JP2013158944A - Non-combustible decorative sheet - Google Patents
Non-combustible decorative sheet Download PDFInfo
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- JP2013158944A JP2013158944A JP2012020723A JP2012020723A JP2013158944A JP 2013158944 A JP2013158944 A JP 2013158944A JP 2012020723 A JP2012020723 A JP 2012020723A JP 2012020723 A JP2012020723 A JP 2012020723A JP 2013158944 A JP2013158944 A JP 2013158944A
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- 239000000463 material Substances 0.000 claims abstract description 80
- 150000007529 inorganic bases Chemical class 0.000 claims abstract description 70
- 239000004568 cement Substances 0.000 claims abstract description 18
- 230000002787 reinforcement Effects 0.000 claims abstract 2
- 239000010410 layer Substances 0.000 claims description 202
- 238000009499 grossing Methods 0.000 claims description 26
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical group [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 24
- 230000003014 reinforcing effect Effects 0.000 claims description 24
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 claims description 20
- 239000011247 coating layer Substances 0.000 claims description 18
- 239000000395 magnesium oxide Substances 0.000 claims description 18
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 12
- 229910001629 magnesium chloride Inorganic materials 0.000 claims description 9
- 239000002002 slurry Substances 0.000 claims description 8
- 229910010272 inorganic material Inorganic materials 0.000 claims description 6
- 239000011147 inorganic material Substances 0.000 claims description 6
- 229920005989 resin Polymers 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 5
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 5
- 229920001187 thermosetting polymer Polymers 0.000 claims description 4
- 238000005034 decoration Methods 0.000 claims description 3
- 239000011521 glass Substances 0.000 claims description 2
- 238000001704 evaporation Methods 0.000 abstract description 2
- 230000008020 evaporation Effects 0.000 abstract description 2
- 239000002360 explosive Substances 0.000 abstract 1
- 229920000877 Melamine resin Polymers 0.000 description 16
- 238000004880 explosion Methods 0.000 description 10
- 239000004640 Melamine resin Substances 0.000 description 8
- 229960002337 magnesium chloride Drugs 0.000 description 8
- 239000011248 coating agent Substances 0.000 description 7
- 238000000576 coating method Methods 0.000 description 7
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 7
- 239000000758 substrate Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 6
- 239000003365 glass fiber Substances 0.000 description 6
- 239000004088 foaming agent Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 238000004519 manufacturing process Methods 0.000 description 5
- 238000010030 laminating Methods 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 238000000465 moulding Methods 0.000 description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 description 3
- 239000002537 cosmetic Substances 0.000 description 3
- 238000005470 impregnation Methods 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 239000002356 single layer Substances 0.000 description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000007796 conventional method Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 230000020169 heat generation Effects 0.000 description 2
- 238000007731 hot pressing Methods 0.000 description 2
- 238000004898 kneading Methods 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000011490 mineral wool Substances 0.000 description 2
- 229910001562 pearlite Inorganic materials 0.000 description 2
- 239000004645 polyester resin Substances 0.000 description 2
- 229920001225 polyester resin Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- 239000012615 aggregate Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 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 1
- 239000004566 building material Substances 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 239000011491 glass wool Substances 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 150000004687 hexahydrates Chemical class 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- 229940050906 magnesium chloride hexahydrate Drugs 0.000 description 1
- DHRRIBDTHFBPNG-UHFFFAOYSA-L magnesium dichloride hexahydrate Chemical compound O.O.O.O.O.O.[Mg+2].[Cl-].[Cl-] DHRRIBDTHFBPNG-UHFFFAOYSA-L 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Landscapes
- Laminated Bodies (AREA)
- Finishing Walls (AREA)
Abstract
Description
本発明は、室内の壁や天井などに使用される不燃化粧板に関する。 The present invention relates to a non-combustible decorative board used for indoor walls and ceilings.
模様や凹凸加工などの化粧処理を施した化粧層を無機基材に積層してなる化粧板は、室内の壁や天井などの建材として広く用いられている。そのような化粧板において、キッチンのガスコンロ周辺などの火を使用する場所には、建築基準法の要請もあり、不燃性の高いもの（不燃化粧板）が使用される。そのような不燃化粧板に用いる無機基材としては、珪酸カルシウム板、マグネシアセメント板等、セメントを主成分とするセメント系無機基材が不燃性能に優れていることから有用であり、当該セメント系無機基材の成分やその配合比を変更して様々の問題点を解決した無機基材が種々提案されている（例えば、特許文献１〜５参照。）。
また、セメント系無機基材は、成型時に原料スラリーに空気が巻込み、表面に凹凸やピンホールを有することから、そのままでは無機基材の表面に他の層を積層した場合には、接着性に劣ったり、凹凸などの影響が他の層にも及び、当該他の層の平滑性が失われたりすることがある。
A decorative board formed by laminating a decorative layer subjected to a decorative process such as a pattern or uneven processing on an inorganic base material is widely used as a building material for indoor walls and ceilings. In such decorative panels, places where fire is used, such as around the gas stove of the kitchen, are also requested by the Building Standards Act, and those with high incombustibility (noncombustible decorative panels) are used. As an inorganic base material used for such a non-combustible decorative board, it is useful because a cement-based inorganic base material mainly composed of cement, such as a calcium silicate board and a magnesia cement board, has excellent non-combustible performance. Various inorganic substrates have been proposed in which various problems have been solved by changing the components of the inorganic substrate and the blending ratio thereof (see, for example, Patent Documents 1 to 5).
