JP2017074703A - Decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative sheet excellent in processability and excellent in aesthetic property.SOLUTION: There is provided a decorative sheet 100 having a surface layer 11 and a core material layer 12, wherein the surface layer 11 contains a melamine resin, the core material layer 12 contains a fire retardant nonwoven fabric, airflow quantity of the fiber sheet measured according to JISL1913:2010 (Frazier formation method) is 2 [cm/(cms)] to 220 [cm/(cms)] and preferably the fiber sheet is constituted by a glass and is nonwoven. There is provided a decorative sheet 100, wherein the surface layer 11 is one by impregnating the melamine resin into a fabric substrate.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a decorative board.

  A good-looking space is produced by attaching a decorative plate to the lobby of a building, a hotel, a condominium, a conference room, the wall of an office, and the like. Such decorative panels are used not only for real estate but also as interior materials for vehicles such as trains, airplanes and ships.

  As such a decorative plate, a decorative plate (melamine decorative plate) having a surface made of a melamine resin is widely used because it has excellent hardness and is hardly scratched (for example, Patent Document 1). reference).

  Moreover, in the melamine decorative board, the thing using a glass cloth is widely used for the purpose of the stability of a shape, the improvement of a flame retardance, etc.

  However, the conventional melamine decorative board has a problem that it is inferior in workability such as bending molding, although it is excellent in hardness and the like.

  In addition, as described above, when glass cloth is used, the flame retardancy of the melamine decorative board can be improved, but on the other hand, the surface of the melamine decorative board (design surface) has an uneven surface. As a result, there is a problem that the aesthetics of the melamine decorative board are lowered.

JP 2013-202906 A

  An object of the present invention is to provide a decorative board having excellent processability and excellent aesthetics.

Such an object is achieved by the present inventions (1) to (12) below.
(1) A decorative board having a surface layer and a core material layer,
The surface layer contains a melamine resin,
The core material layer includes a flame retardant fiber sheet,
The air flow rate of the fiber sheet measured according to JIS L1913: 2010 (Fragile method) is 2 [cm ³ / (cm ² · s)] or more and 220 [cm ³ / (cm ² · s)] or less. A decorative board characterized by that.

  (2) The decorative sheet according to (1), wherein the fiber sheet includes fibers made of an inorganic material.

(3) The decorative board according to (2), wherein the fiber is made of glass.
(4) The decorative board according to any one of (1) to (3), wherein an average diameter of fibers constituting the fiber sheet is 6 μm or more and 13 μm or less.

  (5) The decorative board according to any one of (1) to (4), wherein the fiber sheet has a thickness of 230 μm or more and 800 μm or less.

(6) The decorative board according to any one of (1) to (5), wherein the basis weight of the fiber sheet is 15 g / m ² or more and 180 g / m ² or less.

  (7) The decorative sheet according to any one of (1) to (6), wherein the fiber sheet is a nonwoven fabric.

  (8) The decorative board according to (7), wherein an average length of fibers constituting the nonwoven fabric is 6000 μm or more and 25000 μm or less.

  (9) The decorative board according to any one of (1) to (8), wherein the surface layer is a fibrous base material impregnated with the melamine resin.

(10) The decorative board according to (9), wherein the base material contains titanium oxide.
(11) The decorative sheet according to any one of (1) to (10), wherein the surface layer has a surface on the side facing the core layer made of a material containing a urethane resin.

  (12) The decorative board according to any one of (1) to (11), wherein a surface roughness Ra of the surface layer is 600 μm or less.

  ADVANTAGE OF THE INVENTION According to this invention, while being excellent in a flame retardance, it is excellent in workability and can provide the decorative board excellent in aesthetics.

It is sectional drawing which shows suitable embodiment of the decorative board of this invention. It is sectional drawing which shows suitable embodiment of the manufacturing method of the decorative board of this invention. It is sectional drawing which shows other suitable embodiment of the decorative board of this invention. It is sectional drawing which shows other suitable embodiment of the decorative board of this invention. It is a figure which shows the diamond indenter (a) used for the measurement of the Martens hardness in this specification, the schematic diagram (b) of pushing operation, and an example (c) of pushing load and displacement.

  Hereinafter, the decorative board of the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.

<< decorative board >>
A decorative plate can be attached to a lobby of a building, a hotel, a condominium, a wall surface of a conference room, an office, or the like to improve the appearance of the space. Further, the decorative plate may be used not only as a real estate, but also as an interior material for vehicles such as trains, airplanes, ships, and the like.

FIG. 1 is a cross-sectional view showing a preferred embodiment of the decorative board of the present invention.
As shown in FIG. 1, a decorative board (melamine decorative board) 100 has a surface layer 11 and a core material layer 12.

<Surface layer>
The surface layer (melamine-based resin layer) 11 includes a melamine-based resin on the first surface 111 side serving as a design surface.

  The melamine resin contained in the surface layer 11 is a polymer containing at least a melamine compound and an aldehyde compound as constituent components.

  The melamine compound constituting the melamine-based resin is a compound having a 1,3,5-triazine skeleton and having three amino groups introduced into the triazine ring.

  As a preferable structure of a melamine compound, what is represented by following formula (3) etc. are mentioned, for example.

（式（３）中、Ｒ^１、Ｒ^２およびＲ^３は、それぞれ独立に、水素原子または置換基を有していてもよい炭素数が１以上４以下の炭化水素基である。）

(In formula (3), R ¹ , R ² and R ³ are each independently a hydrogen atom or a hydrocarbon group having 1 to 4 carbon atoms which may have a substituent.)

As the melamine compound, a compound (melamine) in which R ¹ , R ² and R ³ in formula (3) are all hydrogen atoms is particularly preferable.

