JP2013099939A - 化粧板 - Google Patents
化粧板 Download PDFInfo
- Publication number
- JP2013099939A JP2013099939A JP2012227061A JP2012227061A JP2013099939A JP 2013099939 A JP2013099939 A JP 2013099939A JP 2012227061 A JP2012227061 A JP 2012227061A JP 2012227061 A JP2012227061 A JP 2012227061A JP 2013099939 A JP2013099939 A JP 2013099939A
- Authority
- JP
- Japan
- Prior art keywords
- resin
- decorative board
- decorative
- weight
- impregnated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229920005989 resin Polymers 0.000 claims abstract description 39
- 239000011347 resin Substances 0.000 claims abstract description 39
- 229920000178 Acrylic resin Polymers 0.000 claims abstract description 26
- 239000004925 Acrylic resin Substances 0.000 claims abstract description 26
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 26
- 238000002156 mixing Methods 0.000 claims abstract description 18
- 239000007787 solid Substances 0.000 claims abstract description 18
- 230000009477 glass transition Effects 0.000 claims abstract description 17
- 229910000000 metal hydroxide Inorganic materials 0.000 claims abstract description 15
- 150000004692 metal hydroxides Chemical class 0.000 claims abstract description 15
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 11
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims abstract description 8
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims abstract description 8
- 239000011230 binding agent Substances 0.000 claims abstract description 7
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 claims abstract description 6
- 229920005749 polyurethane resin Polymers 0.000 claims abstract description 6
- 239000000839 emulsion Substances 0.000 claims description 24
- 239000000463 material Substances 0.000 claims description 18
- 239000006087 Silane Coupling Agent Substances 0.000 claims description 12
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical group [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 claims description 6
- 239000004745 nonwoven fabric Substances 0.000 claims description 6
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- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 29
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- 230000000052 comparative effect Effects 0.000 description 19
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 15
- 229910000019 calcium carbonate Inorganic materials 0.000 description 14
- 238000005452 bending Methods 0.000 description 13
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- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 10
- 229920001568 phenolic resin Polymers 0.000 description 10
- BPSIOYPQMFLKFR-UHFFFAOYSA-N trimethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CO[Si](OC)(OC)CCCOCC1CO1 BPSIOYPQMFLKFR-UHFFFAOYSA-N 0.000 description 10
- 238000012360 testing method Methods 0.000 description 9
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- 238000011156 evaluation Methods 0.000 description 6
