JP2013158950A - Non-combustible decorative sheet - Google Patents
Non-combustible decorative sheet Download PDFInfo
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- JP2013158950A JP2013158950A JP2012020749A JP2012020749A JP2013158950A JP 2013158950 A JP2013158950 A JP 2013158950A JP 2012020749 A JP2012020749 A JP 2012020749A JP 2012020749 A JP2012020749 A JP 2012020749A JP 2013158950 A JP2013158950 A JP 2013158950A
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- 239000000463 material Substances 0.000 claims abstract description 74
- 150000007529 inorganic bases Chemical class 0.000 claims abstract description 63
- 239000004568 cement Substances 0.000 claims abstract description 21
- 230000002787 reinforcement Effects 0.000 claims abstract 2
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 claims description 29
- 239000002023 wood Substances 0.000 claims description 28
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical group [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 27
- 230000003014 reinforcing effect Effects 0.000 claims description 24
- 239000000395 magnesium oxide Substances 0.000 claims description 21
- 239000008187 granular material Substances 0.000 claims description 17
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 15
- 229910001629 magnesium chloride Inorganic materials 0.000 claims description 14
- 229920005989 resin Polymers 0.000 claims description 9
- 239000011347 resin Substances 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 8
- 229920001187 thermosetting polymer Polymers 0.000 claims description 7
- 239000002002 slurry Substances 0.000 claims description 5
- 239000007787 solid Substances 0.000 claims description 3
- 238000005034 decoration Methods 0.000 claims description 2
- 239000011521 glass Substances 0.000 claims description 2
- 239000011236 particulate material Substances 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 194
- 239000002253 acid Substances 0.000 description 26
- 229920000877 Melamine resin Polymers 0.000 description 19
- 239000004640 Melamine resin Substances 0.000 description 13
- 239000011248 coating agent Substances 0.000 description 13
- 238000000576 coating method Methods 0.000 description 13
- 229960002337 magnesium chloride Drugs 0.000 description 13
- 239000005011 phenolic resin Substances 0.000 description 11
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 10
- 238000004880 explosion Methods 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 7
- 238000001878 scanning electron micrograph Methods 0.000 description 7
- 239000003365 glass fiber Substances 0.000 description 6
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000000203 mixture Substances 0.000 description 6
- 238000002360 preparation method Methods 0.000 description 6
- 239000000758 substrate Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 238000005470 impregnation Methods 0.000 description 5
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical compound NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 239000003513 alkali Substances 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 239000004088 foaming agent Substances 0.000 description 4
- 238000010030 laminating Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- 239000002585 base Substances 0.000 description 2
- 239000002537 cosmetic Substances 0.000 description 2
- 238000003475 lamination Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 230000002265 prevention Effects 0.000 description 2
- 239000010936 titanium Substances 0.000 description 2
- 229910052719 titanium Inorganic materials 0.000 description 2
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 229920000298 Cellophane Polymers 0.000 description 1
- 239000004641 Diallyl-phthalate Substances 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 229920001131 Pulp (paper) Polymers 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- -1 and the like Chemical compound 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
- 238000007796 conventional method Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 210000004209 hair Anatomy 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- 238000004898 kneading Methods 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
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920003987 resole Polymers 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 239000002025 wood fiber Substances 0.000 description 1
- 210000002268 wool Anatomy 0.000 description 1
Landscapes
- Building Environments (AREA)
- Laminated Bodies (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、不燃化粧板は、表面側に位置する化粧層（表面化粧層）にも不燃性が要求されることから、壁紙のような易燃性材料は使用できず、不燃性が高い熱硬化性樹脂などが好適に使用される。
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, non-combustible decorative boards require a non-combustible material for the decorative layer (surface decorative layer) located on the surface side, so that non-combustible materials such as wallpaper cannot be used, and are highly non-combustible thermosetting. Resins and the like are preferably used.
一方、熱硬化性樹脂を用いた表面化粧層は気密性が高く、無機基材表面にそのまま形成すると無機基材が密封された状態となる。他方、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という問題があった。
そこで、爆裂を防止するため、無機基材内部に木片（吸水性粒状物）を含有させることが知られている。すなわち、加熱により生じる水蒸気を木片に吸収させることで、水蒸気の逃げ場を確保して爆裂を防止しようとするものである。
On the other hand, a surface decorative layer using a thermosetting resin has high airtightness, and when formed directly on the surface of the inorganic base material, the inorganic base material is sealed. On the other hand, since the inorganic base as described above generally contains moisture, when the inorganic base is heated, the internal moisture becomes water vapor, and in a state where the inorganic base is sealed, the water vapor loses escape and rises. There was a problem that explosion occurred when the pressure of water vapor exceeded the strength of the substrate.