In addition, cement-based inorganic base material has air entrained in the raw slurry at the time of molding, and has irregularities and pinholes on the surface, so if other layers are laminated on the surface of the inorganic base material as is, May be inferior to the other layers, or the influence of unevenness may be exerted on other layers and the smoothness of the other layers may be lost.
本発明は、以上の従来の問題点に鑑みなされたものであり、その課題は、無機基材表面の凹凸やピンホールの問題を解消した不燃化粧板を提供することにある。 This invention is made | formed in view of the above conventional trouble, The subject is providing the nonflammable decorative board which eliminated the unevenness | corrugation of an inorganic base material surface, and the problem of a pinhole.
上記課題を解決する本発明は以下の通りである。
（１）セメントを主成分とする無機基材の一方の面側に表面化粧層を有する不燃化粧板であって、
前記無機基材の表面化粧層側の面上に、表面の凹凸を平滑にする平滑化層と、該平滑化層を被覆する被覆層とが順次積層され、かつ前記無機基材が、複数の無機層と、各無機層間に位置する少なくとも１層の無機補強部材層とを含む積層構造からなり、
前記複数の無機層のうち最も表面化粧層側に位置する無機層の厚みが最も薄いことを特徴とする不燃化粧板。
The present invention for solving the above problems is as follows.
(1) A non-combustible decorative board having a surface decorative layer on one side of an inorganic base material mainly composed of cement,
On the surface of the inorganic base material on the surface decorative layer side, a smoothing layer for smoothing the unevenness of the surface and a coating layer for covering the smoothing layer are sequentially laminated, and the inorganic base material has a plurality of It has a laminated structure including an inorganic layer and at least one inorganic reinforcing member layer located between the inorganic layers,
An incombustible decorative board, wherein the inorganic layer located closest to the surface decorative layer among the plurality of inorganic layers has the smallest thickness.
（２）前記最も表面化粧層側に位置する無機層の厚みが０．１〜０．５ｍｍであることを特徴とする前記（１）に記載の不燃化粧板。 (2) The incombustible decorative board according to (1), wherein the inorganic layer located closest to the surface decorative layer has a thickness of 0.1 to 0.5 mm.
（３）前記無機補強部材層を構成する無機補強部材がガラスネットからなることを特徴とする前記（１）又は（２）に記載の不燃化粧板。 (3) The non-combustible decorative board according to (1) or (2), wherein the inorganic reinforcing member constituting the inorganic reinforcing member layer is made of a glass net.
（４）前記平滑化層を構成する材料が、無機材からなるパテであることを特徴とする前記（１）〜（３）のいずれかに記載の不燃化粧板。 (4) The incombustible decorative board according to any one of (1) to (3), wherein the material constituting the smoothing layer is a putty made of an inorganic material.
（５）前記被覆層を構成する材料が、ウレタン樹脂であることを特徴とする前記（１）〜（４）のいずれかに記載の不燃化粧板。 (5) The incombustible decorative board according to any one of (1) to (4), wherein the material constituting the coating layer is a urethane resin.
（６）前記無機層が、少なくとも、酸化マグネシウムと、塩化マグネシウムとを含むスラリーを硬化させてなるマグネシアセメントであることを特徴とする前記（１）〜（５）のいずれかに記載の不燃化粧板。 (6) The incombustible makeup according to any one of (1) to (5), wherein the inorganic layer is magnesia cement obtained by curing a slurry containing at least magnesium oxide and magnesium chloride. Board.
（７）前記無機基材が、表面化粧層側から順に、第１無機層、第２無機層、及び第３無機層からなり、第１無機層と第２無機層との間に無機補強部材層を１層有し、第２無機層と第３無機層との間に無機補強部材層を２層有することを特徴とする前記（１）〜（６）のいずれかに記載の不燃化粧板。 (7) The inorganic base material is composed of a first inorganic layer, a second inorganic layer, and a third inorganic layer in this order from the surface decorative layer side, and an inorganic reinforcing member between the first inorganic layer and the second inorganic layer. The noncombustible decorative board according to any one of (1) to (6), wherein the non-combustible decorative board has one layer and two inorganic reinforcing member layers between the second inorganic layer and the third inorganic layer. .
（８）前記表面化粧層が熱硬化性樹脂を含んでなることを特徴とする前記（１）〜（７）のいずれかに記載の不燃化粧板。 (8) The non-combustible decorative board according to any one of (1) to (7), wherein the surface decorative layer comprises a thermosetting resin.
（９）さらに、前記無機基材の表面化粧層側の面とは反対の面側にバッカー層を有することを特徴とする前記（１）〜（８）のいずれかに記載の不燃化粧板。 (9) The noncombustible decorative board according to any one of (1) to (8), further comprising a backer layer on a surface opposite to the surface of the inorganic base material on the surface decorative layer side.
本発明によれば、無機基材表面の凹凸やピンホールの問題を解消した不燃化粧板を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, the nonflammable decorative board which eliminated the unevenness | corrugation of an inorganic base material surface and the problem of a pinhole can be provided.