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
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- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical compound C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- NKSJNEHGWDZZQF-UHFFFAOYSA-N ethenyl(trimethoxy)silane Chemical compound CO[Si](OC)(OC)C=C NKSJNEHGWDZZQF-UHFFFAOYSA-N 0.000 description 2
- 238000007561 laser diffraction method Methods 0.000 description 2
- 239000006028 limestone Substances 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000000790 scattering method Methods 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229920006337 unsaturated polyester resin Polymers 0.000 description 2
- WYTZZXDRDKSJID-UHFFFAOYSA-N (3-aminopropyl)triethoxysilane Chemical compound CCO[Si](OCC)(OCC)CCCN WYTZZXDRDKSJID-UHFFFAOYSA-N 0.000 description 1
- LTQBNYCMVZQRSD-UHFFFAOYSA-N (4-ethenylphenyl)-trimethoxysilane Chemical compound CO[Si](OC)(OC)C1=CC=C(C=C)C=C1 LTQBNYCMVZQRSD-UHFFFAOYSA-N 0.000 description 1
- VZXTWGWHSMCWGA-UHFFFAOYSA-N 1,3,5-triazine-2,4-diamine Chemical compound NC1=NC=NC(N)=N1 VZXTWGWHSMCWGA-UHFFFAOYSA-N 0.000 description 1
- XDQWJFXZTAWJST-UHFFFAOYSA-N 3-triethoxysilylpropyl prop-2-enoate Chemical compound CCO[Si](OCC)(OCC)CCCOC(=O)C=C XDQWJFXZTAWJST-UHFFFAOYSA-N 0.000 description 1
- SJECZPVISLOESU-UHFFFAOYSA-N 3-trimethoxysilylpropan-1-amine Chemical compound CO[Si](OC)(OC)CCCN SJECZPVISLOESU-UHFFFAOYSA-N 0.000 description 1
- UUEWCQRISZBELL-UHFFFAOYSA-N 3-trimethoxysilylpropane-1-thiol Chemical compound CO[Si](OC)(OC)CCCS UUEWCQRISZBELL-UHFFFAOYSA-N 0.000 description 1
- KBQVDAIIQCXKPI-UHFFFAOYSA-N 3-trimethoxysilylpropyl prop-2-enoate Chemical compound CO[Si](OC)(OC)CCCOC(=O)C=C KBQVDAIIQCXKPI-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- JIGUQPWFLRLWPJ-UHFFFAOYSA-N Ethyl acrylate Chemical compound CCOC(=O)C=C JIGUQPWFLRLWPJ-UHFFFAOYSA-N 0.000 description 1
- VVQNEPGJFQJSBK-UHFFFAOYSA-N Methyl methacrylate Chemical compound COC(=O)C(C)=C VVQNEPGJFQJSBK-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 229920002978 Vinylon Polymers 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- FMRLDPWIRHBCCC-UHFFFAOYSA-L Zinc carbonate Chemical compound [Zn+2].[O-]C([O-])=O FMRLDPWIRHBCCC-UHFFFAOYSA-L 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- CWAFVXWRGIEBPL-UHFFFAOYSA-N ethoxysilane Chemical compound CCO[SiH3] CWAFVXWRGIEBPL-UHFFFAOYSA-N 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 1
- 239000001095 magnesium carbonate Substances 0.000 description 1
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 1
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 1
- 239000000347 magnesium hydroxide Substances 0.000 description 1
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000000149 penetrating effect Effects 0.000 description 1
- PNJWIWWMYCMZRO-UHFFFAOYSA-N pent‐4‐en‐2‐one Natural products CC(=O)CC=C PNJWIWWMYCMZRO-UHFFFAOYSA-N 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
