けられる。当該意匠層は、簡易に意匠層を形成できることから印刷による印刷層であることが好ましい。当該印刷層は、グラビア印刷、オフセット印刷、シルクスクリーン印刷、転写印刷、インクジェット印刷等の任意の方法により形成できる。なかでも、グラビア印刷とすることで、高い意匠性と優れた生産性を両立できる。 The decorative sheet used in the present invention is provided with various colored and patterned design layers according to the mode of use. The design layer is preferably a printed layer by printing because the design layer can be easily formed. The printing layer can be formed by any method such as gravure printing, offset printing, silk screen printing, transfer printing, and ink jet printing. In particular, by using gravure printing, both high designability and excellent productivity can be achieved.
本発明に使用する化粧シートは、少なくとも上記の紙質層、樹脂フィルム層及び意匠層が積層された複層構造を有する。積層順は特に制限されるものではないが、熱圧形成時の凹凸形状追従性や、意匠性を得やすく、良好な耐汚染性を得やすいことから、紙質層上に樹脂フィルム層が積層され、当該樹脂フィルム上に意匠層が設けられた構成が好ましい。当該構成においては、紙質層と樹脂フィルム層とがラミネートされた構成であると層間の密着性が得やすくなる。 The decorative sheet used in the present invention has a multilayer structure in which at least the paper layer, the resin film layer, and the design layer are laminated. The order of lamination is not particularly limited, but the resin film layer is laminated on the paper layer because it is easy to obtain uneven shape conformability during hot pressure formation and design, and it is easy to obtain good contamination resistance. A configuration in which a design layer is provided on the resin film is preferable. In this configuration, when the paper layer and the resin film layer are laminated, the adhesion between the layers is easily obtained.
また、化粧シートの表層には、耐擦傷性や、耐汚染性を付与するために、アクリルウレタン樹脂等のトップコートが設けられていることも好ましい。当該トップコートには熱硬化型やＵＶ硬化型、ＥＢ硬化型などの各種の硬化性樹脂が採用できる。 Moreover, it is also preferable that the surface layer of the decorative sheet is provided with a top coat such as an acrylic urethane resin in order to impart scratch resistance and stain resistance. Various curable resins such as a thermosetting type, a UV curable type, and an EB curable type can be used for the top coat.
本発明に使用する化粧シート及び化粧シートを構成する各層の厚さや坪量は、良好な意匠性を実現しつつ後述する有機物総量を越えない範囲で適宜調整すればよいが、樹脂フィルム層の坪量は１００μｍ以下とすることが好ましく、９０μｍいかであることが更に好ましく、より好ましくは１０〜５０μｍである。樹脂フィルム層を当該範囲とすることで、有機物総量が多くなりすぎず好適な耐汚染性と不燃性を確保しやすくなる。また紙質層の坪量は３０〜１００ｇ／ｍ２程度、印刷層の坪量は１０〜４０ｇ／ｍ２程度とすることが好ましい。また、化粧シートとしては、坪量を７０〜１８０ｇ／ｍ２程度とすることで良好な追従性や意匠性、不燃性を得やすくなる。 The thickness and basis weight of each layer constituting the decorative sheet and the decorative sheet used in the present invention may be appropriately adjusted within a range not exceeding the total amount of organic matter described later while realizing good design properties. The amount is preferably 100 μm or less, more preferably 90 μm, and more preferably 10 to 50 μm. By setting the resin film layer in this range, the total amount of organic substances does not increase too much, and it becomes easy to ensure suitable stain resistance and nonflammability. The basis weight of the paper quality layer 30 to 100 g / m 2 approximately, the basis weight of the print layer is preferably set to 10 to 40 g / m 2 approximately. Moreover, as a decorative sheet, it becomes easy to obtain favorable followability, designability, and nonflammability by setting the basis weight to about 70 to 180 g / m 2 .
［不燃性基材］
本発明に使用する不燃性基材は、表層に金属薄膜層を有する不燃性基板であり、好適な不燃性を実現しやすいことから、無機質基材上に金属薄膜層を有する不燃性基材を好ましく使用できる。
[Non-combustible substrate]
The non-combustible substrate used in the present invention is a non-combustible substrate having a metal thin film layer on the surface layer, and it is easy to realize a suitable non-combustibility. Therefore, a non-combustible substrate having a metal thin film layer on an inorganic substrate is used. It can be preferably used.