Then, in order to prevent explosion, it is known to contain a piece of wood (water-absorbing granular material) inside the inorganic base material. In other words, water vapor generated by heating is absorbed by a piece of wood so as to secure an escape place for water vapor and prevent explosion.
しかしながら、上記のように木片を含有する無機基材は、その表面にも木片の一部が露出しており、表面から突出した木片により凹凸が生じて平滑性が失われ、無機基材の上に形成される層との密着性が低下したり、表面化粧した場合に表面層（表面化粧層）に凹凸が生じたりするという問題があった。 However, as described above, the inorganic base material containing a piece of wood has a part of the piece of wood exposed on the surface, and the piece of wood protruding from the surface has irregularities and loses smoothness. There is a problem that the adhesion to the layer formed on the surface is lowered, or the surface layer (surface decorative layer) is uneven when the surface is decorated.
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、セメントを主成分とし、吸水性粒状物を含有する無機基材を有する不燃化粧板において、無機基材上に形成される層との接着性に優れ、かつ表面化粧層の平滑性に優れた不燃化粧板を提供することにある。 The present invention has been made in view of the above-described conventional problems, and the problem thereof is a non-combustible decorative board having an inorganic base material containing cement as a main component and containing water-absorbing particulates. An object of the present invention is to provide a non-combustible decorative board having excellent adhesion to a layer to be formed and excellent smoothness of a surface decorative layer.
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、次の条件（Ａ）又は（Ｂ）を満足することを特徴とする不燃化粧板。
（Ａ）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には吸水性粒状物を含有せず、該無機層以外の無機層に吸水性粒状物を含有する。
（Ｂ）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が最大長さ１ｍｍ以上の吸水性粒状物を含有せず、かつ最も表面化粧層側に位置する無機層以外の無機層が最大長さ１ｍｍ以上の吸水性粒状物を含有する。
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,
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 satisfies the following condition (A) or (B): Incombustible decorative board.
(A) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particles, and the inorganic layers other than the inorganic layer contain water-absorbing particles.
(B) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particulates having a maximum length of 1 mm or more, and other than the inorganic layer positioned closest to the surface decorative layer The inorganic layer contains water-absorbing particulates having a maximum length of 1 mm or more.
（２）前記条件（Ａ）及び（Ｂ）のいずれも、最も表面化粧層側に位置する無機層以外の無機層における吸水性粒状物が、該無機層の全固形分に対して２〜１０質量％含有することを特徴とする前記（１）に記載の不燃化粧板。 (2) In any of the conditions (A) and (B), the water-absorbing granular material in the inorganic layer other than the inorganic layer located closest to the surface decorative layer is 2 to 10 with respect to the total solid content of the inorganic layer. The incombustible decorative board according to (1) above, which is contained by mass%.
（３）前記吸水性粒状物が木質材からなることを特徴とする請求項１又は２に記載の不燃化粧板。 (3) The non-combustible decorative board according to claim 1 or 2, wherein the water-absorbing granular material is made of a wood material.
（４）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たマグネシアセメント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 non-combustible decorative board according to any one of (1) to (3), wherein the inorganic layer is magnesia cement obtained by curing a slurry containing at least magnesium oxide and magnesium chloride. .
（５）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）〜（４）のいずれかに記載の不燃化粧板。 (5) The non-combustible decorative board according to any one of (1) to (4), wherein the inorganic reinforcing member constituting the inorganic reinforcing member layer is made of a glass net.
（６）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）〜（５）のいずれかに記載の不燃化粧板。 (6) The non-combustible decorative board according to any one of (1) to (5), wherein the surface decorative layer comprises a thermosetting resin.
（７）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）〜（６）のいずれかに記載の不燃化粧板。 (7) The non-combustible decorative board according to any one of (1) to (6), further comprising a backer layer on a surface opposite to the surface on the surface decorative layer side of the inorganic base material.
（８）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）〜（７）のいずれかに記載の不燃化粧板。 (8) The inorganic base material includes a first inorganic layer, a second inorganic layer, and a third inorganic layer in order from the surface decorative layer side, and an inorganic reinforcing member between the first inorganic layer and the second inorganic layer. The non-combustible decorative board according to any one of (1) to (7), 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. .