  Thereby, the hardness and workability of the decorative board 100 can be made compatible at a higher level. Moreover, the synthesis | combination of the melamine type resin which comprises the decorative board 100 can be performed more efficiently.

  The aldehyde compound constituting the melamine resin may be any compound having an aldehyde group (—CHO) in the molecule, and examples thereof include those represented by the following formula (2).

（式（２）中、Ｒは、水素原子または置換基を有していてもよい炭素数が１以上１０以下の炭化水素基である。）

(In the formula (2), R is a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms which may have a substituent.)

As the aldehyde compound, formaldehyde is particularly preferable.
Thereby, the hardness and workability of the decorative board 100 can be made compatible at a higher level. Moreover, the synthesis | combination of the melamine type resin which comprises the decorative board 100 can be performed more efficiently.

  The melamine resin contained in the surface layer 11 may be a polymer including at least a melamine compound and an aldehyde compound as constituent components, and may include other constituent components. Examples of such components include guanamine compounds and sulfonamide compounds.

  When the melamine-based resin contained in the surface layer 11 contains a guanamine compound as a constituent component, the surface layer (melamine-based resin layer) 11 has a sufficiently high hardness and is not easily scratched. The workability of 100 can be made more excellent.

  A guanamine compound is a compound having a 1,3,5-triazine skeleton, in which two amino groups are introduced into the triazine ring.

  A preferable structure of the guanamine compound includes, for example, a structure represented by the following formula (1).

（式（１）中、Ｒは、水素原子または置換基を有していてもよい炭素数が１以上１０以下の炭化水素基である。）

(In formula (1), R is a hydrogen atom or a hydrocarbon group having 1 to 10 carbon atoms which may have a substituent.)

  Examples of the guanamine compound include acetoguanamine, benzoguanamine, formguanamine, and the like. Particularly, a compound (acetoguanamine) in which R in the formula (1) is a methyl group is preferable.

  Thereby, the hardness and workability of the decorative board 100 can be made compatible at a higher level. Moreover, the synthesis | combination of the melamine type resin which comprises the decorative board 100 can be performed more efficiently.

  When the melamine resin contained in the surface layer 11 contains a sulfonamide compound as a constituent component, the moisture resistance, antifouling property, durability and the like of the decorative board 100 can be made particularly excellent.

Examples of the sulfonamide compound include p-toluenesulfonamide (CH ₃ -C ₆ H ₅ —SO ₂ NH ₂ ), sulfonamide, methanesulfonamide, benzenesulfonamide, toluene-4-sulfonamide, and 4-chlorobenzenesulfone. Amide, 4-aminobenzenesulfonamide, N-butyl-4-methyl-benzenesulfonamide, N-phenyl-benzenesulfonamide, N-phenyl-4-methyl-benzenesulfonamide, 4-amino-N-pyridine-2 -Ylbenzenesulfonamide, 4-amino-N- (5-methyl-thiazol-2-yl) -benzenesulfonamide, 4-amino-N-thiazol-2-yl-benzenesulfonamide, 4-amino-N- (5-Methyl-isoxazol-3-yl) -benzene Sulfonamide, 4-amino-N- (2,6-dimethoxy-pyrimidin-4-yl) -benzenesulfonamide, 1,2-benzisothiazol-3 (2H) -one 1,1-dioxide, 4-amino -6-chloro-benzene-1,3-disulfonic acid diamide, 6-ethoxy-benzothiazole-2-sulfonic acid amide, 5-dimethylamino-naphthalene-1-sulfonic acid amide, 4-sodiumoxy-benzenesulfonamide, N- (4-benzenesulfonylamino-phenyl) -benzenesulfonamide and the like can be mentioned, among which p-toluenesulfonamide is preferable.

  Thereby, the moisture resistance, antifouling property, durability, etc. of the decorative board 100 can be further improved. Moreover, the synthesis | combination of the melamine type resin which comprises the decorative board 100 can be performed more efficiently.

The surface layer 11 may contain materials other than the melamine resin described above.
For example, divalent or higher polyalkylene glycol and derivatives thereof, urethane resin, acrylic resin, vinyl acetate copolymer, styrene butadiene rubber (SBR), nitrile rubber (NBR), a compound having a structure containing fluorine or silicon, A thickener, a penetration enhancer, an antifoaming agent, etc. are mentioned.

  In the case of containing a divalent or higher polyalkylene glycol or a derivative thereof, the elastic modulus of the cured resin can be lowered, and the workability and toughness (hardness to crack) can be made more excellent.

  Specific examples of the divalent or higher polyalkylene glycol and derivatives thereof include, for example, polyethylene glycol, polypropylene glycol, polybutylene glycol, poly (oxyethylene-oxypropylene) glycol, poly (oxyethylene-oxytetramethylene) glycol, poly (Oxypropylene-oxytetramethylene) glycol (above, divalent polyalkylene glycol or derivative thereof), polyethylene glycol glyceryl ether, polypropylene glycol glyceryl ether, polybutylene glycol glyceryl ether, poly (ethylene glycol-propylene glycol) glyceryl ether, Poly (propylene glycol-tetramethylene glycol) glyceryl ether (above trivalent polyalkylene) Glycol polyvalent ether), polyethylene glycol pentaerythritol ether, polypropylene glycol pentaerythritol ether, polybutylene glycol pentaerythritol ether, poly (ethylene glycol-propylene glycol) pentaerythritol ether (above, tetravalent polyalkylene glycol polyvalent ether), etc. Is mentioned.

  In addition, by including a urethane-based resin, the bonding strength between the surface layer 11 and the core material layer 12 can be improved, and more excellent flexibility can be imparted to the decorative board 100. The bending workability of the plate 100 can be further improved.