本発明の不燃化粧板は、セメントを主成分とする無機基材の一方の面側に表面化粧層を有する不燃化粧板であって、前記無機基材の表面化粧層側の面上に、表面の凹凸を平滑にする平滑化層と、該平滑化層を被覆する被覆層とが順次積層され、かつ前記無機基材が、複数の無機層と、各無機層間に位置する少なくとも１層の無機補強部材層とを含む積層構造からなり、前記複数の無機層のうち最も表面化粧層側に位置する無機層の厚みが最も薄いことを特徴としている。
本発明においては、無機基材表面の凹凸などを解消し、表面を平滑にするため、無機基材の表面化粧層側の面に、無機材からなるパテによる平滑化層を形成し、さらにその上にプライマーによる被覆層を形成したものである。
一方、無機基材の表面に平滑化層及び被覆層を形成すると、そのままでは無機基材が密封された状態となると考えられる。また、上記のような無機基材は一般に水分を含むことから、無機基材が加熱されると内部の水分が水蒸気となり、無機基材が密封された状態ではその水蒸気が逃げ場を失い、上昇した水蒸気による圧力が基材の強度に勝ると爆裂が起こることが想定される。
そこで、後述するように無機基材中の含水分の蒸発による爆裂の発生を防止するため、無機基材を所定の積層構造としたのである。
以下、本発明の不燃化粧板の構成要素それぞれについて説明する。
The non-combustible decorative board of the present invention is a non-combustible decorative board having a surface decorative layer on one surface side of an inorganic base material mainly composed of cement, the surface of the inorganic base material on the surface decorative layer side surface. A smoothing layer that smoothes the unevenness of the film and a coating layer that covers the smoothing layer are sequentially laminated, and the inorganic base material is a plurality of inorganic layers and at least one inorganic layer located between the inorganic layers. It has a laminated structure including a reinforcing member layer, and is characterized in that the inorganic layer located closest to the surface decorative layer among the plurality of inorganic layers has the smallest thickness.
In the present invention, in order to eliminate irregularities on the surface of the inorganic base material and smooth the surface, a smoothing layer made of an inorganic material is formed on the surface of the inorganic base material on the surface decorative layer side. A coating layer with a primer is formed thereon.
On the other hand, when the smoothing layer and the coating layer are formed on the surface of the inorganic base material, it is considered that the inorganic base material is sealed as it is. Moreover, since the inorganic base material as described above generally contains moisture, when the inorganic base material is heated, the internal moisture becomes water vapor, and in a state where the inorganic base material is sealed, the water vapor loses escape and rises. It is assumed that explosion occurs when the pressure of water vapor exceeds the strength of the substrate.
Therefore, as described later, the inorganic base material has a predetermined laminated structure in order to prevent the occurrence of explosion due to evaporation of moisture in the inorganic base material.
Hereinafter, each component of the incombustible decorative board of the present invention will be described.
［無機基材］
本発明においては、無機基材を、複数の無機層と、各無機層間に位置する少なくとも１層の無機補強部材層とを含む積層構造からなり、複数の無機層のうち最も表面化粧層側に位置する無機層の厚みが最も薄くなるように構成している。換言すると、無機基材を複数の無機層に分割して、各無機層間に無機補強部材層を有する構成とし、かつ最も表面化粧層側に位置する無機層の厚みを最も薄くした構成としている。当該構成によると、各無機層の厚みは無機基材を単層の無機層から構成した場合と比較して薄く、しかも、表面化粧層側の無機層が最も薄いため、密封状態となる無機層はその薄い無機層であり、密封される体積が小さく、水蒸気による無機基材の変形ないし爆裂の発生が抑えられる。
[Inorganic substrate]
In the present invention, the inorganic base material has a laminated structure including a plurality of inorganic layers and at least one inorganic reinforcing member layer located between the inorganic layers, and is closest to the surface decorative layer side among the plurality of inorganic layers. The thickness of the positioned inorganic layer is configured to be the thinnest. In other words, the inorganic base material is divided into a plurality of inorganic layers to have an inorganic reinforcing member layer between the inorganic layers, and the thickness of the inorganic layer located closest to the surface decorative layer is the smallest. According to the said structure, the thickness of each inorganic layer is thin compared with the case where an inorganic base material is comprised from a single-layer inorganic layer, and since the inorganic layer by the side of a surface decoration layer is the thinnest, the inorganic layer used as a sealing state Is a thin inorganic layer having a small hermetically sealed volume and can suppress the occurrence of deformation or explosion of the inorganic base material due to water vapor.
（無機層）
無機基材の構成層の１つである無機層は、セメントを主成分とする材料からなり、当該材料としては、例えば、マグネシアセメント、パルプ混入セメント板、木毛セメント板などが挙げられる。
無機層としてマグネシアセメントを用いたものは、少なくとも、酸化マグネシウムと、塩化マグネシウムとを含むスラリーを硬化させて形成することができる。より具体的には、酸化マグネシウム（ＭｇＯ）と塩化マグネシウム（ＭｇＣｌ２）とを混合し、さらに骨材や起泡剤や水を加えて混練して得られたスラリーを塗工して形成される。骨材としては、ロックウール、グラスウール等の無機質繊維、木片、パルプ等の有機質繊維が用いられる。起泡剤としては、市販されている界面活性剤系のものを用いることができる。
以上の無機層たるマグネシアセメント板は気硬性セメント板であり、下記に示すような酸化マグネシウムと塩化マグネシウムの硬化反応（水和反応）が進行する。
ＭｇＯ＋Ｈ２Ｏ → Ｍｇ（ＯＨ）２
５Ｍｇ（ＯＨ）２ ＋ ＭｇＣｌ２＋８Ｈ２Ｏ → ５Ｍｇ（ＯＨ）２・ＭｇＣｌ２・８Ｈ２Ｏ
(Inorganic layer)
The inorganic layer which is one of the constituent layers of the inorganic base material is made of a material mainly composed of cement, and examples of the material include magnesia cement, pulp-mixed cement board, and wood wool cement board.