本発明によれば、セメントを主成分とし、吸水性粒状物を含有する無機基材を有する不燃化粧板において、無機基材上に形成される層との接着性に優れ、かつ表面化粧層の平滑性に優れた不燃化粧板を提供することができる。 According to the present invention, in a non-combustible decorative board having an inorganic base material containing a cement as a main component and containing water-absorbing particulates, the non-combustible decorative board has excellent adhesion to the layer formed on the inorganic base material, and is a surface decorative layer. An incombustible decorative board having excellent smoothness 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、次の条件（Ａ）又は（Ｂ）を満足することを特徴としている。
（Ａ）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には吸水性粒状物を含有せず、該無機層以外の無機層に吸水性粒状物を含有する。
（Ｂ）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が最大長さ１ｍｍ以上の吸水性粒状物を含有せず、かつ最も表面化粧層側に位置する無機層以外の無機層が最大長さ１ｍｍ以上の吸水性粒状物を含有する。
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 incombustible decorative board of the present invention is an incombustible decorative board having a surface decorative layer on one surface side of an inorganic base material containing cement as a main component, wherein the inorganic base material includes a plurality of inorganic layers and each inorganic layer. It is characterized by having a laminated structure including at least one inorganic reinforcing member layer positioned at and satisfying the following condition (A) or (B).
(A) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particles, and the inorganic layers other than the inorganic layer contain water-absorbing particles.
(B) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particulates having a maximum length of 1 mm or more, and other than the inorganic layer positioned closest to the surface decorative layer The inorganic layer contains water-absorbing particulates having a maximum length of 1 mm or more.
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る構成としている。
[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.
（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、さらに吸水性粒状物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。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 water-absorbing particulates, a foaming agent or water. Is done. 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
（吸水性粒状物）
本発明において、複数の無機層のうちの少なくとも１層に吸水性粒状物を含有するが、当該吸水性粒状物が存在することで、加熱により無機基材内部で水蒸気が発生しても水蒸気は吸水性粒状物に吸収されるため爆裂の発生を防止することができる。吸水性粒状物の形状としては、特に限定されるものではなく、立方体や直方体などでもよいし、板状や球状でもよい。
なお、吸水性粒状物が爆裂を防止するメカニズムとして、上記の他、不燃化粧板の燃焼時に他の材料に先行して吸水性粒状物が燃焼することで無機基材内部に空隙が生じ、その空隙が水蒸気の逃げ場となって爆裂を防止することも考えられる。
(Water-absorbing granular material)
In the present invention, water-absorbing particulates are contained in at least one of the plurality of inorganic layers, but the presence of the water-absorbing particulates allows water vapor to be generated even if steam is generated inside the inorganic base material by heating. Explosion can be prevented because it is absorbed by the water-absorbing granular material. The shape of the water-absorbing granular material is not particularly limited, and may be a cube or a rectangular parallelepiped, or may be a plate shape or a spherical shape.
In addition to the above, as a mechanism for preventing the water-absorbing granular material from exploding, voids are generated inside the inorganic base material by burning the water-absorbing granular material prior to other materials when the non-combustible decorative board is burned. It is also conceivable that the void serves as a refuge for water vapor and prevents explosion.
吸水性粒状物のサイズとしては、（１）最も表面化粧層側に位置する無機層に用いるものと、（２）それ以外の無機層に用いるものとで異なる。（１）の場合は、本発明における条件（Ａ）又は（Ｂ）により規定されるため後述する。
（２）の場合は、特に限定はないが、十分な爆裂防止効果を得る観点から、目開き８５０〜１７００μｍのふるい（好ましくは、目開き１０００〜１４００μｍのふるい）を通過するサイズであることが好ましい。
また、前記（２）の場合の吸水性粒状物は、十分な爆裂防止効果を得る観点から、無機基材の全固形分に対して２〜１０質量％含有することが好ましく、５〜８質量％含有することがより好ましい。
以上のような吸水性粒状物としては、木片、木質繊維束、木質パルプ、木毛、木粉等の木質材が挙げられ、中でも、木片、木粉を用いることが好ましい。
The size of the water-absorbing granular material is different between (1) used for the inorganic layer located closest to the surface decorative layer and (2) used for the other inorganic layers. The case (1) will be described later because it is defined by the condition (A) or (B) in the present invention.
In the case of (2), there is no particular limitation, but from the viewpoint of obtaining a sufficient explosion prevention effect, the size should pass through a sieve having an opening of 850 to 1700 μm (preferably, a sieve having an opening of 1000 to 1400 μm). preferable.