  The urethane-based resin may be included in any form. For example, the urethane-based resin may be included in a state of being mixed with the melamine-based resin described above, but included in the surface layer 11 in the form of particles. (Particularly, obtained by removing the solvent after applying an emulsion in which particles composed of a material containing a urethane resin are dispersed in a solvent).

  As a result, the bonding strength between the surface layer 11 and the core material layer 12 can be further improved, and further excellent flexibility can be imparted to the decorative board 100, so that the bending workability of the decorative board 100 can be improved. Can be further improved.

  The particles may be composed of, for example, a urethane resin alone, but include an acrylic resin together with the urethane resin, in particular, a different phase between the acrylic resin and the urethane resin in a single particle. Particles having a structure (urethane acrylic composite particles) are preferable.

  Since each of the urethane-based resin and the acrylic-based resin is excellent in the adhesive strength with the core material layer 12, the use of urethane-acrylic composite particles can express good adhesive strength with the core material layer 12. it can. In addition, the excellent characteristics of urethane resins (excellent toughness, elasticity, flexibility) and the excellent characteristics of acrylic resins (excellent transparency, durability, weather resistance, chemical resistance, Both are effective.

  In the present specification, “heterophasic structure” means a structure in which a plurality of phases composed of different types of resins are present in one particle, and examples thereof include a core-shell structure, a localized structure, and a sea-island structure. It is done.

  Among the foregoing, the urethane-acrylic composite particles preferably have a core-shell structure in which the acrylic component is a core and the urethane component is a shell.

  When the urethane-acrylic composite particles have the above-described core-shell structure, the properties of the urethane-based resin are imparted to the outer shell while having the properties of both the urethane-based resin and the acrylic-based resin.

  In the above description, the case where the particles contained in the surface layer 11 include a urethane-based resin has been representatively described. However, other thermoplastic resins (for example, vinyl acetate-based copolymer, styrene-butadiene rubber (SBR)). ), Particles including nitrile rubber (NBR), etc.), the same effects as described above can be obtained.

  When the surface layer 11 includes the particles, the particles are preferably unevenly distributed on the second surface 112 side of the surface layer 11.

  Thereby, the effect by including the said particle | grain is exhibited more notably, and the effect by having comprised with the material containing a melamine type resin as mentioned above can be exhibited more notably.

  Moreover, the arrangement | sequence state between the particle | grains in the 2nd surface 112 side of the surface layer 11 is not specifically limited, For example, a linear structure etc. are mentioned. The structure of the particles and the arrangement state between the particles can be confirmed by, for example, a scanning electron microscope (SEM).

  The average particle size of the particles is preferably 30 nm or more and 100 nm or less, and more preferably 60 nm or more and 90 nm or less.

  Thereby, when the surface layer 11 includes a surface layer base material (a surface layer base material containing a fibrous substance) as described later, the impregnation property between the fibers of the particles is improved. Since the emulsion resin particles can be impregnated into a deep part, the flexibility of the surface layer 11 can be made particularly excellent.

  In this specification, the average particle diameter means a volume-based average particle diameter unless otherwise specified.

  Here, the particle diameter can be measured by dispersing the target particles in water by ultrasonic treatment for 1 minute using a laser diffraction particle size distribution analyzer SALD-7000.

  Further, the surface layer 11 may include a sheet-like surface layer base material containing a fibrous substance.

  Thereby, for example, the resin material (melamine-based resin, resin constituting the particles, etc.) described above can be suitably supported in an impregnated state, and the durability and the like of the decorative board 100 are particularly excellent. be able to. In particular, by having a surface layer base material, the melamine-based resin is unevenly distributed on one surface (first surface 111) side of the surface layer 11, and the particles are disposed on the other surface (second surface 112) side. Since these can be unevenly distributed, they can be effectively prevented from being mixed inadvertently, and these functions can be exhibited more effectively. In addition, since the surface layer 11 includes the surface layer base material, the aesthetic property (aesthetic appearance) of the decorative board 100 can be easily and reliably obtained by using a surface layer base material that has been printed in advance. It can be made excellent.

  The material of the surface layer substrate is not particularly limited, and for example, pulp, linter, synthetic fiber, glass fiber, or the like can be used. Moreover, the titanium oxide containing decorative paper etc. which contain pigments, such as a titanium oxide, can be used as needed.

  Moreover, it is preferable that the surface layer base material is not composed of a woven fabric. Thereby, the smoothness of the surface of the decorative board 100 can be made more excellent, and the aesthetics of the decorative board 100 can be made more excellent.

  In particular, when the surface layer base material contains titanium oxide, the color development of the printed portion provided on the surface layer base material can be made more excellent, and the decorative plate 100 can be made more aesthetic. Can be. Moreover, the flame retardance of the decorative board 100 can be made more excellent.

The basis weight of the surface layer substrate is not particularly limited, is preferably 40 g / ^{m 2} or more 150 g / ^{m 2} or less.

  When the basis weight is less than the lower limit, the surface layer base material absorbs the resin, and the coating process is difficult due to the problem of cutting and wrinkling in the step of impregnating the surface layer base material with the resin. Further, it may be difficult to adjust the amount of resin impregnation carried on each of the first surface and the second surface.

  On the other hand, when the basis weight exceeds the above upper limit, in the case where the surface layer base material absorbs the resin, the impregnation amount of the resin carried by the surface layer base material is likely to be uneven, and the decorative board 100 is flexible. In addition to lowering the productivity, it may cause a reduction in productivity and cost.

  The thickness of the surface layer base material is not particularly limited, but is preferably 50 μm or more and 300 μm or less, more preferably 80 μm or more and 200 μm or less, and further preferably 90 μm or more and 110 μm or less.

