JP2022034047A - Substrate material of inner wall material and inner wall material using the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a substrate material of an incombustible inner wall material that can meet the requirement of production of multi-product small lot inner wall material, and an inner wall material using the same.

SOLUTION: A substrate material 1 of an inner wall material comprises a sealer layer 3 formed with an aqueous sealer for adhering a resin made decorative film onto the surface of a calcium silicate plate 2. The aqueous sealer forming the sealer layer 3 is an aqueous inorganic sealer that has the solid content containing silicate of 100 mass%. And the aqueous sealer is an aqueous acrylic resin coating material that has the solid content containing acrylic resin of 40 to 60 mass%, and silicate of 60 to 40 mass%.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2022,JPO&INPIT

Description

The present invention relates to a base material for an inner wall material and an inner wall material using the same, and more specifically, an inner wall material for manufacturing a nonflammable inner wall material by adhering an arbitrary decorative film on the surface. It is related to the base material of the above and the inner wall material using it.

Conventionally, as the inner wall material, an inorganic base material such as gypsum board or calcium silicate board is used as the core material, and the surface of the core material is UV-coated, or a decorative film such as a vinyl chloride sheet or diallyl phthalate impregnated paper is used. An inner wall material provided with a decorative layer is known. These inner wall materials are formed by laminating and integrating an inorganic base material as a core material, a sealer layer, an adhesive layer, and a resin-impregnated decorative layer in order from the bottom. Further, as a nonflammable material, Patent Document 1 (Japanese Unexamined Patent Publication No. 6-143484) discloses a nonflammable decorative plate obtained by laminating and molding a calcium silicate plate and a resin-impregnated decorative paper.

Since the core material of these inner wall materials is nonflammable, they are superior in fire protection compared to those using a wood-based base material as the core material. It is widely used for such purposes. However, these conventional inner wall materials have problems of inferior surface physical properties, for example, wear resistance, scratch resistance, heat resistance, and nonflammability, and Patent Document 2 (Japanese Patent Laid-Open No. 2016) solves the problems. -155261 (Japanese Patent Publication No. 155261), a non-combustible decorative material formed by laminating a non-combustible melamine resin decorative plate on an inorganic base material via an adhesive and pressing the mixture is proposed.

Japanese Unexamined Patent Publication No. 6-143484 Japanese Unexamined Patent Publication No. 2016-155261

In the case of the invention of Patent Document 1, the inorganic base material as the core material, the primer layer, the adhesive layer, and the resin-impregnated decorative layer are laminated and integrated in this order from the bottom. In the case of the invention, the core material, the primer layer, the adhesive layer, the nonflammable melamine resin decorative board, the slurry-impregnated core paper, the intermediate layer, and the melamine resin-impregnated pattern paper are laminated and integrated in this order from the bottom. It is commercialized by laminating and integrating from the core material to the surface decorative layer. Therefore, if the same product is mass-produced, there is no problem, but it is not possible to meet the demand for a wide variety of small lots in a profitable manner.

Further, in the case of the invention of Patent Document 2, nonflammability is imparted by laminating a nonflammable melamine resin decorative board on an inorganic base material via an adhesive and pressing it, but it takes time and effort to process it. ..

The present invention has been made in view of such problems in the prior art, and is capable of meeting the demand for manufacturing a wide variety of small lot inner wall materials, a base material for a nonflammable inner wall material, and an inner wall using the same. The task is to provide materials.

The invention according to claim 1 for solving the above problems includes a sealer layer formed of an aqueous sealer for adhering a resin decorative film having an adhesive layer on the back surface on at least the front surface of the calcium silicate plate. It is the base material of the inner wall material
The water-based sealer forming the sealer layer is an aqueous inorganic sealer having a solid content of 100% by mass of a silicate, or a water-based acrylic resin paint having a solid content of 40 to 60% by mass of an acrylic resin and 60 to 40% by mass of a silicate. It is a base material of the inner wall material, which is characterized by being.

In one embodiment, the coating amount in the case of the water-based inorganic sealer is around 27.2 to 45.7 g / m ² , and the coating amount in the case of the water-based acrylic resin paint is around 26.1 g / m ² .

The invention according to claim 3 for solving the above-mentioned problems is such that the sealer layer on the surface of the base material of the inner wall material according to claim 1 or 2 is appropriately patterned and colored on the front surface and adhered to the back surface. It is made by adhering a resin decorative film with layers, and in the nonflammability test by ISO-5660-1, the total calorific value is 7.2 MJ / m ² or less, and the maximum adhesive strength by the 180 degree peeling test is 10. It is an inner wall material characterized in that it is in the range of ~ 22N.

The present invention is as described above, and since the base material according to the present invention is distributed as an independent product as a base material common to each inner wall material, the inner wall material manufacturer can use it. It is possible to manufacture an inner wall material having a desired pattern and color by utilizing the above, and there is an effect that it is possible to meet the demand for supply of a wide variety and small lot of inner wall materials.

It is sectional drawing which shows the base material of the inner wall material which concerns on this invention, and the structure of the inner wall material using it.