Moreover, it is preferable to contain 2-10 mass% with respect to the total solid of an inorganic base material from a viewpoint of obtaining the sufficient explosion prevention effect in the water absorbing granular material in the case of said (2), and 5-8 mass. % Content is more preferable.
Examples of the water-absorbing granular material as described above include wood materials such as wood pieces, wood fiber bundles, wood pulp, wood hair, wood powder, among which wood pieces and wood powder are preferably used.
以上の複数の無機層は、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。
そして、本発明においては、複数の無機層について、次の条件（Ａ）又は（Ｂ）を満足する。
（Ａ）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には吸水性粒状物を含有せず、該無機層以外の無機層に吸水性粒状物を含有する。
（Ｂ）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が最大長さ１ｍｍ以上の吸水性粒状物を含有せず、かつ最も表面化粧層側に位置する無機層以外の無機層が最大長さ１ｍｍ以上の吸水性粒状物を含有する。
ここで、「最大長さ」とは、吸水性粒状物において最も長い部位の直線距離を意味する。具体的には、吸水性粒状物の最大長さは以下のようにして測定することができる。すなわち、まず不燃化粧板を切断し（このとき、切断面に積層構造が現れる様な方向に切断しても、その面に対して例えば４５度程度傾斜していてもよい。）、切断面（端面）を観察する。具体的にはＳＥＭ画像を解析し、ＳＥＭ画像の視野の中にある吸水性粒状物の中で最大長さを有するものを測定対象とし、この測定対象についてコンピュータで画像処理して最大長さを得る。そして、例えば、切断面（端面）の１０箇所においてＳＥＭ画像を取得して上記の作業を行い、その中での最大値をもって無機基材中の吸水性粒状物の最大長さとすることができる。
すなわち、本発明においては、各無機層において、最も表面化粧層側に位置する無機層には吸水性粒状物を含有しないか（条件（Ａ））、あるいは最も表面化粧層側に位置する無機層に吸水性粒状物を含有したとしても最大長さ１ｍｍ以上のものは含有しない（条件（Ｂ））ことを条件としている。このように構成することで、無機基材の表面化粧層側の面には吸水性粒状物が存在しないか、存在したとしても小さいものであり、無機基材表面の平滑性が保たれ、その上に形成する層との優れた接着性を確保することができる。
さらに、無機基材表面は優れた平滑性が保たれるため、その上に形成される層、ひいては最表面の表面化粧層の平滑性にも優れることとなる。
すなわち本発明においては、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には吸水性粒状物を含有しないか、含有しても小さいものであるため優れた平滑性が得られると共に、最も表面化粧層側に位置する無機層以外の無機層には吸水性粒状物を含有するため爆裂を防止することができる。つまり、本発明においては、それら２つの効果が一体として発現している。
The plurality of inorganic layers are preferably 2 to 5 layers, and more preferably 3 to 4 layers.
And in this invention, the following conditions (A) or (B) are satisfied about a some inorganic layer.
(A) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particles, and the inorganic layers other than the inorganic layer contain water-absorbing particles.
(B) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particulates having a maximum length of 1 mm or more, and other than the inorganic layer positioned closest to the surface decorative layer The inorganic layer contains water-absorbing particulates having a maximum length of 1 mm or more.
Here, the “maximum length” means the linear distance of the longest part in the water-absorbing granular material. Specifically, the maximum length of the water-absorbing granular material can be measured as follows. That is, first, the incombustible decorative board is cut (at this time, it may be cut in such a direction that the laminated structure appears on the cut surface, or may be inclined by, for example, about 45 degrees with respect to the cut surface). Observe the end face. Specifically, the SEM image is analyzed, and the water-absorbing granular material in the field of view of the SEM image has the maximum length as a measurement target, and the measurement target is subjected to image processing by a computer to determine the maximum length. obtain. Then, for example, SEM images are acquired at 10 locations on the cut surface (end surface) and the above operation is performed, and the maximum value in the SEM image can be set as the maximum length of the water-absorbing granular material in the inorganic base material.
That is, in the present invention, in each inorganic layer, the inorganic layer positioned closest to the surface decorative layer does not contain water-absorbing particulates (condition (A)), or the inorganic layer positioned closest to the surface decorative layer. Even if it contains water-absorbing particulates, it does not contain any material with a maximum length of 1 mm or more (condition (B)). By comprising in this way, the surface of the inorganic base material on the surface decorative layer side is free of water-absorbing particulates or is small even if it exists, and the smoothness of the surface of the inorganic base material is maintained. Excellent adhesion with the layer formed on the top can be ensured.