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- 239000004814 polyurethane Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 229940088417 precipitated calcium carbonate Drugs 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000013112 stability test Methods 0.000 description 1
- 125000005504 styryl group Chemical group 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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- 238000010998 test method Methods 0.000 description 1
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- 125000003396 thiol group Chemical group [H]S* 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- JXUKBNICSRJFAP-UHFFFAOYSA-N triethoxy-[3-(oxiran-2-ylmethoxy)propyl]silane Chemical compound CCO[Si](OCC)(OCC)CCCOCC1CO1 JXUKBNICSRJFAP-UHFFFAOYSA-N 0.000 description 1
- YUYCVXFAYWRXLS-UHFFFAOYSA-N trimethoxysilane Chemical compound CO[SiH](OC)OC YUYCVXFAYWRXLS-UHFFFAOYSA-N 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 239000011667 zinc carbonate Substances 0.000 description 1
- 229910000010 zinc carbonate Inorganic materials 0.000 description 1
- 235000004416 zinc carbonate Nutrition 0.000 description 1
Images
Classifications
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Abstract
【解決手段】(a1)ガラス転移温度Tgが0℃を超えるアクリル樹脂、ガラス転移温度Tgが0℃を超える塩化ビニル樹脂、アクリルウレタン、及び水性ポリウレタン樹脂からなる群から選択される少なくとも1種の熱可塑性樹脂、及び(a2)熱硬化性樹脂の配合割合が固形分比で1:0〜0.5である(a)バインダー成分、及び(b)吸熱性金属水酸化物を含むプリプレグ2と、熱硬化性樹脂含浸化粧紙1とが積層され、一体化されたことを特徴とする化粧板5。
【選択図】図1
Description
(a1)ガラス転移温度Tgが0℃を超えるアクリル樹脂、ガラス転移温度Tgが0℃を超える塩化ビニル樹脂、アクリルウレタン、及び水性ポリウレタン樹脂からなる群から選択される少なくとも1種の熱可塑性樹脂、及び(a2)熱硬化性樹脂の配合割合が固形分比で1:0〜0.5である(a)バインダー成分、及び(b)吸熱性金属水酸化物を含むプリプレグと、熱硬化性樹脂含浸化粧紙とが積層され、一体化されたことを特徴とする。
(a1)熱可塑性樹脂は、ガラス転移温度Tgが0℃を超えるアクリル樹脂、ガラス転移温度Tgが0℃を超える塩化ビニル樹脂、アクリルウレタン、及び水性ポリウレタン樹脂からなる群から選択される少なくとも1種である。アクリルウレタン、及び水性ポリウレタン樹脂のガラス転移温度Tgは特に限定されない。
本発明の化粧板において、プリプレグは、例えば、(c)シランカップリング剤を含むことができる。この場合、(c)シランカップリング剤を含まない場合よりも、JIS K−6902「熱硬化性樹脂高圧化粧板試験方法」の耐煮沸性において、重量増加率が一層小さくなり、また、プリプレグと熱硬化性樹脂含浸化粧紙との密着性が一層向上する。
(実施例1)
(1)スラリーの製造
以下の成分を含むスラリーを製造した。
平均粒子径8μmの水酸化アルミニウム(吸熱性金属水酸化物):200重量部
平均粒子径1μmの重質炭酸カルシウム(非含水無機充填材):40重量部
なお、前記のアクリル樹脂エマルジョンは(a1)成分の一実施形態である。
(2)プリプレグの製造
50g/m2のガラス繊維不織布(繊維質基材)に、前記(1)で製造したスラリーを、数式1で定義される算出方法で含浸率が800%となるように含浸し、乾燥してプリプレグを製造した。
(3)メラミン樹脂含浸化粧紙の製造
坪量100g/m2である白色の熱硬化性樹脂化粧板用の化粧紙に、メラミン−ホルムアルデヒド樹脂を主成分とする樹脂液を、数式1で定義される算出方法で含浸率が130%となるように含浸し、乾燥してメラミン樹脂含浸化粧紙を製造した。
(4)メラミン樹脂含浸バランス紙の製造
坪量23g/m2である熱硬化性樹脂化粧板用の表面紙に、メラミン−ホルムアルデヒド樹脂を主成分とする樹脂液を、数式1で定義される算出方法で含浸率が280%となるように含浸し、乾燥してメラミン樹脂含浸バランス紙を製造した。
(5)不燃性化粧板の製造
下から順に、前記(4)で製造したメラミン樹脂含浸バランス紙を1枚、前記(2)で製造したプリプレグを2枚、及び前記(3)で製造したメラミン樹脂含浸化粧紙を1枚積層し、フラット仕上げプレートを用いて、130℃、70kg/cm2、60分間の条件で熱圧成形して一体化し、不燃性化粧板を製造した。図1に示すように、製造した不燃性化粧板5は、1枚のメラミン樹脂含浸化粧紙1、2枚のプリプレグ2、及び1枚のメラミン樹脂含浸バランス紙3を積層した構造を有する。
基本的には前記実施例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を30重量部とした。
(実施例3)
基本的には前記実施例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、エポキシ基含有シランの1種である3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)を2.4重量部加えた。