  Thereby, the effect by providing the surface layer base material as described above can be exhibited more significantly while making the workability of the decorative board 100 more excellent.

  The surface layer base material constituting the surface layer 11 preferably supports the particles described above on the second surface 112 side facing the core material layer 12.

  Thereby, the adhesiveness between the surface layer 11 and the core material layer 12 can be made particularly excellent, the durability of the decorative board 100 can be made particularly excellent, and the workability of the decorative board 100 can be improved. Can be made particularly excellent.

  In the present specification, the surface layer base material carrying the resin means that the resin adheres to the surface of the surface layer base material (carrier) or is impregnated in the voids inside the surface layer base material. It means a state in which it is possible to develop the performance of the resin carried after the molding of the material. The resin may not be uniformly distributed on the surface of the surface layer base material and the inside of the surface layer base material.

  Moreover, the surface layer 11 may be provided with what does not contain a fibrous substance as a sheet-like surface layer base material.

  For example, the surface layer 11 may include a metal film (for example, metal foil) as the surface layer base material.

  Thereby, the external appearance of the decorative board 100 can be made to exhibit the glossiness excellent in a high-class feeling, and the improvement of aesthetics can be aimed at.

  Moreover, the surface layer 11 may contain the film (sheet | seat) comprised with the resin material as a surface layer base material.

  Thereby, a decorative board with less ink bleeding can be provided, and the aesthetics can be further improved.

  The surface layer 11 is formed by supporting a resin containing a melamine resin on the first surface 111 side.

  Thereby, a suitable surface hardness can be imparted to the surface of the surface layer 11 on the first surface 111 side, that is, the surface of the surface layer 11.

The content of the melamine resin in the resin supported on the first surface 111 side of the surface layer 11 is not particularly limited, but is preferably 80% by mass or more and 100% by mass or less, and 95% by mass or more and 100% by mass. % Or less is more preferable.
Thereby, the effects as described above are more remarkably exhibited.

  The thickness of the surface layer 11 is not particularly limited, but is preferably 50 μm or more and 300 μm or less, more preferably 80 μm or more and 200 μm or less, and further preferably 90 μm or more and 110 μm or less.

  Thereby, the balance of the shape stability and workability of the decorative board 100 can be made particularly excellent, and the hardness and the like of the decorative board 100 can also be made particularly excellent.

Martens hardness of the surface of the surface layer 11 (the first surface 111) is preferably at 300N / mm ² or more 700 N / mm ² or less, more preferably at 350 N / mm ² or more 650 N / mm ² or less, More preferably, it is 400 N / mm ² or more and 600 N / mm ² or less.

  As a result, the hardness of the surface layer 11 is sufficiently high, scratches are particularly difficult to be made, and the workability of the decorative board 100 is particularly excellent.

In addition, the Martens hardness in this specification is a value measured using a surface film physical property tester (PICODETOR HM-500, manufactured by Fisher Instruments Co., Ltd.), and a specific measuring method is as follows. . In this measurement method, the diamond indenter (Vickers indenter) shown in FIG. 5 (a) is used to push the diamond indenter into the measurement sample as shown in FIG. 5 (b), and the diagonal line of the pyramid-shaped depression formed on the surface. The surface area A (mm ² ) is calculated from the length of and the hardness is obtained by dividing the test load F (N). As shown in FIG. 5 (c), the indentation conditions were as follows. First, a load of 0 to 5 mN was applied for 10 seconds, and then a 5 mN load was maintained for 5 seconds. Unloading to ~ 0mN is performed in 10 seconds. And the hardness calculated | required by F / A based on the surface area A and the test load F is the said Martens hardness. In addition, you may perform the measurement of Martens hardness about the cross section of a surface layer (melamine-type resin layer), in order to avoid the influence of the hardness of layers other than a surface layer (melamine-type resin layer), for example. In this case, the decorative board is embedded with a resin (cold-curing type epoxy two-component curable resin), allowed to stand at room temperature for 24 hours or more and cured, and then the cured embedded sample is mechanically polished to obtain a surface layer ( The cross section of the melamine-based resin layer) is exposed, and the Martens hardness of the cross section is measured by pushing a diamond indenter into the cross section (at a position avoiding the fine particles such as filler when the layer contains fine particles). be able to. In the examples described later, the Martens hardness was measured in this way.

<Core material layer>
In addition to the surface layer (melamine-based resin layer) 11, the decorative board 100 of the present embodiment further includes a core material layer 12 including a flame retardant fiber sheet, and the core material layer 12 is the surface layer 11. It is joined to the second surface 112 side.

  Thereby, the shape stability and durability of the decorative board 100 are particularly excellent. Moreover, the flame retardance as the decorative board 100 whole can be made excellent.

Although the fiber sheet which comprises the core material layer 12 should just have a flame retardance, the calorific value of the decorative board 100 at the time of performing a corn calorie combustion test, for example is 8 MJ / m < ² >. preferably a is the the following, more preferably those of 7 mJ / m ² or less, even more preferably those of 6 mJ / m ² or less.

And the fiber sheet which comprises the core material layer 12 satisfies the following conditions. That is, the air flow rate (hereinafter also simply referred to as “air flow rate”) of the fiber sheet measured in accordance with JIS L1913: 2010 (Fragile method) is 2 [cm ³ / (cm ² · s)] or more and 220. [Cm ³ / (cm ² · s)] or less.

  Thereby, while being excellent in a flame retardance, it can provide the decorative board excellent in workability, excellent in surface smoothness, and excellent in aesthetics.

  On the other hand, the workability (especially bending workability) of the decorative board 100 will fall remarkably that the ventilation | gas_flowing amount of a fiber sheet is less than the said lower limit.