Furthermore, since the surface of the inorganic substrate is maintained with excellent smoothness, the layer formed thereon, and hence the outermost surface decorative layer, is also excellent in smoothness.
That is, in the present invention, among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particulates, or even if contained, excellent smoothness is obtained. At the same time, since the inorganic layer other than the inorganic layer located closest to the surface decorative layer contains water-absorbing particulates, explosion can be prevented. That is, in the present invention, these two effects are manifested as an integral unit.
（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を構成する無機補強部材としては、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、各無機層間において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 constituting the inorganic reinforcing member layer include those in which a glass fiber, rock wool, carbon fiber or the like formed in a mesh shape is knitted in a lattice shape, and in particular, the glass fiber is knitted in a lattice shape. Is preferred. 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, more preferably 2 to 3 layers, between the inorganic 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.
［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。
[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.
［酸含有層］
本発明の不燃化粧板において、表面化粧層の接着力を向上させるには、酸を含有してなる酸含有層を介して無機基材に貼付することが好ましい。
セメント系の無機基材はアルカリ性を呈することから、無機基材の表面に上記のようなメラミン樹脂含浸の表面化粧層をそのまま形成しようとすると、アルカリによりメラミン樹脂の硬化が阻害され接着力が劣化する。そこで、酸含有層を介して表面化粧層を形成することで、メラミン樹脂硬化時のアルカリの影響を阻止し、表面化粧層の接着強度を向上させることができる。
[Acid-containing layer]
In the incombustible decorative board of the present invention, in order to improve the adhesive strength of the surface decorative layer, it is preferable to apply the adhesive to the inorganic base material via an acid-containing layer containing an acid.
Since the cement-based inorganic base material exhibits alkalinity, if the surface decorative layer impregnated with melamine resin as described above is formed as it is on the surface of the inorganic base material, the curing of the melamine resin is inhibited by the alkali and the adhesive strength deteriorates. To do. Therefore, by forming the surface decorative layer via the acid-containing layer, it is possible to prevent the influence of alkali when the melamine resin is cured and to improve the adhesive strength of the surface decorative layer.
酸含有層としては、酸を含有させた樹脂含浸紙を用いることが好ましい。具体的には、フェノール樹脂及び酸をコア紙に含浸させたフェノール樹脂含浸紙を例示することができる。このようなフェノール樹脂含浸紙は、コア紙にフェノール樹脂及び酸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。コア紙としては、例えば水酸化アルミニウム抄造紙が用いられる。コア紙の坪量は、コア紙の厚みや重さを考慮して１００〜１６０ｇ／ｍ２であることが好ましい。フェノール樹脂の含浸率は、含浸されるフェノール樹脂の機能を十分に発現するために２０〜４０質量％であることが好適である。加熱、乾燥の温度は、コア紙にフェノール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。なお、フェノール樹脂含浸紙に用いるフェノール樹脂としては、熱硬化性であるレゾール型フェノール樹脂が好ましい。
その他、酸含有層としては、酸を含有させた塗工液（ペースト）を塗工して形成することもできる。
As the acid-containing layer, it is preferable to use resin-impregnated paper containing acid. Specifically, a phenol resin impregnated paper in which a core paper is impregnated with a phenol resin and an acid can be exemplified. Such a phenol resin-impregnated paper is produced by impregnating a core paper with a phenol resin and an acid at a predetermined impregnation rate, followed by heating and drying. As the core paper, for example, aluminum hydroxide paper is used. The basis weight of the core paper is preferably 100 to 160 g / m 2 in consideration of the thickness and weight of the core paper. The impregnation rate of the phenol resin is preferably 20 to 40% by mass in order to sufficiently express the function of the impregnated phenol resin. The heating and drying temperatures are preferably set to 100 to 140 ° C. in order to firmly fix the phenol resin to the core paper. In addition, as a phenol resin used for a phenol resin impregnated paper, the resol type phenol resin which is thermosetting is preferable.
In addition, the acid-containing layer can be formed by applying a coating liquid (paste) containing an acid.
酸含有層には、そのｐＨが７．０〜８．５となるように酸が配合されることが好ましく、同ｐＨが７．５〜８．０となるように酸が配合されることがより好ましい。酸含有層のｐＨが７．０〜８．５となるように酸が配合されることで、アルカリ性を呈する無機基材から漏出するアルカリ成分を中和し、表面化粧層形成時にアルカリ成分の悪影響を防止することができる。 The acid-containing layer is preferably formulated with an acid such that the pH is 7.0 to 8.5, and the acid is preferably blended so that the pH is 7.5 to 8.0. More preferred. By blending the acid so that the pH of the acid-containing layer is 7.0 to 8.5, the alkali component leaking from the inorganic base material exhibiting alkalinity is neutralized, and the adverse effect of the alkali component when forming the surface decorative layer Can be prevented.