無機質基材としては、火山性ガラス複層板又はケイ酸カルシウム板を好ましく使用できる。これら基材は難燃性が高いため良好な不燃性を有する不燃化粧板を実現しやすくなる。また、適度な柔軟性を有するため、エンボス加工による凹凸の付与に好適である。これら無機質基材の厚みは材質にもよるが、通常２〜１５ｍｍであり、発熱性や取り回し性、などの観点から２〜９ｍｍのものが好ましい。また、これら無機質基材には、他の層との密着性を高めるために、シーラー塗布やサンダー等の表面処理が行われていても良い。 As the inorganic substrate, a volcanic glass multilayer plate or a calcium silicate plate can be preferably used. Since these base materials have high flame retardancy, it becomes easy to realize a non-combustible decorative board having good non-combustibility. Moreover, since it has moderate softness | flexibility, it is suitable for provision of the unevenness | corrugation by embossing. Although the thickness of these inorganic base materials depends on the material, it is usually 2 to 15 mm, and preferably 2 to 9 mm from the viewpoint of exothermic property and handling property. In addition, these inorganic base materials may be subjected to surface treatment such as sealer coating or sanding in order to enhance adhesion with other layers.
本発明に使用する不燃性基材は表層に金属薄膜層を設けることで、凹凸加工時の基材層や化粧シート層の復元を抑制し、良好な意匠性を実現できる。当該金属薄膜層としては、例えば、アルミニウム箔、鉄箔、ステンレス箔、銅箔等の金属箔を好ましく使用できる。なかでも、アルミニウム箔は入手容易であり、伸縮性にすぐれることから、特に好ましく使用できる。金属薄膜層の厚さは凹凸成型性や不燃性を実現できる範囲であれば特に制限されないが５〜１５μｍであることが好ましい。 By providing a metal thin film layer on the surface layer of the incombustible base material used in the present invention, it is possible to suppress the restoration of the base material layer and the decorative sheet layer at the time of uneven processing, and to realize good design properties. As the said metal thin film layer, metal foil, such as aluminum foil, iron foil, stainless steel foil, copper foil, can be used preferably, for example. Among these, aluminum foil is particularly easily used because it is easily available and has excellent stretchability. The thickness of the metal thin film layer is not particularly limited as long as it can achieve uneven moldability and nonflammability, but is preferably 5 to 15 μm.
金属薄膜層は、上記無機質基材の化粧シートが設けられる側の表面に設けられていればよいが、無機質基材の化粧シートが設けられる側の他面にも積層すると、湿度や温度による基材の変形を抑制できるため、無機質基材の両面に金属薄膜層を有することも好ましい。また、当該化粧シートが設けられる側の他面側には、反り防止を目的として、防湿紙、フィルム、金属薄膜層などを積層しても良い。 The metal thin film layer only needs to be provided on the surface on the side on which the decorative sheet of the inorganic base material is provided. Since deformation of the material can be suppressed, it is also preferable to have metal thin film layers on both sides of the inorganic base material. Further, moisture-proof paper, a film, a metal thin film layer, or the like may be laminated on the other surface side on which the decorative sheet is provided for the purpose of preventing warpage.
不燃化粧板としての性能を確保するため、本発明で使用する化粧板基材は、不燃性基材全体として、後述する燃焼試験での発熱量が４ＭＪ以下であることが望ましい。 In order to ensure the performance as a non-combustible decorative board, it is desirable that the decorative board substrate used in the present invention has a calorific value of 4 MJ or less in a combustion test described later as a whole non-combustible base material.