Those using magnesia cement as the inorganic layer can be formed by curing a slurry containing at least magnesium oxide and magnesium chloride. More specifically, it is formed by mixing magnesium oxide (MgO) and magnesium chloride (MgCl 2 ), and further applying a slurry obtained by kneading by adding aggregate, foaming agent and water. . As the aggregate, inorganic fibers such as rock wool and glass wool, and organic fibers such as wood chips and pulp are used. As the foaming agent, commercially available surfactants can be used.
The magnesia cement board which is the above inorganic layer is an air-hard cement board, and the hardening reaction (hydration reaction) of magnesium oxide and magnesium chloride as shown below proceeds.
MgO + H 2 O → Mg (OH) 2
5Mg (OH) 2 + MgCl 2 + 8H 2 O → 5Mg (OH) 2 · MgCl 2 · 8H 2 O
以上の無機層は、効率的に爆裂を防止する観点から、２〜５層とすることが好ましく、３〜４層とすることがより好ましい。 From the viewpoint of efficiently preventing explosion, the above inorganic layers are preferably 2 to 5 layers, and more preferably 3 to 4 layers.
（無機補強部材層）
無機基材の各無機層間には、強度の向上を目的として、少なくとも１層の無機補強部材層が設けられる。当該無機補強部材層は、網目状等に形成されたガラス繊維、ロックウール、炭素繊維などを格子状に編んだものが挙げられ、中でも、ガラス繊維を格子状に編んだものが好ましい。また、無機補強部材層の坪量は、強度の向上及び作製を容易にする観点から、３０〜７０ｇ／ｍ２が好ましい。
当該無機補強部材層は、１〜４層設けることが好ましく、２〜３層設けることがより好ましい。
(Inorganic reinforcing member layer)
At least one inorganic reinforcing member layer is provided between the inorganic layers of the inorganic base material for the purpose of improving the strength. Examples of the inorganic reinforcing member layer include those in which glass fibers, rock wool, carbon fibers and the like formed in a mesh shape are knitted in a lattice shape, and in particular, those in which glass fibers are knitted in a lattice shape are preferable. The basis weight of the inorganic reinforcing member layer is preferably 30 to 70 g / m 2 from the viewpoint of improving the strength and facilitating the production.
The inorganic reinforcing member layer is preferably provided in 1 to 4 layers, and more preferably in 2 to 3 layers.
無機基材の製造方法としては、例えば、以下の方法が挙げられる。まず、上述の無機層を形成するためのスラリーを層状に塗工して無機層を形成し、その無機層上に無機補強部材層を少なくとも１層形成し、さらにその上に上記と同様に無機層を形成するという過程を、所望の積層構造となるまで繰り返すことで積層構造を得て、その積層構造を硬化することで無機基材が得られる。 As a manufacturing method of an inorganic base material, the following methods are mentioned, for example. First, the slurry for forming the above-mentioned inorganic layer is applied in layers to form an inorganic layer, and at least one inorganic reinforcing member layer is formed on the inorganic layer. By repeating the process of forming a layer until a desired laminated structure is obtained, a laminated structure is obtained, and the laminated structure is cured to obtain an inorganic base material.
以上の無機基材において、複数の無機層のうち最も表面化粧層側に位置する無機層の厚みが最も薄くする形成するのであるが、具体的には、当該厚みとしては、０．１〜０．５ｍｍとすることが好ましく、０．１〜０．２ｍｍとすることがより好ましい。
また、最も表面化粧層側に位置する無機層以外の無機層の厚みとしては、１．４〜２．０ｍｍとすることが好ましく、０．７〜２．０ｍｍとすることがより好ましい。
In the above inorganic base material, the inorganic layer located closest to the surface decorative layer among the plurality of inorganic layers is formed to have the smallest thickness. Specifically, the thickness is 0.1 to 0. 0.5 mm is preferable, and 0.1 to 0.2 mm is more preferable.
Moreover, as thickness of inorganic layers other than the inorganic layer located in the surface cosmetic layer side most, it is preferable to set it as 1.4-2.0 mm, and it is more preferable to set it as 0.7-2.0 mm.
以上の無機基材としては、基材強度を確保するという観点から、表面化粧層側から順に、第１無機層、第２無機層、及び第３無機層からなり、第１無機層と第２無機層との間に無機補強部材層を１層有し、第２無機層と第３無機層との間に無機補強部材層を２層有する構成とすることが最も好ましい。
具体的には、第１無機層の厚みを０．１〜０．５ｍｍとし、第２無機層の厚みを１．４〜２．０ｍｍとし、第３無機層の厚みを０．７〜１．２ｍｍとすることが好ましい。これらの厚みの範囲を外れる場合でも、各無機層の厚みの比、すなわち、第１無機層：第２無機層：第３無機層＝１：（２．８〜２０）：（１．４〜１２）程度であることが好ましい。
As the above inorganic base material, from the viewpoint of ensuring the strength of the base material, the first inorganic layer, the second inorganic layer, and the third inorganic layer are sequentially formed from the surface decorative layer side. It is most preferable that one inorganic reinforcing member layer is provided between the inorganic layer and two inorganic reinforcing member layers are provided between the second inorganic layer and the third inorganic layer.
Specifically, the thickness of the first inorganic layer is 0.1 to 0.5 mm, the thickness of the second inorganic layer is 1.4 to 2.0 mm, and the thickness of the third inorganic layer is 0.7 to 1.mm. 2 mm is preferable. Even when the thickness is out of the range, the thickness ratio of each inorganic layer, that is, first inorganic layer: second inorganic layer: third inorganic layer = 1: (2.8-20) :( 1.4- 12) is preferable.