酸含有層に含有する酸としては強酸であること、すなわち２５℃におけるｐＫａが−８．０〜５．０の酸が好ましく、同ｐＫａが−３．０〜１．０の酸がより好ましい。上述の通り、酸含有層はｐＨが７．０〜８．５となるように含有すればよいが、弱酸でそのｐＨを達成しようとするとその使用量が必然的に多くなるのに対し、強酸であれば含有量は少量で済む。
酸含有層に使用する酸としては、具体的には、塩酸、パラトルエンスルホン酸、ギ酸、酢酸等が挙げられ、パラトルエンスルホン酸が好ましい。
The acid contained in the acid-containing layer is preferably a strong acid, that is, an acid having a pKa at 25 ° C. of −8.0 to 5.0, and more preferably an acid having a pKa of −3.0 to 1.0. As described above, the acid-containing layer may be contained so as to have a pH of 7.0 to 8.5. However, when the pH is reached with a weak acid, the amount of use is inevitably increased, whereas a strong acid is used. If so, the content is small.
Specific examples of the acid used in the acid-containing layer include hydrochloric acid, p-toluenesulfonic acid, formic acid, acetic acid, and the like, and p-toluenesulfonic acid is preferable.
また、セメント系の無機基材を用いた不燃化粧板は、従来であれば、無機基材がアルカリ性であるために製造時に樹脂が未硬化の状態で残り、強い臭気が発生するという問題があったが、本発明においては、酸含有層を設けることで中和され、樹脂の硬化が進み未反応物が減少し臭気が軽減される。 Further, conventional non-combustible decorative boards using a cement-based inorganic base material have a problem that a strong odor is generated because the resin remains in an uncured state during production because the inorganic base material is alkaline. However, in the present invention, the acid-containing layer is neutralized, the resin is cured, the unreacted substances are reduced, and the odor is reduced.
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、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.
Non-combustible decorative board is a lamination process of laminating at least a surface decorative layer and a backer layer on both front and back surfaces of an inorganic base material, and hot press molding an inorganic base material in which the surface decorative layer and the backer layer are laminated on both front and back surfaces. It is manufactured through a molding process.
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］
（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。なお、以下の木片としては、最大長さが０．８ｍｍのサイズのものを用いた。また、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。
（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％
木片 ０質量％
（２）第２無機層用塗工液
酸化マグネシウム ７３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％
木片 ７質量％
（３）第３無機層用塗工液
酸化マグネシウム ７８質量％
塩化マグネシウム １５質量％
起泡剤 １質量％
木片 ６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。
[Example 1]
(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. In addition, as the following wood pieces, those having a maximum length of 0.8 mm were used. 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.
(1) First inorganic layer coating solution Magnesium oxide 82% by mass
Magnesium chloride 18% by mass
Wood mass 0% by mass
(2) Second inorganic layer coating solution Magnesium oxide 73% by mass
Magnesium chloride 16% by mass
Pearlite 4% by mass
Foaming agent 1% by mass
7% by weight of wood
(3) Third inorganic layer coating solution Magnesium oxide 78% by mass
Magnesium chloride 15% by mass
Foaming agent 1% by mass
Wood 6% 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.
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
（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、フェノール樹脂含浸紙、無機基材、フェノール樹脂含浸紙、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３ｍｍ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)
Laminate melamine resin impregnated paper, phenolic resin impregnated paper, inorganic base material, phenolic resin impregnated paper, and melamine resin impregnated paper in order from the bottom, heat and press molding with a hot press machine, 3mm thick incombustible A decorative board was produced. 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ついて、以下の評価を行った。
［木片の最大長さの測定］
得られた不燃化粧板に対して、切断面に積層構造が現れる様な方向に切断し、切断面（端面）のＳＥＭ画像を解析した。具体的には、ＳＥＭ画像の視野の中にある吸水性粒状物の中で最大長さを有するものを測定対象とし、この測定対象についてコンピュータで画像処理して最大長さを得た。そして、切断面（端面）の１０箇所においてＳＥＭ画像を取得して上記の作業を行い、その中での最大の値をもって基材中の木片の最大長さとした。結果を表１に示す。
［平滑性評価］
得られた無機基材について、表面の凹凸やピンホールの有無を目視にて確認し平滑性を評価した。
The following evaluation was performed about the obtained incombustible decorative board.