［不燃化粧板］
本発明の不燃化粧板は、上記不燃性基材の金属薄膜層側表面に、上記構成の化粧シートを積層し、不燃性基材上の有機物量を１８０ｇ／ｍ２とした化粧板に対し、その表面に熱圧成型により凹凸形状を付与した不燃化粧板である。本発明においては、金属薄膜層を有する不燃性基材を使用し、当該不燃性基材に積層する化粧シートを紙質基材と樹脂フィルム基材の複層構成とし、有機物量を一定量以下とすることで、凹凸形状への好適な追従性と意匠性を実現でき、化粧板表面の耐汚染性を確保しながら、不燃性能を確保できる。
[Non-combustible decorative board]
The incombustible decorative board of the present invention is a laminate in which the decorative sheet having the above-described configuration is laminated on the surface of the incombustible base material on the metal thin film layer side, and the decorative board has an organic substance amount of 180 g / m 2 on the incombustible base material. It is a non-combustible decorative board having a concavo-convex shape formed on its surface by hot-pressure molding. In the present invention, a non-combustible base material having a metal thin film layer is used, and the decorative sheet laminated on the non-combustible base material has a multilayer structure of a paper-based base material and a resin film base material, and the amount of organic matter is a certain amount or less. By doing so, it is possible to achieve suitable followability and design to the uneven shape, and to ensure non-combustibility while ensuring the stain resistance of the decorative plate surface.
不燃性基材と化粧シートとの積層はラミネートによる積層を好ましく使用でき、ラミネート手法としては、酢酸ビニル系、エチレン酢ビ共重合系水性ビニルウレタン系或いは反応性ホットメルト接着剤等の基材塗布またはシート塗布による手法が使用できる。 Lamination of the non-flammable substrate and the decorative sheet can be preferably performed by lamination. As a lamination method, vinyl acetate-based, ethylene vinyl acetate copolymer-based aqueous vinyl urethane-based or reactive hot melt adhesive, etc. Alternatively, a technique by sheet coating can be used.
また、不燃性基材と化粧シートとの積層に際しては、化粧シートとの接着性を高めるために、紙質層を介して不燃性基材と化粧シートとを積層することも好ましい。当該紙質層を介した積層においては、不燃性基材表層の金属薄膜層表面に紙質層を有する基材と、化粧シートとを積層することが好ましい。なお紙質層は、下記発熱量を超過しない範囲で適宜選択すればよい。 In addition, when laminating the non-combustible base material and the decorative sheet, it is also preferable to laminate the non-combustible base material and the decorative sheet via a paper layer in order to enhance the adhesion to the decorative sheet. In the lamination via the paper layer, it is preferable to laminate a base material having a paper layer on the surface of the metal thin film layer of the non-combustible base material and a decorative sheet. In addition, what is necessary is just to select a paper quality layer suitably in the range which does not exceed the following calorific value.
本発明の不燃化粧板における不燃性基材上の有機物総量は、不燃性基材の化粧シート側の表面から上の有機物の総量であり、化粧シートに含まれる有機物量に加え、化粧シートと不燃性基材との積層に使用する接着剤等の有機物の総量である。本発明においては、各層を上記構成とすると共に、当該有機物総量を１８０ｇ／ｍ２以下、好ましくは１７０ｇ／ｍ２以下とすることで、凹凸形状への追従性や意匠性、耐汚染性を確保しつつ、好適な不燃性を実現できる。 The total amount of organic matter on the incombustible base material in the incombustible decorative board of the present invention is the total amount of organic matter above the surface of the incombustible base material on the decorative sheet side, and in addition to the amount of organic matter contained in the decorative sheet, It is the total amount of organic substances such as an adhesive used for lamination with the conductive substrate. In the present invention, each layer has the above-described configuration, and the total amount of organic matter is 180 g / m 2 or less, preferably 170 g / m 2 or less, thereby ensuring followability to uneven shapes, design properties, and contamination resistance. However, suitable nonflammability can be realized.
凹凸形状の形成は、化粧シートラミネート後の不燃化粧板に対し、凹凸を有する版や、エンボスロールによる熱圧プレスなどの熱圧成型により形成できる。 The uneven shape can be formed by hot-pressure molding such as a plate having unevenness or a hot-press press using an embossing roll on the incombustible decorative plate after lamination of the decorative sheet.