（平滑化層）
上記のような無機基材は、成型時に原料スラリーに空気が巻込み、表面に凹凸やピンホールを有することがある。従って、そのままでは無機基材の表面に他の層を積層した場合には、密着性に劣ったり、凹凸などの影響が他の層にも及び、当該他の層の平滑性が失われたりすることがある。そこで、そのような無機基材表面の凹凸などを解消し、表面を平滑にするため、本発明においては、無機基材の表面化粧層側の面に無機材からなるパテを用いてなる平滑化層が形成される。
平滑化層に用いる、無機材からなるパテとしては、炭酸カルシウムパテ、石膏パテ、等が挙げられ、中でも、炭酸カルシウムパテが好ましい。
また、平滑化層の厚みは、凹凸やピンホールの影響を解消するという観点から、０．１〜０．５ｍｍとすることが好ましく、０．２〜０．３ｍｍとすることがより好ましい。
以上の平滑化層は、ロールコーター、カーテンフローコーター、ダイコーター等で形成することができる。
(Smoothing layer)
The inorganic base material as described above may have air in the raw slurry at the time of molding and have irregularities and pinholes on the surface. Therefore, when another layer is laminated on the surface of the inorganic base material as it is, the adhesiveness is inferior, the influence of unevenness is exerted on the other layer, and the smoothness of the other layer is lost. Sometimes. Therefore, in order to eliminate such irregularities on the surface of the inorganic base material and make the surface smooth, in the present invention, the surface of the inorganic base material on the surface facing layer side is smoothed using a putty made of an inorganic material. A layer is formed.
Examples of the putty made of an inorganic material used for the smoothing layer include calcium carbonate putty and gypsum putty. Of these, calcium carbonate putty is preferable.
Further, the thickness of the smoothing layer is preferably 0.1 to 0.5 mm, more preferably 0.2 to 0.3 mm, from the viewpoint of eliminating the influence of unevenness and pinholes.
The above smoothing layer can be formed by a roll coater, a curtain flow coater, a die coater or the like.
（被覆層）
本発明において、平滑化層上にさらにプライマーによる被覆層が形成される。上述のように、無機基材の表面に平滑化層を形成することで、目視できる程度の凹部やピンホールを埋めることができるが、化粧層との密着が十分ではない。そこで、無機基材と化粧層との密着を良くするために被覆層を形成する。
平滑化層に用いるプライマーとしては、ウレタン樹脂、アクリル樹脂、エポキシ樹脂、フェノール樹脂、ポリエステル樹脂が挙げられ、中でも、ウレタン樹脂が好ましい。
また、被覆層の厚みは、無機基材と化粧層との密着性を確保するという観点から、０．０５〜０．２０ｍｍとすることが好ましく、０．０５〜０．１０ｍｍとすることがより好ましい。
以上の被覆層は、ロールコーター、カーテンフローコーター、ダイコーター等で形成することができる。
(Coating layer)
In this invention, the coating layer by a primer is further formed on a smoothing layer. As described above, by forming the smoothing layer on the surface of the inorganic base material, it is possible to fill the visible concave portions and pinholes, but the adhesion with the decorative layer is not sufficient. Therefore, a coating layer is formed in order to improve the adhesion between the inorganic base material and the decorative layer.
Examples of the primer used for the smoothing layer include a urethane resin, an acrylic resin, an epoxy resin, a phenol resin, and a polyester resin. Among these, a urethane resin is preferable.
In addition, the thickness of the coating layer is preferably 0.05 to 0.20 mm, more preferably 0.05 to 0.10 mm, from the viewpoint of ensuring adhesion between the inorganic base material and the decorative layer. preferable.
The above coating layer can be formed with a roll coater, a curtain flow coater, a die coater or the like.
［表面化粧層］
本発明の不燃化粧板においては、無機基材の一方の面側には表面化粧層を有する。表面化粧層は、不燃化粧板の表面側に位置するものであり、その表面に化粧処理が施される。
表面化粧層の材料としては、例えば、熱硬化性樹脂を含んでなるものが挙げられ、熱硬化性樹脂としては、メラミン樹脂、ジアリルフタレート樹脂、ポリエステル樹脂が好ましい。表面化粧層は、具体的には、パターン紙にメラミン樹脂等を含浸させたものを用いることが好ましい。以下に、パターン紙にメラミン樹脂を含浸させたもの（メラミン樹脂含浸紙と称する。）について説明する。
[Surface decorative layer]
In the incombustible decorative board of this invention, it has a surface decorative layer in the one surface side of an inorganic base material. A surface decorative layer is located in the surface side of a nonflammable decorative board, and the cosmetic treatment is given to the surface.
Examples of the material for the surface decorative layer include those comprising a thermosetting resin, and preferred examples of the thermosetting resin include melamine resins, diallyl phthalate resins, and polyester resins. Specifically, it is preferable to use a surface decorative layer in which pattern paper is impregnated with melamine resin or the like. Hereinafter, a pattern paper impregnated with melamine resin (referred to as melamine resin-impregnated paper) will be described.