[Measure the maximum length of wood pieces]
The obtained incombustible decorative board was cut in such a direction that a laminated structure appears on the cut surface, and an SEM image of the cut surface (end surface) was analyzed. Specifically, among the water-absorbing particulates in the field of view of the SEM image, the object having the maximum length was used as a measurement object, and the measurement object was subjected to image processing by a computer to obtain the maximum length. And SEM image was acquired in 10 places of a cut surface (end surface), and said operation | work was performed, and let the maximum value in it be the maximum length of the piece of wood in a base material. The results are shown in Table 1.
[Smoothness evaluation]
About the obtained inorganic base material, the presence or absence of the unevenness | corrugation of a surface and the presence or absence of a pinhole was confirmed visually, and smoothness was evaluated.
［接着性評価］
ＪＩＳ Ｋ５６００−５−６に準拠し、表面化粧層をカッターを用いて縦２０ｍｍ×横２０ｍｍの範囲を２ｍｍ角の格子パターンにカットした。その後、セロテープ（登録商標）を貼り付け、約６０度の角度で引き剥がした。剥がした後の外観状況で、以下の判定基準に従い、分類０〜分類５に６段階で評価判定した。判定結果を表１に示す。
〜判定基準〜
分類０：どの格子の目にも剥がれがない。
分類１：カットの交差点で塗膜の小さな剥がれがあるが、クロスカット部分で影響を受けるのは５％を上回ることはない。
分類２：カットの縁に沿って剥がれが見られ、クロスカット部分で影響を受けるのは５％を超えるが１５％を上回ることはない。
分類３：カットの縁に沿って部分的又は全面的に剥がれており、クロスカット部分で影響を受けるのは１５％を超えるが３５％を上回ることはない。
分類４：カットの縁に沿って部分的又は全面的に大剥がれを生じているが、クロスカット部分で影響を受けるのは３５％を上回ることはない。
分類５：カットの縁に沿って部分的又は全面的に大剥がれを生じており、クロスカット部分で影響を受けるのは３５％を超える。
[Adhesion evaluation]
In accordance with JIS K5600-5-6, the surface decorative layer was cut into a 2 mm square lattice pattern in a range of 20 mm long × 20 mm wide using a cutter. Then, cellophane (registered trademark) was applied and peeled off at an angle of about 60 degrees. According to the following judgment criteria, the appearance after peeling was evaluated and judged in 6 stages from classification 0 to classification 5. The determination results are shown in Table 1.
~ Criteria ~
Classification 0: There is no peeling in the eyes of any lattice.
Classification 1: Although there is a small peeling of the coating film at the intersection of the cuts, it does not exceed 5% to be affected by the crosscut part.
Classification 2: Peeling is seen along the edge of the cut, and the cross-cut portion is affected more than 5% but not more than 15%.
Classification 3: Peeled partially or completely along the edge of the cut, and the cross-cut portion is affected by more than 15% but not more than 35%.
Category 4: Large or partial peeling occurs along the edge of the cut, but the cross-cut portion does not exceed 35%.
Classification 5: Large or partial peeling occurs along the edge of the cut, and the cross cut portion is affected by over 35%.
［実施例２］
実施例１の無機基材の作製において、「（１）第１無機層用塗工液」の組成を以下のようにしたことを除き、実施例１と同様にして不燃化粧板を作製した。
酸化マグネシウム ８２質量％
塩化マグネシウム １７質量％
木片 １質量％
[Example 2]
In preparation of the inorganic base material of Example 1, a noncombustible decorative board was prepared in the same manner as in Example 1 except that the composition of “(1) first inorganic layer coating solution” was as follows.
Magnesium oxide 82% by mass
Magnesium chloride 17% by mass
1% by weight of wood
［実施例３］
実施例１の無機基材の作製において、「（１）第１無機層用塗工液」の組成を以下のようにしたことを除き、実施例１と同様にして不燃化粧板を作製した。
酸化マグネシウム ７９質量％
塩化マグネシウム １６質量％
木片 ５質量％
[Example 3]
In preparation of the inorganic base material of Example 1, a noncombustible decorative board was prepared in the same manner as in Example 1 except that the composition of “(1) first inorganic layer coating solution” was as follows.