  Moreover, when the air flow rate of the fiber sheet exceeds the upper limit, the surface smoothness of the surface layer 11 is drastically lowered, and the aesthetics of the decorative board 100 are significantly lowered. In order to solve such a problem, it is conceivable to increase the thickness of the surface layer 11, but in such a case, the workability (particularly bending workability) of the decorative board 100 is significantly lowered. Moreover, it becomes difficult to make the flame retardance of the decorative board 100 as a whole excellent.

As described above, the air flow rate of the fiber sheet constituting the core layer may be 2 [cm ³ / (cm ² · s)] or more and 220 [cm ³ / (cm ² · s)] or less. It is preferably 10 [cm ³ / (cm ² · s)] or more and 200 [cm ³ / (cm ² · s)] or less, and 75 [cm ³ / (cm ² · s)] or more and 190 [cm ³ / s (Cm ² · s)] or less is more preferable.

  Thereby, the effect mentioned above is exhibited more notably and all of a flame retardance, workability, and aesthetics can be made more excellent in a higher level.

The fiber sheet constituting the core material layer 12 is preferably a nonwoven fabric.
Unlike a woven fabric (for example, glass cloth, etc.) in which fibers are regularly arranged and where the fibers overlap regularly, the nonwoven fabric is irregularly arranged, and the portions where the fibers overlap are also irregular ( Will be located randomly). For this reason, the smoothness of the entire surface can be made high, the unevenness at the part where the fibers overlap and other parts are difficult to be visually recognized, and the aesthetics of the decorative board 100 are more excellent. can do.

The fiber sheet constituting the core material layer 12 is preferably subjected to defibrating treatment.
Thereby, the fiber sheet which comprises the core material layer 12 shall satisfy | fill the conditions of the air flow rate as mentioned above more easily and reliably.

  The fiber sheet included in the core material layer 12 may be composed of any material as long as it is composed of a flame retardant material, but preferably includes fibers composed of an inorganic material. .

  In general, the flame-retardant inorganic material is excellent in chemical stability, and the durability of the decorative board 100 can be further improved.

In particular, the fibers of the fiber sheet are preferably made of a glass material.
Thereby, the rigidity etc. of the decorative board 100 can be made especially excellent. Further, since the glass material is relatively inexpensive and easily available, it is advantageous from the viewpoint of cost reduction and stable production of the decorative board 100.

  Examples of the glass constituting the fiber sheet include E glass, C glass, A glass, S glass, D glass, NE glass, T glass, and H glass.

Among these, T glass is preferable.
Thereby, the thermal expansion coefficient of a fiber sheet can be made small.

  And it is preferable that the fiber sheet contained in the core material layer 12 satisfies the following conditions. That is, the average diameter (average thickness) of the fibers constituting the fiber sheet is A [μm], the average length of the fibers is B [μm], and in any in-plane direction of the fiber sheet included in the core material layer 12. The tensile strength in a certain first direction is T [N / 25 mm], and the tensile strength is in the in-plane direction of the fiber sheet included in the core material layer 12 and in the second direction orthogonal to the first direction. When the strength is Y [N / 25 mm], it is preferable that the conditions of the following formula [1] and the following formula [2] are satisfied.

1000 ≦ B / A ≦ 2000 (1)
0.4 ≦ T / Y ≦ 2.5 (2)

  Thereby, workability and aesthetics of the decorative board 100 can be made compatible at a higher level. Moreover, when attaching a decorative board to a wall surface or the like, an adhesive (such as an adhesive tape) is usually used, but by satisfying the above conditions, the adhesiveness between the decorative board and the adhesive is excellent. The bonding strength between the decorative plate and the adherend (wall surface or the like) can be made excellent.

  Tensile strength (tensile strength) can be determined by measuring a sample with a width of 25 mm in accordance with JIS P 8113, and a tensile tester (for example, a desktop horizontal tensile tester No. 2000 (Kumagaya Riki Kogyo) Etc.) and the like, and the average value can be adopted as the tensile strength (tensile strength). In the examples described later, a desktop horizontal tensile tester No. 2000 (manufactured by Kumagai Riki Kogyo Co., Ltd.) was used to measure the tensile strength (tensile strength) by such a method.

As described above, there is a relationship of 1000 ≦ B / A ≦ 2000 between the average diameter A [μm] of the fibers constituting the fiber sheet included in the core material layer 12 and the average length B [μm] of the fibers. However, it is more preferable that the relationship of 1100 ≦ B / A ≦ 1950 is satisfied, and it is more preferable that the relationship of 1200 ≦ B / A ≦ 1900 is satisfied.
Thereby, the effect mentioned above is exhibited more notably.

Further, as described above, the tensile strength T [N / 25 mm] in the first direction which is an arbitrary in-plane direction of the fiber sheet included in the core material layer 12, the fiber sheet included in the core material layer 12. The relationship of 0.4 ≦ T / Y ≦ 2.5 is satisfied between the in-plane direction and the tensile strength Y [N / 25 mm] in the second direction orthogonal to the first direction. However, it is more preferable to satisfy the relationship of 0.5 ≦ T / Y ≦ 2.0, and it is even more preferable to satisfy the relationship of 0.67 ≦ T / Y ≦ 1.5.
Thereby, the effect mentioned above is exhibited more notably.

  The average diameter A of the fibers constituting the fiber sheet contained in the core material layer 12 is preferably 6 μm or more and 13 μm or less, and more preferably 7 μm or more and 12 μm or less.

  Thereby, the surface smoothness of the surface layer 11 and the aesthetics of the decorative board 100 can be made more excellent, and the workability of the decorative board 100 can be made more excellent.