メラミン樹脂含浸紙は、パターン紙にメラミン樹脂を所定の含浸率で含浸させた後、加熱、乾燥させることにより作製される。パターン紙としては、例えばチタン紙が用いられる。パターン紙の坪量は、パターン紙の厚みや重さを考慮して８０〜１５０ｇ／ｍ２であることが好ましい。メラミン樹脂の含浸率は、含浸されるメラミン樹脂の機能を十分に発現するために８０〜１２０質量％であることが好適である。加熱、乾燥の温度は、パターン紙にメラミン樹脂を強固に固着させるために１００〜１４０℃に設定することが好ましい。 The melamine resin-impregnated paper is produced by impregnating a melamine resin with a predetermined impregnation rate in a pattern paper, and then heating and drying. For example, titanium paper is used as the pattern paper. The basis weight of the pattern paper is preferably 80 to 150 g / m 2 in consideration of the thickness and weight of the pattern paper. The impregnation rate of the melamine resin is preferably 80 to 120% by mass in order to sufficiently express the function of the impregnated melamine resin. The heating and drying temperatures are preferably set to 100 to 140 ° C. in order to firmly fix the melamine resin to the pattern paper.
［バッカー層］
また、本発明の不燃化粧板においては、無機基材の表面化粧層側の面とは反対の面側にバッカー層を設けることが好ましい。
バッカー層は、不燃化粧板の裏面側に位置するものであり、材料としては表面化粧層と同じものを用いることができるが、裏面側に位置するものであることから、表面化粧層のように化粧処理を施す必要はない。
なお、上記のようにバッカー層を設ける場合において、バッカー層が設けられる無機基材表面の凹凸やピンホールを解消するために、表面化粧層側の面と同様に、平滑化層及び被覆層を形成することが好ましい。
[Backer layer]
Moreover, in the incombustible decorative board of this invention, it is preferable to provide a backer layer in the surface side opposite to the surface by the side of the surface decoration layer of an inorganic base material.
The backer layer is located on the back side of the non-combustible decorative board, and the same material as the surface decorative layer can be used as the material, but since it is located on the back side, like the surface decorative layer There is no need to apply cosmetic treatment.
In the case of providing a backer layer as described above, in order to eliminate irregularities and pinholes on the surface of the inorganic base material on which the backer layer is provided, a smoothing layer and a covering layer are provided in the same manner as the surface of the surface decorative layer side. Preferably formed.
以上の本発明の不燃化粧板の厚みは２．８〜３．２ｍｍとすることが好ましい。 The thickness of the non-combustible decorative board of the present invention is preferably 2.8 to 3.2 mm.
次に、本発明の不燃化粧板の製造方法について説明する。
不燃化粧板は、平滑化層及び被覆層を形成した無機基材の表裏両面に少なくとも表面化粧層及びバッカー層を積層する積層工程と、前記表面化粧層及びバッカー層が表裏両面に積層された無機基材を熱圧成形する熱圧成形工程とを経て製造される。
積層工程では、例えば下から順に、メラミン樹脂含浸紙（バッカー層）、無機基材、及びメラミン樹脂含浸紙（表面化粧層）を積層する。
Next, the manufacturing method of the incombustible decorative board of this invention is demonstrated.
The non-combustible decorative board includes a lamination step of laminating at least a surface decorative layer and a backer layer on both front and back surfaces of an inorganic base material on which a smoothing layer and a coating layer are formed, and an inorganic material in which the surface decorative layer and the backer layer are laminated on both front and back surfaces. It is manufactured through a hot-pressure forming step of hot-pressing the substrate.
In the lamination step, for example, melamine resin-impregnated paper (backer layer), inorganic base material, and melamine resin-impregnated paper (surface decorative layer) are laminated in order from the bottom.
熱圧成形工程では、上記積層物を熱圧プレス装置で加熱、加圧成形する。
加熱条件は不燃化粧板の温度が１２５〜１５０℃、加圧条件は１．９６〜９．８０ＭＰａ（２０〜１００ｋｇ／ｃｍ２）であることが好ましい。温度が１２５℃未満又は圧力が１．９６ＭＰａ未満の場合には、無機基材に対する表面化粧層・バッカー層の密着性が不足し、剥離が発生し易くなる。一方、温度が１５０℃を超える場合又は圧力が９．８０ＭＰａを超える場合には、無機基材に大きな力が作用するため、亀裂が発生するおそれがある。
In the hot press molding step, the laminate is heated and pressure-molded by a hot press machine.
It is preferable that the temperature of the noncombustible decorative board is 125 to 150 ° C. and the pressing condition is 1.96 to 9.80 MPa (20 to 100 kg / cm 2 ). When the temperature is less than 125 ° C. or the pressure is less than 1.96 MPa, the adhesion of the surface decorative layer / backer layer to the inorganic base material is insufficient, and peeling easily occurs. On the other hand, when the temperature exceeds 150 ° C. or when the pressure exceeds 9.80 MPa, a large force acts on the inorganic base material, which may cause cracks.
以下に、実施例により本発明をさらに具体的に説明するが、本発明は以下の実施例に限定されるものではない。 EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the following examples.
［実施例１〜４］
（無機基材の作製）
表面化粧層側から順に、第１無機層／無機補強部材層／第２無機層／無機補強部材層／無機補強部材層／第３無機層の積層構造の無機基材を作製するに当たり、まず以下の組成の第１無機層〜第３無機層用の塗工液を調製した。
（１）第１無機層用塗工液
酸化マグネシウム ８２質量％
塩化マグネシウム １８質量％
（２）第２無機層用塗工液
酸化マグネシウム ７９質量％
塩化マグネシウム １６質量％
パーライト ４質量％
起泡剤 １質量％
（３）第３無機層用塗工液
酸化マグネシウム ８０質量％
塩化マグネシウム １７質量％
パーライト ２重量％
起泡剤 １質量％
常法に従い、各塗工液において、上記各成分を混合して、水を加えて混練して塗工液を得た。なお、塩化マグネシウムは、塩化マグネシウム・６水和物を用いてもよく、その場合、塩化マグネシウムそのものが上記配合率となるように換算して配合すればよい。
[Examples 1 to 4]
(Preparation of inorganic substrate)
In order to prepare an inorganic base material having a laminated structure of first inorganic layer / inorganic reinforcing member layer / second inorganic layer / inorganic reinforcing member layer / inorganic reinforcing member layer / third inorganic layer in order from the surface decorative layer side, first, The coating liquid for the 1st inorganic layer-3rd inorganic layer of the composition of was prepared.