Magnesium oxide 79% by mass
Magnesium chloride 16% by mass
Wood 5% by mass
［実施例４］
実施例１の無機基材の作製において、「（１）第１無機層用塗工液」の組成を以下のようにしたことを除き、実施例１と同様にして不燃化粧板を作製した。
酸化マグネシウム ７５質量％
塩化マグネシウム １５質量％
木片 １０質量％。
[Example 4]
In preparation of the inorganic base material of Example 1, a noncombustible decorative board was prepared in the same manner as in Example 1 except that the composition of “(1) first inorganic layer coating solution” was as follows.
Magnesium oxide 75% by mass
Magnesium chloride 15% by mass
Wood pieces 10% by mass.
［実施例５］
実施例１の無機基材の作製において、「（１）第１無機層用塗工液」の組成を以下のようにしたことを除き、実施例１と同様にして不燃化粧板を作製した。
酸化マグネシウム ７１質量％
塩化マグネシウム １４質量％
木片 １５質量％
[Example 5]
In preparation of the inorganic base material of Example 1, a noncombustible decorative board was prepared in the same manner as in Example 1 except that the composition of “(1) first inorganic layer coating solution” was as follows.
Magnesium oxide 71% by mass
Magnesium chloride 14% by mass
Wood mass 15% by mass
［比較例１］
実施例１の無機基材の作製において、「（１）第１無機層用塗工液」の組成を以下のようにしたことを除き、実施例１と同様にして不燃化粧板を作製した。なお、木片は、最大長さが１．５ｍｍのサイズのものを用いた。
酸化マグネシウム ８２質量％
塩化マグネシウム １７質量％
木片 １質量％
[Comparative Example 1]
In preparation of the inorganic base material of Example 1, a noncombustible decorative board was prepared in the same manner as in Example 1 except that the composition of “(1) first inorganic layer coating solution” was as follows. In addition, the wood piece of the size whose maximum length is 1.5 mm was used.
Magnesium oxide 82% by mass
Magnesium chloride 17% by mass
1% by weight of wood
表１より、実施例１〜３の不燃化粧板は、表面が平滑な無機基材が得られ、接着性に優れていた。また、実施例４及び５の不燃化粧板は、表面に微数の凹凸があるものの実用上問題なく、接着性に優れていた。これに対し、比較例１の不燃化粧板は、無機基材表面に凹凸が多く平滑性に劣り、十分な接着性が得られなかった。つまり、比較例１は、第１無機層に含有させた木片の最大長さが１．４ｍｍであったことのみが実施例２と異なることから、第１無機層に最大長さ１ｍｍ以上の木片を含有しないと上記効果が得られることが分かる。 From Table 1, the incombustible decorative board of Examples 1-3 obtained the inorganic base material with the smooth surface, and was excellent in adhesiveness. Moreover, although the incombustible decorative board of Examples 4 and 5 had a few unevenness | corrugations on the surface, there was no problem practically and it was excellent in adhesiveness. On the other hand, the noncombustible decorative board of Comparative Example 1 had many irregularities on the surface of the inorganic base material and was inferior in smoothness, and sufficient adhesiveness was not obtained. In other words, Comparative Example 1 is different from Example 2 only in that the maximum length of the piece of wood contained in the first inorganic layer was 1.4 mm, and therefore the piece of wood having a maximum length of 1 mm or more in the first inorganic layer. It turns out that the said effect is acquired when it does not contain.
Claims (8)
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、次の条件（Ａ）又は（Ｂ）を満足することを特徴とする不燃化粧板。
（Ａ）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には吸水性粒状物を含有せず、該無機層以外の無機層に吸水性粒状物を含有する。
（Ｂ）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が最大長さ１ｍｍ以上の吸水性粒状物を含有せず、かつ最も表面化粧層側に位置する無機層以外の無機層が最大長さ１ｍｍ以上の吸水性粒状物を含有する。 A non-combustible decorative board having a surface decorative layer on one side of an inorganic base material mainly composed of cement,
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 satisfies the following condition (A) or (B): Incombustible decorative board.
(A) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particles, and the inorganic layers other than the inorganic layer contain water-absorbing particles.
(B) Among the plurality of inorganic layers, the inorganic layer located closest to the surface decorative layer does not contain water-absorbing particulates having a maximum length of 1 mm or more, and other than the inorganic layer positioned closest to the surface decorative layer The inorganic layer contains water-absorbing particulates having a maximum length of 1 mm or more.
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| US11020940B2 (en) * | 2017-01-12 | 2021-06-01 | Euro Trade Flooring, S.L. | Plate for covering horizontal and vertical surfaces |
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| US11020940B2 (en) * | 2017-01-12 | 2021-06-01 | Euro Trade Flooring, S.L. | Plate for covering horizontal and vertical surfaces |
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