形成される凹凸形状は、意匠層の意匠や、使用態様に応じて適宜好適な態様に形成すればよく、例えば、木目を強調するよう、なだらかな凸部を中心に、周囲が等高線状に段階的に凹んでいる凹凸形状（浮造り形状）が好ましく例示できる。また、断面半円状の凹部と凸部が交互に繰り返される凹凸、断面半円状の凹部と平らな凸部が交互に繰り返される凹凸、あるいは、断面半円状の凸部が繰り返され、凹部は半円同士が接する溝部分によって形成される凹凸等が形成され、これら凹凸により表面から視認した際に凹部や凸部が縞状や直線状等の模様を形成するような幾何学的な凹凸形状であることも好ましい。このような形状においては、凸部や凹部のピッチが数ｍｍ〜数ｃｍ程度、好ましくは０．５ｍｍ〜５ｃｍ程度の一定周期で繰り返されている形状が好ましい。 The concavo-convex shape to be formed may be suitably formed in accordance with the design of the design layer and the usage mode, for example, with a gentle convex portion at the center, and the periphery is contoured so as to emphasize the grain. An example of a concave and convex shape (floating shape) that is concave is preferable. Also, a concave and convex portion having a semicircular concave section and a convex portion that are alternately repeated, a concave and convex portion having a semicircular concave portion and a flat convex portion that are alternately repeated, or a convex portion having a semicircular cross section and a concave portion. Are irregularities formed by grooves where the semicircles contact each other, and these irregularities form geometrical irregularities such that when viewed from the surface, the depressions and projections form patterns such as stripes and straight lines. It is also preferable that it has a shape. In such a shape, a shape in which the pitch of the convex portion and the concave portion is repeated at a constant period of about several mm to several cm, preferably about 0.5 mm to 5 cm is preferable.
また、本発明の不燃化粧板は、凹凸の凸部の頂部と凹部の底部との差（凸部の最大高さ）が０．１〜２．０ｍｍであることが好ましく、０．３〜１．５ｍｍがより好ましく、０．５〜１．２ｍｍが特に好ましい。本発明の不燃化粧板は、当該範囲の凹凸形状を好適に形成でき、特に０．５ｍｍ以上の深さの凹凸の深い形状の形成においても層間の剥離や化粧シートの浮き、剥がれが生じにくく好適に凹凸形状へ追従でき、好適な意匠性を実現できる。 In the incombustible decorative board of the present invention, the difference (maximum height of the convex portion) between the top of the convex portion of the concave and convex portions and the bottom portion of the concave portion is preferably 0.1 to 2.0 mm, and 0.3 to 1 0.5 mm is more preferable, and 0.5 to 1.2 mm is particularly preferable. The incombustible decorative board of the present invention can suitably form an uneven shape within the above range, and is particularly suitable for the formation of uneven shapes with a depth of 0.5 mm or more, which does not easily cause delamination between layers or float and peeling of the decorative sheet. It is possible to follow the uneven shape and to realize a suitable design.
本発明の不燃性化粧板は、優れた意匠性と好適な不燃性を有することから、店舗・公共建築などの内装壁面などに好適に適用できる。 Since the nonflammable decorative board of the present invention has excellent design properties and suitable nonflammability, it can be suitably applied to interior wall surfaces of shops and public buildings.
（実施例１）
＜化粧シートの調製＞
坪量６０ｇ／ｍ２の含浸紙（ＧＦＮ−６０ 興人製）と厚さ２４μｍのポリエチレンテレフタレート（ＰＥＴ）フィルム（単位面積あたりの質量２３ｇ／ｍ２）をウレタン系接着剤（塗布量１２ｇ／ｍ２）でドライラミネートしてシート基材とし、シート基材のＰＥＴフィルム側表面にグラビア印刷方式でアクリルウレタンインキの絵柄層及びウレタンのトップコート層を塗布量２６ｇ／ｍ２になるように印刷を行うことで、有機物含量が１２１ｇ／ｍ２の化粧シートを得た。
Example 1
<Preparation of decorative sheet>
An impregnated paper with a basis weight of 60 g / m 2 (manufactured by GFN-60 Kojin) and a polyethylene terephthalate (PET) film with a thickness of 24 μm (mass of 23 g / m 2 per unit area) is a urethane-based adhesive (coating amount 12 g / m). 2 ) Dry laminate to form a sheet substrate, and print the surface layer of acrylic urethane ink and urethane topcoat layer on the PET film side surface of the sheet substrate to a coating amount of 26 g / m 2 by gravure printing. As a result, a decorative sheet having an organic content of 121 g / m 2 was obtained.