  When the fiber sheet contained in the core material layer 12 is a nonwoven fabric, the average length B of the fibers constituting the nonwoven fabric is preferably 6000 μm or more and 25000 μm or less, and more preferably 7000 μm or more and 22000 μm or less.

  Thereby, the surface smoothness of the surface layer 11 and the aesthetics of the decorative board 100 can be made more excellent, and the workability of the decorative board 100 can be made more excellent.

The tensile strength in the direction in which the tensile strength is maximum among the in-plane directions of the fiber sheet included in the core material layer 12 is preferably 150 [N / 25 mm] or more, and preferably 290 [N / 25 mm] or more. It is more preferable that
Thereby, the durability and workability of the decorative board 100 can be further improved.

The tensile strength in the direction in which the tensile strength is minimum among the in-plane directions of the fiber sheet included in the core material layer 12 is preferably 50 [N / 25 mm] or more, and 140 [N / 25 mm] or more. It is more preferable that
Thereby, the durability and workability of the decorative board 100 can be further improved.

Although the basic weight of the fiber sheet contained in the core material layer 12 is not particularly limited, it is preferably 15 g / m ² or more and 180 g / m ² or less, more preferably 50 g / m ² or more and 110 g / m ² or less. preferable.

  Thereby, while making the workability of the decorative board 100 and the ease of handling especially excellent, the flame retardance as the decorative board 100 whole can be made more excellent.

The thickness of the fiber sheet contained in the core material layer 12 is preferably 230 μm or more and 800 μm or less, more preferably 240 μm or more and 790 μm or less, and further preferably 300 μm or more and 600 μm or less.
Thereby, the durability and workability of the decorative board 100 can be further improved.

The density of the fiber sheet contained in the core material layer 12 is preferably 0.12 g / cm ³ or more and 0.14 g / cm ³ or less.

  Thereby, while being able to make the surface smoothness of the surface layer 11 and the aesthetics of the decorative board 100 more excellent, the workability and durability of the decorative board 100 can be made more excellent.

  Although the core material layer 12 should just contain a flame-retardant fiber sheet, it may contain a component other than that.

  For example, the core material layer 12 may include various resin materials such as a thermoplastic resin and a thermosetting resin. Thereby, the rigidity and mechanical strength of the decorative board 100 can be made more excellent. Moreover, the flame retardance of the decorative board 100 can be made more excellent.

  Examples of the thermoplastic resin contained in the core material layer 12 include an acrylic resin, a urethane resin, an ethylene vinyl acetate resin, and a styrene butadiene rubber (SBR). Among these, it is preferable to use an acrylic resin and / or a urethane resin.

  Examples of the thermosetting resin contained in the core material layer 12 include phenol resin, epoxy resin, oxetane resin, (meth) acrylate resin, unsaturated polyester resin, diallyl phthalate resin, urea resin, and maleimide resin. It is done. Among these, a phenol resin is preferable from the viewpoint of flame retardancy, heat resistance, and adhesion. These resins can be used alone or in combination.

  Such a core material layer 12 can be suitably formed using, for example, a prepreg including a fiber sheet and a resin material.

  The prepreg is not particularly limited, and for example, a prepreg that is obtained by impregnating the above-described fiber sheet with a resin composition containing a resin material or the like can be used.

  The content of the resin composition contained in the prepreg is not particularly limited as long as the interlayer adhesion strength with the surface layer 11 is sufficient for forming the decorative board 100. However, when a thermoplastic resin is used, the prepreg is not limited. The solid content is preferably 1% by mass or more and 20% by mass or less, and more preferably 1% by mass or more and 10% by mass or less. Moreover, when using a thermosetting resin, it is preferable to contain 1 to 20 mass% by solid content in a prepreg, and it is more preferable to contain 2 to 10 mass%. Thereby, the interlayer adhesive strength of the surface layer 11 and the core material layer 12 can be improved.

  The prepreg can be produced by a conventionally known method. For example, the prepreg can be obtained by impregnating and drying a varnish obtained by dissolving a resin in a solvent in a fiber sheet similar to the above-described fiber sheet.

  Further, the core material layer may include particles as described above as a constituent component of the surface layer 11.

  Thereby, the bonding strength between the surface layer 11 and the core material layer 12 can be made more excellent, and the bending workability around room temperature (25 ° C.) can be made particularly excellent.

  The thickness of the core material layer 12 is preferably 230 μm or more and 800 μm or less, more preferably 240 μm or more and 790 μm or less, and further preferably 300 μm or more and 600 μm or less.

  Thereby, the heat resistance and flame retardance as the whole decorative board 100 can be made especially excellent, preventing the fall of the ease of handling of the decorative board 100, and the increase in production cost.

  The decorative board 100 preferably has an overall thickness (average thickness) of 0.3 mm or greater and 3 mm or less, and more preferably 0.4 mm or greater and 1.2 mm or less.

  Thereby, the decorative board 100 can perform bending more easily, having sufficient mechanical strength.

  The surface roughness Ra of the first surface 111 of the surface layer 11 is preferably 600 μm or less, and more preferably 400 μm or less.

  Thereby, the smoothness of the surface (the 1st surface 111) of the decorative board 100 can be made more excellent, and the aesthetics of the decorative board 100 can be made more excellent.

<< Manufacturing method of decorative board >>
Next, the manufacturing method of the decorative board mentioned above is demonstrated.
FIG. 2 is a cross-sectional view showing a preferred embodiment of the method for producing a decorative board of the present invention.

  First, the first layer 11 ′ composed of a material containing an uncured melamine resin is formed (see FIG. 2 (1 a)). The first layer 11 ′ is a layer that becomes the surface layer 11 described above.