Hereinafter, embodiments for carrying out the present invention will be described with reference to the accompanying drawings. The base material 1 of the inner wall material according to the present invention is characterized in that the surface of the calcium silicate plate 2 is provided with a sealer layer 3 formed of an aqueous sealer for adhering the resin decorative film 4. It is a product and is put on the market in a state before the decorative film 4 is adhered. Then, the decorative film 4 is later covered on the sealer layer 3 by the inner wall material manufacturer to be used as the inner wall material.

The calcium silicate plate 2 itself is a general one, and for example, a calcium silicate plate 2 having a specific gravity of 0.8 and a thickness of about 6 mm is used. Since the surface of the calcium silicate plate 2 is a rough surface, an aqueous sealer is applied on the surface of the calcium silicate plate 2 to make the decorative film 4 adhesive, smoothed, and dried to form the sealer layer 3.

As the aqueous sealer used for forming the sealer layer 3, for example, it is preferable to use an aqueous inorganic sealer having a solid content of 100% by mass of silicate. Alternatively, from the viewpoint of improving the viscosity, an aqueous acrylic resin paint having a solid content of 40 to 60% by mass of an acrylic resin and 60 to 40% by mass of a silicate may be adopted, and the aqueous acrylic resin paint may be diluted and applied. As described above, the aqueous sealer used in the present invention contains a large amount of silicate, which is an inorganic material, and the sealer layer 3 itself has nonflammability, so that the base material 1 as a whole has good nonflammable performance. It becomes a thing.

The application of the water-based sealer for forming the sealer layer 3 is usually performed by spray application or roller application, and the thickness of the sealer layer 3 is adjusted by setting the application amount. If the thickness of the sealer layer 3 is insufficient, the smoothness of the surface thereof becomes insufficient, and the adhesive strength of the decorative film 4 adhered to the sealer layer 3 is inferior. In order to secure sufficient adhesive strength of the decorative film 4, for example, the coating amount in the case of the water-based inorganic sealer is about 27.2 to 45.7 g / m ² , and the coating amount in the case of the water-based acrylic resin paint is about 27.2 to 45.7 g / m 2. It should be around 26.1 g / m ² .

The decorative film 4 adhered on the sealer layer 3 is printed with a wood grain pattern or a wide variety of patterns and color patterns. For example, a vinyl chloride resin having a thickness of 0.17 mm or less that can be printed by gravure. A system film is used. The decorative film 4 is manufactured independently of the base material 1, and for example, a nonflammable certified decorative film with an adhesive such as "Dynoc film" manufactured by 3M Co., Ltd. or "Belvian" manufactured by Takiron Co., Ltd. is used. Can be used.

At the time of use, the decorative film 4 is attached on the sealer layer 3 of the base material 1 of the inner wall material by peeling off the release paper on the back surface thereof. Normally, a wide variety of decorative films 4 having different patterns, colors, etc. are prepared and selectively used when manufacturing the inner wall material, but after receiving an order, printing is performed as requested. You can also do it.

The sealer layer 3 may be formed not only on the front surface of the calcium silicate plate 2 but also on the back surface. This is because if the sealer layer 3 is provided only on the surface, the calcium silicate plate 2 may be warped.

The inner wall material according to the present invention utilizes the base material 1 of the inner wall material, and is desired from a wide variety of resin decorative films on the sealer layer 3 on the surface of the calcium silicate board 2. It is manufactured by selecting and adhering the film 4.

The base material 1 according to the present invention is used as an inner wall material by adhering a decorative film 4, and is required to have nonflammability as an inner wall material by which the decorative film 4 is adhered. Therefore, the test piece for evaluation of nonflammability by the nonflammability test by ISO-5660-1 was an inner wall material in which the decorative film 4 was adhered on the sealer layer 3 of the base material 1.

In order to obtain the nonflammability certification, the result of conducting this nonflammability test for 20 minutes,
・ Total calorific value (MJ / m ² )
Total heat generation amount is 8MJ / m ² or less ・ Maximum heat generation rate (kW / m ² at)
The final heat generation rate must not exceed 200 kW / m ² continuously for 10 seconds or longer.
-Appearance condition It is necessary to satisfy the condition that penetration, cracks and holes to the back surface, which is harmful for fire protection, are not opened. In the case of the inner wall material using the base material 1 according to the present invention, a product having a total calorific value of 7.2 MJ / m ² or less was regarded as an acceptable product so that the certification of nonflammability could be surely obtained.

Further, in the base material 1 according to the present invention, the adhesive strength of the decorative film 4 after the decorative film 4 is adhered onto the sealer layer 3 is an important factor. The adhesive strength test performed in the present invention was a 180-degree peeling test at a speed of 200 mm / min, and those having a maximum point (N) in the range of 10 to 22 N were regarded as acceptable products. The reason why the accepted products are set in such a range is that those with a maximum point (N) of 10 N or less have insufficient adhesive strength and may be partially peeled off to spoil the appearance, and the maximum point (N) is 22 N or more. This is because the one is overstrength, and the water-based sealer is wasted.