＜不燃化粧板の調整＞
ダイコーターを使用してウレタン系反応性ホットメルト接着剤（ＦＨ−１００ ＤＩＣ製）を上記にて調製した化粧シートの含浸紙側表面に４０ｇ／ｍ２塗布し、火山性ガラスを主成分とする無機質基材の片面に１２μｍのアルミニウム層が積層された不燃性基材（ダイライト 大建工業製）の金属面とラミネートすることで化粧面を形成し、ロールにてプレスして厚さ６ｍｍの化粧板を得た。
<Adjustment of incombustible decorative board>
Using a die coater, apply a urethane-based reactive hot melt adhesive (manufactured by FH-100 DIC) to the impregnated paper side surface of the decorative sheet prepared above at 40 g / m 2 , and have volcanic glass as the main component. A decorative surface is formed by laminating with a metal surface of an incombustible base material (Dailite Daiken Kogyo Co., Ltd.) in which an aluminum layer of 12 μm is laminated on one side of an inorganic base material, and it is pressed with a roll and has a thickness of 6 mm. I got a plate.
＜凹凸模様の形成＞
得られた不燃化粧板に対し、凸部の最大高さが１．０ｍｍの木目調の浮造り形状のエンボス加工用金型を使用して熱圧プレスを行い、の化粧板を得た。
<Formation of uneven pattern>
The obtained non-combustible decorative board was hot-pressed using an embossing mold having a grain-like floating shape with a maximum height of the convex part of 1.0 mm to obtain a decorative board.
（比較例１）
坪量６０ｇ／ｍ２の含浸紙（ＧＦＮ−６０ 興人製）を基材とし、グラビア印刷方式でアクリルウレタンインキの絵柄層及びウレタンのトップコート層を塗布量２６ｇ／ｍ２になるように印刷を行うことで、坪量８６ｇ／ｍ２の化粧シートを得た。実施例１にて使用した化粧シートに代えて当該化粧シートを使用した以外は実施例１と同様にして、化粧板を得た。
(Comparative Example 1)
Using impregnated paper with a basis weight of 60 g / m 2 (manufactured by GFN-60 Kojin) as a base material, printing is performed with a gravure printing method so that the pattern layer of acrylic urethane ink and the top coat layer of urethane are applied at a coating amount of 26 g / m 2. A decorative sheet having a basis weight of 86 g / m 2 was obtained. A decorative board was obtained in the same manner as in Example 1 except that the decorative sheet was used instead of the decorative sheet used in Example 1.
（比較例２）
厚さ１００μｍのＰＥＴフィルム（単位面積あたりの質量９８ｇ／ｍ２）を基材とし、グラビア印刷方式でアクリルウレタンインキの絵柄層及びウレタンのトップコート層を塗布量２６ｇ／ｍ２になるように印刷を行うことで、坪量１２４ｇ／ｍ２の化粧シートを得た。実施例１にて使用した化粧シートに代えて当該化粧シートを使用した以外は実施例１と同様にして、化粧板を得た。
(Comparative Example 2)
A PET film with a thickness of 100 μm (mass per unit area of 98 g / m 2 ) is used as a base material, and a graphic layer of acrylic urethane ink and a urethane topcoat layer are printed at a coating amount of 26 g / m 2 by a gravure printing method. A decorative sheet having a basis weight of 124 g / m 2 was obtained. A decorative board was obtained in the same manner as in Example 1 except that the decorative sheet was used instead of the decorative sheet used in Example 1.
（比較例３）
＜化粧シートの調製＞
坪量６０ｇ／ｍ２の含浸紙（ＧＦＮ−６０ 興人製）と厚さ２４μｍのＰＥＴフィルム（単位面積あたりの質量２３ｇ／ｍ２）をウレタン系接着剤（塗布量１２ｇ／ｍ２）でドライラミネートしてシート基材とし、グラビア印刷方式でアクリルウレタンインキの絵柄層及びウレタンのトップコート層を塗布量２６ｇ／ｍ２になるように印刷を行うことで、坪量１２１ｇ／ｍ２の化粧シートを得た。
(Comparative Example 3)
<Preparation of decorative sheet>
Dry impregnated paper with a basis weight of 60 g / m 2 (manufactured by GFN-60 Kojin) and PET film with a thickness of 24 μm (mass per unit area 23 g / m 2 ) with urethane adhesive (application amount 12 g / m 2 ). laminated to a sheet base material, a top coat layer of the picture layer and a urethane acrylic urethane ink by performing the printing so that the coating amount 26 g / m 2 by a gravure printing method, a basis weight of 121g / m 2 decorative sheet Got.