(1) First inorganic layer coating solution Magnesium oxide 82% by mass
Magnesium chloride 18% by mass
(2) Second inorganic layer coating solution Magnesium oxide 79% by mass
Magnesium chloride 16% by mass
Pearlite 4% by mass
Foaming agent 1% by mass
(3) Third inorganic layer coating solution Magnesium oxide 80% by mass
Magnesium chloride 17% by mass
Perlite 2% by weight
Foaming agent 1% by mass
According to a conventional method, each component was mixed in each coating solution, and water was added to knead to obtain a coating solution. Magnesium chloride hexahydrate may be used as the magnesium chloride. In that case, the magnesium chloride may be converted and blended so that the above-mentioned blending ratio is obtained.
次いで、無機補強部材層として、３層分のガラス繊維ネットを準備し、専用の積層装置を用いて、上記積層構造となるように各無機層及びガラス繊維ネットを積層して無機基材を得た。なお、使用したガラス繊維ネットの坪量などを以下に示す。また、第１無機層の厚みは０．１ｍｍとし、第２無機層の厚みは１．７ｍｍとし、第３無機層の厚みは０．９ｍｍとした。
（ガラス繊維ネット）
坪量：５５ｇ／ｍ２
縦ピッチ：２．５ｍｍ 縦糸：１２６０ｄ
横ピッチ：２．５ｍｍ 横糸：６３０ｄ
Next, as the inorganic reinforcing member layer, three layers of glass fiber nets are prepared, and an inorganic base material is obtained by laminating each inorganic layer and the glass fiber net so as to have the above laminated structure using a dedicated laminating apparatus. It was. The basis weight of the glass fiber net used is shown below. The thickness of the first inorganic layer was 0.1 mm, the thickness of the second inorganic layer was 1.7 mm, and the thickness of the third inorganic layer was 0.9 mm.
(Glass fiber net)
Basis weight: 55 g / m 2
Longitudinal pitch: 2.5mm Warp yarn: 1260d
Weft pitch: 2.5mm Weft: 630d
（平滑化層・被覆層の形成）
上記のように得られた無機基材の表面化粧層側の面に、炭酸カルシウムパテ（固形分６０％）をロールコーターにて５０ｇ／ｍ２塗布して平滑化層を形成し乾燥させ、さらにその上にウレタン樹脂プライマー（固形分５０％）をロールコーターにて５０ｇ／ｍ２塗布して被覆層を形成し乾燥させ、最後に表面サンダーをかけ平滑に仕上げた。
平滑化層・被覆層を形成後の無機基材の表面は、目視観察したところ、凹凸やピンホールなどが認められず、平滑な面となった。
(Formation of smoothing layer and coating layer)
The surface of the inorganic base material obtained as described above is coated with 50 g / m 2 of calcium carbonate putty (solid content: 60%) using a roll coater to form a smoothing layer, which is then dried. A urethane resin primer (solid content: 50%) was coated on the top with a roll coater at 50 g / m 2 to form a coating layer and dried. Finally, a surface sander was applied to finish the coating smoothly.
When the surface of the inorganic base material after forming the smoothing layer / coating layer was visually observed, no irregularities or pinholes were observed, and the surface was smooth.
（メラミン樹脂含浸紙（表面化粧層、バッカー層）の作製）
パターン紙として坪量８０ｇ／ｍ２のチタン紙を用い、メラミン樹脂を含浸率が１１０質量％となるように含浸し、１３０℃で乾燥させてメラミン樹脂含浸紙を作製した。
(Production of melamine resin impregnated paper (surface decorative layer, backer layer))
Titanium paper having a basis weight of 80 g / m 2 was used as a pattern paper, impregnated with melamine resin so that the impregnation ratio was 110% by mass, and dried at 130 ° C. to prepare melamine resin-impregnated paper.
（不燃化粧板の製造）
下から順に、メラミン樹脂含浸紙、無機基材、及びメラミン樹脂含浸紙を積層し、熱圧プレス装置で加熱、加圧成形を行い、厚さ３．０ｍｍの不燃化粧板を製造した。加熱条件は、不燃化粧板の温度が１３５℃となるように設定した。加圧条件は、６．８６ＭＰａ（７０ｋｇ／ｃｍ２）とした。なお、表面にはステンレス鋼板をセットしてプレス成形を実施し不燃化粧板を得た。
(Manufacture of non-combustible decorative board)
In order from the bottom, a melamine resin-impregnated paper, an inorganic base material, and a melamine resin-impregnated paper were laminated and heated and pressure-molded with a hot-pressing device to produce a non-combustible decorative board having a thickness of 3.0 mm. The heating conditions were set so that the temperature of the non-combustible decorative board was 135 ° C. The pressing condition was 6.86 MPa (70 kg / cm 2 ). A stainless steel plate was set on the surface, and press molding was performed to obtain a non-combustible decorative plate.