  In particular, in the present embodiment, the first layer 11 ′ includes a surface layer base material, and a resin containing a melamine resin on one surface of the surface layer base material (the first surface 111 serving as a design surface). Is formed (supporting step), and the other surface is supported with the solid content of the emulsion as described above.

  As a method for supporting a resin containing a melamine resin on a surface layer base material, for example, a resin composition containing a melamine resin is used using a known device such as a spray device, a shower device, a kiss coater, or a comma coater. The method of giving etc. are mentioned.

  Examples of the method of supporting the solid content of the emulsion on the surface layer base material include a method of applying the emulsion using a known device such as a spray device, a shower device, a kiss coater, or a comma coater.

  Next, a resin composition containing a melamine-based resin of the first layer 11 ′ was applied to a base 12 ′ made of a material (core material layer material) containing a flame retardant fiber sheet prepared separately. It arrange | positions so that the surface of a side may be opposed (refer FIG. 2 (1b)). The base body 12 ′ is a layer that becomes the core material layer 12 described above.

  Next, heating is performed while the first layer 11 ′ and the base 12 ′ are in contact with each other. Thus, the decorative layer 100 having the surface layer 11 and the core material layer 12 is obtained by thermocompression bonding of the first layer 11 ′ and the base body 12 ′ (see FIG. 2 (1 c)). Further, by this heating, the resin composition containing the melamine resin contained in the first layer 11 ′ is polymerized and cured (curing step). Thereby, the hardness and durability of the decorative board 100 are particularly excellent.

  The heating conditions are not particularly limited, but it is preferable to perform the heating at a heating temperature of 130 ° C. to 150 ° C. and a pressure of 2 MPa to 8 MPa. The heating time is preferably 10 minutes or more and 60 minutes or less.

  Further, when the decorative plate 100 is molded, a mirror finish can be achieved by overlapping a mirror finish plate on the first surface side of the first layer 11 ′.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention. It is.

  For example, the decorative board of the present invention is not limited to the form of the decorative board 100 shown in FIG. 1, and when it is desired to give mechanical strength or the like, as shown in FIG. Another core material layer material may be laminated and two core material layers may be laminated to form a three-layer structure of the surface layer 11, the core material layer 12, and the core material layer 14. Moreover, you may have another layers other than a surface layer and a core material layer, for example, as shown in FIG. 4, it has the protective layer 15 in the outermost layer by the side of a design surface, or a core material layer side The support layer 16 may be provided as the outermost layer.

The protective layer 15 is not particularly limited. For example, a paper substrate having a basis weight of 10 g / m ² or more and 50 g / m ² or less, a melamine resin alone, or a melamine resin, aluminum hydroxide, magnesium hydroxide, Or it can obtain by impregnating the resin composition containing the inorganic filler chosen from silica, and drying this.

  The support layer 16 is not particularly limited. For example, a base material similar to that used for the surface layer base material is impregnated with a resin that can be used on the first surface side or the second surface side of the surface layer. Prepregs, metal foils, and the like can be used.

  In the present invention, the decorative board may have an intermediate layer between the surface layer and the core material layer.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail based on an Example and a comparative example, this invention is not limited to this.

Example 1
Using a titanium oxide-containing decorative paper (Dai Nippon Printing Co., Ltd.) having a thickness of 100 μm and a basis weight of 80 g / m ² as the surface layer base material, a urethane acrylic composite is provided on the second surface side of the titanium oxide-containing decorative paper. An emulsion of particles (“SU-100” manufactured by Chuo Rika Kogyo Co., Ltd., average particle size: 84 nm, dispersion medium: water) was applied to a solid content of 40 g / m ^2, and then the first of the decorative paper was used. On the surface side (design surface side) of melamine resin (reaction molar ratio 1.4, resin solid content 50 mass%) was applied so as to be 50 g / m ^2, and then with a hot air dryer at 120 ° C. After drying for 90 seconds, a surface layer material (first layer) having a resin ratio of 53 mass% and a volatile content of 3 mass% was obtained. The melamine-based resin is prepared by adding raw material melamine and formalin to the reaction kettle at a predetermined blending ratio, adding a catalyst, raising the temperature to the boiling point, performing a reflux reaction, and confirming that melamine dissolution is complete before reaching the reaction end point. Then, it synthesize | combined by the method of adjusting resin solid content by a dehydration process and cooling.

  Substrate composed of a core layer material composed of a prepreg containing a binder on the second surface side of the obtained surface layer material (first layer) using a flame-retardant glass cloth as a fiber sheet as a base material Were laminated for 40 minutes under conditions of 140 ° C. and 2 MPa to obtain a decorative board (melamine decorative board) having a thickness of 0.18 mm having a surface layer and a core material layer.

The flame retardant substrate (fiber sheet) is composed of glass fiber of T glass, the average diameter of the glass fiber is 7 μm, the density is 0.85 g / cm ³ , the thickness is 81 μm, and the basis weight is 69 g / m. ² and the thing (glass cloth) whose air permeability is 95.4 [cm < ³ > / (cm < ² > * s)] were used.

(Examples 2-9)
A decorative board was produced in the same manner as in Example 1 except that the conditions of the fiber sheet constituting the core layer and the binder conditions were changed as shown in Table 1.

(Example 10)
A decorative board was produced in the same manner as in Example 5 except that an aluminum foil having a thickness of 40 μm and subjected to urethane primer treatment was used as the surface layer base material.

(Comparative Examples 1 and 2)
A decorative board was produced in the same manner as in the above example except that the conditions of the fiber sheet constituting the core material layer were changed as shown in Table 1.