＜不燃化粧板の調整＞
ダイコーターを使用してウレタン系反応性ホットメルト接着剤（ＦＨ−１００ ＤＩＣ製）を調整した化粧シートの面に４０ｇ／ｍ２塗布し、火山性ガラスを主成分とする無機質基材の片面に１２μｍのアルミニウム層が積層された不燃性基材（ダイライト 大建工業製）の非金属面とラミネートすることで化粧面を形成し、厚さ６ｍｍの化粧板を得た。
<Adjustment of incombustible decorative board>
40 g / m 2 is applied to the surface of a decorative sheet prepared with a urethane-based reactive hot melt adhesive (manufactured by FH-100 DIC) using a die coater, and applied to one side of an inorganic base material mainly composed of volcanic glass. A decorative surface was formed by laminating with a non-metallic surface of a non-combustible base material (dielight Daiken Kogyo Co., Ltd.) on which an aluminum layer of 12 μm was laminated, and a decorative plate having a thickness of 6 mm was obtained.
＜凹凸模様の形成＞
実施例１と同様の手法で化粧板を得た。
<Formation of uneven pattern>
A decorative board was obtained in the same manner as in Example 1.
実施例及び比較例にて得られた化粧板について、以下の評価を行った。得られた結果を表１に示した。 The decorative plates obtained in Examples and Comparative Examples were evaluated as follows. The obtained results are shown in Table 1.
＜汚染性試験＞
得られた化粧板の表面に汚染物質（クレヨン（赤色）、油性マーカーペン（黒色））を２４時間放置後、ラッカーシンナーを染み込ませたウェスで拭き取りを行い、化粧板の汚染状況を目視で評価した。汚染物質による残色が確認されなかったものを○、残色が確認されたものを×とした。
<Contamination test>
After leaving the pollutants (crayon (red), oil-based marker pen (black)) on the surface of the resulting decorative board for 24 hours, wipe with a cloth soaked with lacquer thinner, and visually evaluate the contamination of the decorative board. did. The case where the residual color due to the pollutant was not confirmed was marked with ◯, and the case where the residual color was confirmed was marked with X.
＜発熱性試験＞
得られた化粧板を１００ｍｍ×１００ｍｍのサイズにカットし、ＪＩＳＡ５４３０：２００８の附属書ＪＡに記載されている、コーンカロリーメーターによる発熱性試験を行い、２０分試験の発熱性試験・評価方法を行った。総発熱量が８ＭＪ／ｍ２以下であり、最高発熱速度が１０秒連続して２００ｋｗ／ｍ２以下のものを○、２００ｋｗ／ｍ２を超えるものを×とした。
<Exothermic test>
The obtained decorative board is cut into a size of 100 mm × 100 mm, and the exothermic test with a cone calorimeter described in Annex JA of JIS A5430: 2008 is performed, and the exothermic test / evaluation method of a 20-minute test is performed. It was. A total calorific value of 8 MJ / m 2 or less and a maximum heat generation rate of 200 kW / m 2 or less for 10 seconds continuously were evaluated as ◯, and those exceeding 200 kw / m 2 were evaluated as x.
＜意匠性評価＞
得られた化粧板の表面を観察し、凹凸形状の形成に際しての凹凸部の浮き、ハガレなどの欠陥の有無を目視で確認した。欠陥がないものを○、欠陥が生じたものを×とした。
<Design evaluation>
The surface of the obtained decorative board was observed, and the presence or absence of defects such as floating of the concavo-convex portion and peeling during the formation of the concavo-convex shape was visually confirmed. The case where there was no defect was shown as ◯, and the case where a defect occurred was shown as ×.