得られた不燃化粧板に対して、以下の不燃試験を実施した。結果を表１に示す。
［不燃試験］
（１）爆裂の有無
以下のようにして、加熱時における爆裂の有無を確認した。
ＩＳＯ５６６０に準拠したコーンカロリーメーターを使用し、２０分の発熱性試験において爆裂した場合を×、爆裂しなかった場合を○とした。なお、５点測定して、１点でも爆裂したものは×とした。
（２）不燃性
不燃性は、総発熱量７．２ＭＪ／ｍ２以下、最高発熱速度が１０秒以上継続して２００ｋｗ／ｍ２を超えない場合を○、 総発熱量７．２〜８．０ＭＪ／ｍ２、最高発熱速度が１０秒以上継続して２００ｋｗ／ｍ２を超えない場合を△、総発熱量８ＭＪ／ｍ２を超えるか、あるいは最高発熱速度が１０秒以上継続して２００ｋｗ／ｍ２を超えた場合を×とした。
The following incombustibility test was implemented with respect to the obtained incombustible decorative board. The results are shown in Table 1.
[Nonflammability test]
(1) Presence or absence of explosion The presence or absence of explosion during heating was confirmed as follows.
The cone calorimeter based on ISO5660 was used, and the case where it exploded in the 20-minute exothermic test was set to x, and the case where it did not explode was set to (circle). In addition, it measured with 5 points | pieces and the thing which exploded even at 1 point | piece was set as x.
(2) non-flammable non-flammable, the total calorific value 7.2MJ / m 2 or less, ○ a case not exceeding 200 kW / m 2 was continued up to the heat generation rate is more than 10 seconds, the total calorific value from 7.2 to 8. 0 mJ / m 2, a case where the maximum heat generation rate does not exceed 200 kW / m 2 continued for more than 10 seconds △, or greater than the total heating value 8 MJ / m 2, or the maximum heat release rate is continuously more than 10 seconds 200 kW / a case in which exceeded m 2 was ×.
［比較例１］
実施例１において用いた積層構造の無機基材の代わりに、以下のようにして作製した単層構造の無機基材を用いたこと以外は実施例１と同様にして不燃化粧板を作製した。
（無機基材の作製）
常法に従い、酸化マグネシウム（ＭｇＯ）と塩化マグネシウム（ＭｇＣｌ２）・６水和物、パーライト、起泡剤とを、それぞれ、７９質量％、１６質量％、４質量％、１質量％となるように混合し、適量の水とを加えて混練したスラリーを板状に成形し、無機基材を得た。
そして、得られた不燃化粧板に対して、実施例１と同様にして不燃試験を実施した。結果を表２に示す。
[Comparative Example 1]
A noncombustible decorative board was produced in the same manner as in Example 1 except that an inorganic base material having a single layer structure produced as follows was used instead of the inorganic base material having a laminated structure used in Example 1.
(Preparation of inorganic substrate)
According to a conventional method, magnesium oxide (MgO), magnesium chloride (MgCl 2 ) · hexahydrate, pearlite, and foaming agent are 79% by mass, 16% by mass, 4% by mass, and 1% by mass, respectively. A slurry obtained by mixing and kneading with an appropriate amount of water was molded into a plate shape to obtain an inorganic base material.
And the incombustible test was implemented like Example 1 with respect to the obtained incombustible decorative board. The results are shown in Table 2.
表１及び表２より、表面に平滑化層及び被覆層を形成した無機基材を使用した場合であっても、無機基材を積層構造とした実施例１〜４は爆裂が生じなかったのに対し、単層構造の無機基材を用いた比較例１は爆裂が生じた。このことより、無機基材表面に平滑化層及び被覆層を形成した場合には加熱すると爆裂が生じることになるが、無機基材を積層構造にすると、爆裂を防止できることが分かる。 From Table 1 and Table 2, even if it was a case where the inorganic base material which formed the smoothing layer and the coating layer on the surface was used, Examples 1-4 which made the inorganic base material laminated structure did not produce explosion On the other hand, in Comparative Example 1 using an inorganic base material having a single layer structure, explosion occurred. From this, it can be seen that when a smoothing layer and a coating layer are formed on the surface of an inorganic base material, explosion occurs when heated, but when the inorganic base material has a laminated structure, explosion can be prevented.
Claims (9)
前記無機基材の表面化粧層側の面上に、表面の凹凸を平滑にする平滑化層と、該平滑化層を被覆する被覆層とが順次積層され、かつ前記無機基材が、複数の無機層と、各無機層間に位置する少なくとも１層の無機補強部材層とを含む積層構造からなり、
前記複数の無機層のうち最も表面化粧層側に位置する無機層の厚みが最も薄いことを特徴とする不燃化粧板。 A non-combustible decorative board having a surface decorative layer on one side of an inorganic base material mainly composed of cement,
On the surface of the inorganic base material on the surface decorative layer side, a smoothing layer for smoothing the unevenness of the surface and a coating layer for covering the smoothing layer are sequentially laminated, and the inorganic base material has a plurality of It has a laminated structure including an inorganic layer and at least one inorganic reinforcing member layer located between the inorganic layers,
An incombustible decorative board, wherein the inorganic layer located closest to the surface decorative layer among the plurality of inorganic layers has the smallest thickness.
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| JP2017043003A (en) * | 2015-08-27 | 2017-03-02 | 東リ株式会社 | Incombustible sheet |
| US11020940B2 (en) * | 2017-01-12 | 2021-06-01 | Euro Trade Flooring, S.L. | Plate for covering horizontal and vertical surfaces |
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