(実施例4)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を26重量部とし、また、3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)の配合量を2.2重量部とした。
(実施例5)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を32重量部とし、また、3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)の配合量を2.2重量部とした。
(実施例6)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を26重量部とし、また、3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)の配合量を1.9重量部とした。
(実施例7)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を34重量部とし、水酸化アルミニウムの配合量を120重量部とし、重質炭酸カルシウムの配合量を120重量部とし、3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)の配合量を2.2重量部とした。
(実施例8)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を34重量部とし、水酸化アルミニウムの配合量を240重量部とし、3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)の配合量を2.2重量部とした。
(実施例9)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、3−グリシドキシプロピルトリメトキシシラン((c)シランカップリング剤)の配合量を2.2重量部とした。また、メラミン樹脂含浸バランス紙を用いずに不燃性化粧板を製造した。図2に示すように、製造した不燃性化粧板5'は、1枚のメラミン樹脂含浸化粧紙1、及び2枚のプリプレグ2を積層した構造を有する。
(実施例10)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、3−グリシドキシプロピルトリメトキシシランの代わりに、3−(2−アミノエチル)アミノプロピルトリメトキシシラン(SH−6020、商品名、東レ・ダウコーニング株式会社製)を2.2重量部用いた。3−(2−アミノエチル)アミノプロピルトリメトキシシランは、(c)シランカップリング剤の一実施形態である。
(実施例11)
基本的には前記実施例3と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョン(品番AXN−150、アイカ工業株式会社製、平均粒子径225nm)の代わりに、同量のアクリルウレタンエマルジョン(WEM−3008.商品名、大成ファインケミカル株式会社製)を用い、また、3−グリシドキシプロピルトリメトキシシランの配合量を2.2重量部とした。
(実施例12)
基本的には前記実施例11と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリルウレタンエマルジョン(WEM−3008.商品名、大成ファインケミカル株式会社製)の代わりに、高分子量の熱可塑性ウレタン樹脂を水に安定に分散させた非イオン性の水性ポリウレタン樹脂(ハイドラン(登録商標)WLI−602、DIC株式会社製)を同量用いた。
(実施例13)
基本的には前記実施例11と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリルウレタンエマルジョン(WEM−3008.商品名、大成ファインケミカル株式会社製)の代わりに、塩ビ系重合体を主成分とする塩ビ系水溶液(ビニブラン(登録商標)711、ガラス転移温度30℃、日信化学工業株式会社製)を同量用いた。
(実施例14)
基本的には前記実施例4と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの配合量を24重量部とし、さらに、メラミン−ホルムアルデヒド樹脂を12重量部配合した。
(比較例1)
(1)スラリーの製造
以下の成分を含むスラリーを製造した。
平均粒子径8μmの水酸化アルミニウム:200重量部
平均粒子径1μmの重質炭酸カルシウム:40重量部
3−グリシドキシプロピルトリメトキシシラン:2.2重量部
(2)プリプレグの製造
50g/m2のガラス繊維不織布(繊維質基材)に、前記(1)で製造したスラリーを、数式1で定義される算出方法で含浸率が760%となるように含浸し、乾燥してプリプレグを製造した。
(3)メラミン樹脂含浸化粧紙の製造
前記実施例1と同様にメラミン樹脂含浸化粧紙を製造した。
(4)メラミン樹脂含浸バランス紙の製造
前記実施例1と同様にメラミン樹脂含浸バランス紙を製造した。
(5)不燃性化粧板の製造
下から順に、前記(4)で製造したメラミン樹脂含浸バランス紙を1枚、前記(2)で製造したプリプレグを2枚、及び前記(3)で製造したメラミン樹脂含浸化粧紙を1枚積層し、フラット仕上げプレートを用いて、130℃、70kg/cm2、60分間の条件で熱圧成形して一体化し、不燃性化粧板を製造した。
(比較例2)
基本的には前記比較例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、フェノール−ホルムアルデヒド樹脂の代わりに同量のメラミン−ホルムアルデヒド樹脂を用いた。
(比較例3)
基本的には前記比較例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、フェノール−ホルムアルデヒド樹脂の代わりに、熱可塑性樹脂であるガラス転移温度(Tg)47℃のアクリル樹脂エマルジョン(品番AXN−150、アイカ工業株式会社製、平均粒子径225nm)18重量部(固形分)と、メラミン−ホルムアルデヒド樹脂18重量部(固形分)とを用いた。
(比較例4)
基本的には前記比較例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、フェノール−ホルムアルデヒド樹脂の代わりに、熱可塑性樹脂であるガラス転移温度(Tg)47℃のアクリル樹脂エマルジョン(品番AXN−150、アイカ工業株式会社製、平均粒子径225nm)12重量部(固形分)と、メラミン−ホルムアルデヒド樹脂24重量部(固形分)とを用いた。
(比較例5)