Hereinafter, the present invention will be described in more detail by way of examples, but the present invention is not limited thereto.

[Example 1]
An aqueous inorganic sealer having a solid content of 100% by mass of silicate was used as an aqueous sealer on a calcium silicate plate 2 having a thickness of 6 mm, and this was diluted with water to a dilution ratio of 50% and applied once with a roller. A base material 1 having a sealer layer 3 having a coating amount of 27.2 g / m ² is formed, the release paper of the decorative film 4 (“Dynoc film” manufactured by 3M) is peeled off, and the film is attached onto the sealer layer 3. The inner wall material (1) was produced (Example 1).

[Example 2]
The inner wall material (2) was prepared from the base material 1 formed in the same manner as in Example 1 except that the dilution ratio was 100% and the coating amount was 29.4 g / m ² .
[Example 3]
The inner wall material (3) was prepared from the base material 1 formed in the same manner as in Example 2 except that the water-based sealer was applied twice to adjust the coating amount to 45.7 g / m ² (Example 3). ..

[Example 4]
A 6 mm thick calcium silicate plate 2 was used as an aqueous sealer with an aqueous acrylic resin paint having a solid content of 50% by mass of acrylic resin and 50% by mass of silicate, which was diluted with water to a dilution ratio of 20%. It is applied once with a roller to form a base material 1 having a sealer layer 3 having a coating amount of 26.1 g / m ² , the release paper of the decorative film 4 similar to that in Example 1 is peeled off, and the top of the sealer layer 3 is peeled off. The inner wall material (4) was produced by sticking to (Example 4).

The inner wall materials (1) to (4) prepared as described above were subjected to a nonflammability test (20 minutes) by ISO-5660-1, the total calorific value (MJ / m ² ) was measured, and the results are as follows. It is shown in Table 1.

Further, the inner wall materials (1) to (4) produced as described above were subjected to a 180-degree peeling test at a speed of 200 mm / min, the maximum point (N) of the adhesive strength was measured, and the results are as follows. It is shown in Table 1.

As shown in Table 1 above, the inner wall materials (1) to (4) according to the embodiment of the present invention are all set as acceptable products and have a total calorific value of 7.2 MJ / m ² or less and 180 degrees. It satisfies the requirement that the maximum point (N) of the adhesive strength in the peeling test is in the range of 10 to 22N.

The base material of the inner wall material according to the present invention and the inner wall material using the same are as described above, and the base material of the inner wall material and the decorative film adhered to the surface thereof are distributed as separate and independent products. Since it is provided, the inner wall material manufacturer obtains the base material of the inner wall material as a common material for the inner wall material, and selects and uses a decorative film having a desired pattern / color base material to manufacture the inner wall material. This makes it possible to meet the demand for a wide variety of products and small lots, so that the industrial utility of the present invention is great.

1 Base material for inner wall material 2 Calcium silicate board 3 Sealer layer 4 Resin decorative film

The invention according to claim 1 for solving the above problems is a base material to be distributed as a common base material for forming an inner wall material.
A sealer layer formed of an aqueous sealer for adhering a resin decorative film having an adhesive layer on the back surface is provided on at least the front surface of the calcium silicate plate.
The water-based sealer forming the sealer layer is an aqueous inorganic sealer having a solid content of 100% by mass of a silicate, or a water-based acrylic resin paint having a solid content of 40 to 60% by mass of an acrylic resin and 60 to 40% by mass of a silicate. It is a base material of the inner wall material, which is characterized by being.

The invention according to claim 3 for solving the above-mentioned problems is such that the sealer layer on the surface of the base material of the inner wall material according to claim 1 or 2 is appropriately patterned and colored on the front surface and adhered to the back surface. It is made by adhering a desired resin decorative film with layers, and in the nonflammability test by ISO-5660-1, the total calorific value is 7.2 MJ / m ² or less, and the maximum point of the adhesive strength by the 180 degree peeling test. Is an inner wall material characterized in that is in the range of 10 to 22N.

Claims (3)

A base material for an inner wall material having a sealer layer formed by an aqueous sealer for adhering a resin decorative film having an adhesive layer on the back surface on at least the front surface of the calcium silicate plate.
The water-based sealer forming the sealer layer is an aqueous inorganic sealer having a solid content of 100% by mass of a silicate, or a water-based acrylic resin paint having a solid content of 40 to 60% by mass of an acrylic resin and 60 to 40% by mass of a silicate. The base material of the inner wall material, which is characterized by being. The first aspect of the present invention, wherein the coating amount in the case of the water-based inorganic sealer is around 27.2 to 45.7 g / m ² , and the coating amount in the case of the water-based acrylic resin paint is around 26.1 g / m ² . Base material for inner wall material. A resin decorative film having an appropriate pattern and color on the front surface and an adhesive layer on the back surface is adhered onto the sealer layer on the surface of the base material of the inner wall material according to claim 1 or 2, and ISO- An inner wall material having a total calorific value of 7.2 MJ / m ² or less in a nonflammability test according to 5660-1 and a maximum adhesive strength in the range of 10 to 22 N in a 180 degree peeling test.

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