Table 1 summarizes the conditions of the decorative plates of the examples and comparative examples. In Table 1, the acrylic resin is “Ac”, the melamine resin (same as that used for forming the surface layer in Example 1) is “MF”, the epoxy resin is “EP”, and the polyvinyl alcohol is “ "PVA". In addition, the Martens hardness of the surface layer of the decorative board of each example was a value in the range of 300 N / mm ^{2 to} 700 N / mm ² . In addition, the fiber sheets constituting the core material layer in the decorative board of each of the above Examples and Comparative Examples 1 and 2 each have a calorific value of 6 MJ / m ² or less when subjected to a corn calorie combustion test. there were. In Examples 1 to 3, glass cloth subjected to defibrating treatment was used.

  In addition, the conditions (flow rate, average fiber length, average fiber diameter (thickness), fiber) shown in Table 1 for the fiber sheets used in the production of the decorative plates of Examples and Comparative Examples 1 and 2 were described. The basis weight, density, thickness, and tensile strength in each direction) of the sheet are values obtained by measurement before adjustment of the prepreg (fiber sheet in a single state), and the decorative board after the decorative board is manufactured. Was consistent with the value obtained by the measurement of the fiber sheet that was fired and then taken out.

[3] Evaluation The following evaluation was performed on the decorative plates of the examples and comparative examples manufactured as described above.

[3.1] Flame resistance (non-flammability)
Conducted by the heat buildup test / evaluation method of (2) ii) 4.10.2 in the non-combustible performance test / evaluation method in the business standard “Non-combustible performance test / evaluation method” of the business standard of the Japan Building Test Center, The flame retardancy of the decorative board was evaluated according to the following criteria.

(Total calorific value)
A: Less than 4.0 MJ / m ² B: 4.0 MJ / m ² or more and less than 8.0 MJ / m ² C: 8.0 MJ / m ² or more

(200kW / m ² overtime)
A: Less than 10 seconds B: More than 10 seconds

[3.2] Bending workability In accordance with the bending formability test (Method A) of JIS K 6902, at room temperature, external bending deformation (deformation in which the surface layer faces outward), internal bending deformation (in which the surface layer faces inward) When deformation was applied, the minimum R without cracks when visually observed from the surface side of the decorative plate surface layer was obtained, and the bending workability of the decorative plate was evaluated according to the following criteria.

(Outer bending deformation)
A: Less than 4.0R.
B: 4.0R or more and less than 6.0R.
C: 6.0R or more and less than 8.0R.
D: 8.0R or more and less than 10.0R.
E: 10.0R or more.

(Inward bending deformation)
A: Less than 3.0R.
B: 3.0R or more and less than 3.5R.
C: 3.5R or more and less than 4.0R.
D: 4.0R or more and less than 4.5R.
E: 4.5R or more.

[3.3] Surface smoothness The surface roughness Ra of the surface layer was determined, and the surface smoothness of the decorative board was evaluated according to the following criteria.

A: Surface roughness Ra is less than 400 μm.
B: The surface roughness Ra is 400 μm or more and less than 600 μm.
C: Surface roughness Ra is 600 μm or more and less than 700 μm.
D: Surface roughness Ra is 700 μm or more and less than 800 μm.
E: Surface roughness Ra is 800 μm or more.

[3.4] Aesthetics The decorative board was observed from the surface layer side, and the aesthetics were evaluated according to the following criteria.

A: It has a very excellent appearance.
B: It has an excellent appearance.
C: It has a good appearance.
D: Surface roughness is conspicuous and aesthetics are slightly inferior.
E: Surface roughness is conspicuous and the aesthetics are very inferior.
These results are summarized in Table 2.

  As can be seen from Table 2, in the present invention, a decorative board having excellent processability and excellent surface smoothness and aesthetics could be obtained. Moreover, in this invention, generation | occurrence | production of defects, such as a crack, was prevented effectively in the decorative board after a process. On the other hand, in the comparative example, a satisfactory result was not obtained.

100: decorative board (melamine decorative board)
11 ': 1st layer 11: Surface layer (melamine type resin layer)
111: 1st surface 112: 2nd surface 12 ': Base | substrate 12: Core material layer 14: Core material layer 15: Protective layer 16: Support layer

Claims (12)

A decorative board having a surface layer and a core layer,
The surface layer contains a melamine resin,
The core material layer includes a flame retardant fiber sheet,
The air flow rate of the fiber sheet measured according to JIS L1913: 2010 (Fragile method) is 2 [cm ³ / (cm ² · s)] or more and 220 [cm ³ / (cm ² · s)] or less. A decorative board characterized by that.   The decorative sheet according to claim 1, wherein the fiber sheet includes fibers made of an inorganic material.   The decorative board according to claim 2, wherein the fibers are made of glass.   The decorative board according to any one of claims 1 to 3, wherein an average diameter of fibers constituting the fiber sheet is 6 µm or more and 13 µm or less.   The decorative board according to any one of claims 1 to 4, wherein a thickness of the fiber sheet is 230 µm or more and 800 µm or less. Veneer according to any one of the to the basis weight of the fiber sheet claims 1 is 15 g / ^{m 2} or more 180 g / ^{m 2} or less 5.   The decorative sheet according to any one of claims 1 to 6, wherein the fiber sheet is a non-woven fabric.   The decorative board according to claim 7, wherein an average length of fibers constituting the nonwoven fabric is 6000 μm or more and 25000 μm or less.   The decorative sheet according to any one of claims 1 to 8, wherein the surface layer is obtained by impregnating a fibrous base material with the melamine resin.   The decorative board according to claim 9, wherein the base material contains titanium oxide.   11. The decorative board according to claim 1, wherein the surface layer has a surface facing the core material layer made of a material containing a urethane-based resin.   The decorative board according to any one of claims 1 to 11, wherein the surface roughness Ra of the surface layer is 600 µm or less.

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