基本的には前記比較例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、フェノール−ホルムアルデヒド樹脂の代わりに、熱可塑性樹脂であるガラス転移温度(Tg)47℃のアクリル樹脂エマルジョン(品番AXN−150、アイカ工業株式会社製、平均粒子径225nm)18重量部(固形分)と、フェノール−ホルムアルデヒド樹脂18重量部(固形分)とを用いた。
(比較例6)
基本的には前記実施例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、アクリル樹脂エマルジョンの代わりに、フェノール−ホルムアルデヒド樹脂11.5重量部(固形分)と、メラミン−ルムアルデヒド樹脂9.5重量部(固形分)とを用いた。
(比較例7)
基本的には前記実施例1と同様にして不燃性化粧板を製造した。ただし、スラリーの製造において、ガラス転移温度Tgが47℃であるアクリル樹脂エマルジョン(品番AXN−150、アイカ工業株式会社製、平均粒子径225nm)の代わりに、ガラス転移温度が−21℃のアクリル樹脂エマルジョン(品番CMX−43、アイカ工業株式会社製)36重量部(固形分)を用いた。
(比較例8)
フェノール−ホルムアルデヒド樹脂含浸コア紙5枚と、メラミン−ホルムアルデヒド樹脂含浸パターン紙1枚とを積層し、130℃、70kg/cm2、60分間の条件で熱圧成形し、厚み1.2mmのメラミン化粧板(公知のメラミン化粧板)を得た。
<化粧板の評価>
各実施例及び各比較例の化粧板について、不燃性、曲げ強度、弾性率、寸法変化率、化粧板の反り、曲げ加工性、及び重量増加率の評価試験を行った。試験の方法は以下のとおりとした。
(i)不燃性
ISO5660に準拠したコーンカロリーメーターによる20分試験の発熱性試験を行った。以下のα〜γの全てを充足した場合は○と評価し、それ以外を×と評価した。
β:最高発熱速度が10秒以上継続して200KW/m2を超えない。
γ:試験開始後20分間、裏面まで貫通する亀裂および穴の発生がない。
(ii)曲げ強度
JIS K 7171「プラスチック−曲げ特性の求め方」に基づき測定した。
(iii)弾性率
JIS K 7171「プラスチック−曲げ特性の求め方」に基づき測定した。
(iv)寸法変化率
JIS K 6902「熱硬化性樹脂高圧化粧板試験方法」の寸法安定性試験に基づき測定した。
(v)化粧板反り
繊維方向が短手方向となっている50mm×300mmのサンプルを室温40℃、湿度30%の環境で24時間養生した。その後、サンプルを水平面上に置いたときの、水平面からの反り高さを測定した。
(vi)曲げ加工性
150mm幅にサンプルを切り出し、所定の半径を持つ曲げ棒に化粧板の繊維方向が曲げ棒と平行になるように当てて曲げ加工し、目視によりクラックの発生の有無を確認した。クラックを生じない最小の曲率を測定値とした。
(vii)重量増加率
JIS K 6902「熱硬化性樹脂高圧化粧板試験方法」の耐煮沸性に基づき測定した。尚、規格値は17%以下である。
2・・・プリプレグ
3・・・メラミン樹脂含浸バランス紙
5、5'・・・不燃性化粧板
Claims (5)
- (a1)ガラス転移温度Tgが0℃を超えるアクリル樹脂、ガラス転移温度Tgが0℃を超える塩化ビニル樹脂、アクリルウレタン、及び水性ポリウレタン樹脂からなる群から選択される少なくとも1種の熱可塑性樹脂、及び(a2)熱硬化性樹脂の配合割合が固形分比で1:0〜0.5である(a)バインダー成分、及び(b)吸熱性金属水酸化物を含むプリプレグと、熱硬化性樹脂含浸化粧紙とが積層され、一体化されたことを特徴とする化粧板。
- 前記プリプレグが更に、(c)シランカップリング剤を含むことを特徴とする請求項1に記載の化粧板。
- 前記(b)吸熱性金属水酸化物が水酸化アルムニウムであることを特徴とする請求項1又は2に記載の化粧板。
- 前記熱可塑性樹脂がアクリル樹脂エマルジョンであることを特徴とする請求項1〜3のいずれか1項に記載の化粧板。
- 前記プリプレグはガラス繊維不織布を基材とすることを特徴とする請求項1〜4のいずれか1項に記載の化粧板。
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WO2015151934A1 (ja) * | 2014-03-31 | 2015-10-08 | アイカ工業株式会社 | 化粧板 |
JP6030800B1 (ja) * | 2015-07-10 | 2016-11-24 | アイカ工業株式会社 | 化粧シート |
JP2017094731A (ja) * | 2015-11-17 | 2017-06-01 | イビデン株式会社 | 化粧板 |
JP2017159577A (ja) * | 2016-03-10 | 2017-09-14 | パナソニックIpマネジメント株式会社 | 表面化粧パネル、これを備えた化粧パネル及びパネル製造方法 |
JP2019507698A (ja) * | 2016-02-09 | 2019-03-22 | トレスパ・インターナショナル・ビー.ブイ.Trespa International B.V. | 誘導コイルを備える化粧パネル |
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KR101948364B1 (ko) | 2019-04-22 |
US20140242871A1 (en) | 2014-08-28 |
EP2767392A1 (en) | 2014-08-20 |
US10449748B2 (en) | 2019-10-22 |
SG11201401304TA (en) | 2014-10-30 |
JP5432353B2 (ja) | 2014-03-05 |
TW201336447A (zh) | 2013-09-16 |
HK1198974A1 (en) | 2015-06-19 |
AU2012321703B2 (en) | 2016-03-17 |
EP2767392B1 (en) | 2019-12-18 |
WO2013054897A1 (ja) | 2013-04-18 |
TWI559876B (en) | 2016-12-01 |
KR20140079773A (ko) | 2014-06-27 |
CN103874576A (zh) | 2014-06-18 |
AU2012321703A1 (en) | 2014-05-01 |
MY163825A (en) | 2017-10-31 |
CN103874576B (zh) | 2016-08-17 |
EP2767392A4 (en) | 2015-06-17 |
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