上記表から明らかなとおり、本発明の不燃化粧板は、発熱量が少なく好適な不燃性を有し、凹凸形状への好適な追従性による良好な意匠性を実現でき、かつ、耐汚染性にも優れるものであった。一方、比較例１の化粧板は、汚染物質による残色が生じ、耐汚染性に劣るものであり、比較例２の化粧板は発熱量が大きく不燃性に劣るものであった。また、比較例３の化粧板は、凹凸形成に際して化粧シートの浮きにより化粧板表面に膨れが生じ、好適な意匠性を実現できないものであった。 As is clear from the above table, the non-combustible decorative board of the present invention has a suitable non-flammability with a low calorific value, can realize a good design property by suitable followability to the uneven shape, and is resistant to contamination. Was also excellent. On the other hand, the decorative board of Comparative Example 1 has a residual color due to contaminants and is inferior in stain resistance, and the decorative board of Comparative Example 2 has a large calorific value and inferior incombustibility. Further, the decorative board of Comparative Example 3 was not able to realize a suitable design because the decorative sheet surface was swollen due to the floating of the decorative sheet during the formation of irregularities.
Claims (4)
前記不燃性基材が、化粧シートが設けられる表層に金属薄膜層を有する不燃性基材であり、
前記化粧シートが紙質層と樹脂フィルム層とを有する積層シート上に意匠層が設けられた化粧シートであり、
前記不燃性基材上の有機物総量が１８０ｇ／ｍ２以下であることを特徴とする不燃化粧板。 The decorative sheet is provided with an uneven shape by hot-pressure molding on the decorative sheet side surface of the non-combustible decorative sheet provided with a decorative sheet on the surface of the non-combustible substrate,
The non-combustible substrate is a non-combustible substrate having a metal thin film layer on the surface layer on which a decorative sheet is provided,
The decorative sheet is a decorative sheet provided with a design layer on a laminated sheet having a paper layer and a resin film layer,
The total amount of organic substances on the non-combustible substrate is 180 g / m 2 or less.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2015077691A (en) * | 2013-10-15 | 2015-04-23 | Dic株式会社 | Decorative sheet, decorative sheet set and method of constructing decorative sheet |
| JP2018051899A (en) * | 2016-09-28 | 2018-04-05 | 大建工業株式会社 | Incombustible decorative sheet |
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| JPS6154588B2 (en) * | 1982-12-22 | 1986-11-22 | Takiron Co | |
| JP2000301661A (en) * | 1999-04-23 | 2000-10-31 | Dainippon Printing Co Ltd | Decorative plate |
| JP2007144655A (en) * | 2005-11-24 | 2007-06-14 | Hokusan Kk | Decorative non-combustible material |
| JP2009018452A (en) * | 2007-07-10 | 2009-01-29 | Dainippon Printing Co Ltd | Noncombustible decorative plate |
| JP2009291967A (en) * | 2008-06-03 | 2009-12-17 | Aica Kogyo Co Ltd | Decorative sheet and manufacturing method of the same |
| JP2011011337A (en) * | 2009-06-30 | 2011-01-20 | Sumitomo Bakelite Co Ltd | Material for plate material, decorative plate, and method for producing the material for plate material |
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| JPS6154588B2 (en) * | 1982-12-22 | 1986-11-22 | Takiron Co | |
| JP2000301661A (en) * | 1999-04-23 | 2000-10-31 | Dainippon Printing Co Ltd | Decorative plate |
| JP2007144655A (en) * | 2005-11-24 | 2007-06-14 | Hokusan Kk | Decorative non-combustible material |
| JP2009018452A (en) * | 2007-07-10 | 2009-01-29 | Dainippon Printing Co Ltd | Noncombustible decorative plate |
| JP2009291967A (en) * | 2008-06-03 | 2009-12-17 | Aica Kogyo Co Ltd | Decorative sheet and manufacturing method of the same |
| JP2011011337A (en) * | 2009-06-30 | 2011-01-20 | Sumitomo Bakelite Co Ltd | Material for plate material, decorative plate, and method for producing the material for plate material |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2015077691A (en) * | 2013-10-15 | 2015-04-23 | Dic株式会社 | Decorative sheet, decorative sheet set and method of constructing decorative sheet |
| JP2018051899A (en) * | 2016-09-28 | 2018-04-05 | 大建工業株式会社 | Incombustible decorative sheet |
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