JP2808386B2 - Flameproof precious wood decorative sheet, flameproof precious wood decorative veneer adhered thereto, and methods of manufacturing these - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement in flame-retardant technology, and more particularly to a decorative veneer sheet which can be subjected to a satisfactory flame-retardant treatment.

[0002] Accordingly, the present invention relates to a flameproof precious wood decorative sheet to which such a flame retarding technique is applied, and a method for producing the same.

[0003] Therefore, the present invention can be used for the following general uses of decorative veneer sheets. :
Architectural interior materials, such as wall materials, ceiling surface materials, column covering materials, and movable partitions: Surface materials for interior products of automobiles and ships: Exterior materials for furniture such as wardrobes: Exterior materials for general wood products such as furniture : Exterior decoration materials for electronic devices and musical instruments.

[0004] As described above, the present invention also relates to a decorative board made of a flame-retardant precious wood obtained by sticking a decorative sheet of a fire-proof precious wood on a substrate, and a method for producing the same.

[0005]

2. Description of the Related Art Due to the depletion of natural wood resources, especially precious wood resources, decorative veneer sheets in which thin veneers are lined with fibrous sheets such as paper and nonwoven fabrics instead of solid wood boards are nowadays.
It is widely used in the applications described above.

[0006]

By the way, wood has a property that it is easily burned by a flame.
It was a drawback of wood products. Under such circumstances, recently, it has been required to perform appropriate flame retarding and non-flammable treatments on a decorative veneer sheet or the like itself.

As a method of making the decorative veneer sheet flame-retardant, first, a method of impregnating the veneer with a liquid of a flame retardant (usually a phosphoric acid type) to impart flame retardancy to the veneer itself can be considered. . However, according to this method, the veneer often turns dark brown by impregnation and subsequent hot-pressure bonding,
There is a drawback that a certain reduction in commercial value cannot be avoided.

As another method which can be considered for flame retardation, there is a method in which paper or nonwoven fabric used for the inner layer of the decorative veneer sheet is subjected to flame retardation treatment by adding a flame retardant. However, in order to impart self-extinguishing property to a paper or nonwoven fabric by adding a phosphoric acid-based flame retardant, it is necessary to add the flame retardant in an amount of about 40 to 50% by weight.
Flame-retarded paper, nonwoven fabric, etc. have increased hygroscopicity,
In the manufacturing process of decorative veneer sheet, the adhesiveness between the paper, non-woven fabric, etc. and the veneer or other layer material is deteriorated, and in particular, peeling occurs during the process of press-bonding using hot melt adhesive, resulting in poor manufacturing. There was a problem that it caused occurrence.

Further, as another flame retarding method, a method of blending a flame retardant into a resin layer in a decorative veneer sheet can be considered. This type of resin layer is usually used to provide flexibility and flexibility to the veneer veneer sheet itself, or to bond together the elements (paper, aluminum foil, etc.) that make up the veneer veneer sheet. It is considered as one of the laminated elements in order to achieve the realization.

The present inventor has conducted research on this method. As a result, simply adding a flame retardant to the resin layer in the decorative veneer sheet naturally increases the flame retardancy.
The adhesive strength between the components of the decorative veneer sheet, especially the adhesive strength between the aluminum foil and the paper or nonwoven fabric, is reduced, and corrosion of the aluminum foil or iron foil in the decorative veneer sheet occurs. In addition, it has been found that there is a problematic decrease in various performances such as poor flexibility and bending suitability of the veneer veneer sheet itself, and further, the increase in the amount of the flame retardant causes the above-mentioned decrease in adhesive strength and corrosion. It was confirmed that deterioration of performance such as generation became remarkable.

[0011] In addition, the present inventor has determined that whether a decorative veneer sheet containing a flame retardant has a twistable / quasi-nonflammable performance depends not only on the thickness of the aluminum foil but also on the flame retardant. It was confirmed that it was significantly related to the thickness of the resin layer to be added, and more importantly, the decrease in the adhesive strength between the components of the decorative veneer sheet due to the addition of the flame retardant was due to the addition of the flame retardant It was confirmed that the difference was significantly different depending on the type of the resin layer to be formed.

The present invention has been made in view of such circumstances, and has as its object to provide a conventional decorative veneer sheet in which a veneer is applied to a veneer on the surface of the sheet or paper inside the sheet. Not only does not cause any disadvantages, but also achieves extremely high flame retardancy (flammability) by blending a flame retardant, and the inclusion of the flame retardant lowers the adhesive strength, causes corrosion, and increases flexibility. Flame retardant precious wood decorative sheet, which does not cause deterioration of performance such as decrease in property, in particular, can achieve quasi-non-flammable performance as a building material and satisfy the above-mentioned corrosion resistance, adhesive strength, etc. It is an object of the present invention to provide a flameproof precious wood decorative sheet having performance.

Another object of the present invention is to provide a decorative board having such a decorative sheet for a fire-resistant wood as a surface material and having the same performance as above. is there. Further, another object of the present invention is to provide a method for producing each of the decorative sheet and the decorative board having a flame-retardant precious wood with certainty and high productivity.

[0014]

SUMMARY OF THE INVENTION The present inventor has proposed a laminated veneer sheet whose surface is a precious wood veneer and contains aluminum foil as a backing material. By further adding, the technology for making the decorative veneer sheet flame-retardant has been studied further. As a result, as a core element of the decorative veneer sheet, an aluminum foil having a thickness of 10 to 30 μm is used. An adhesive resin layer independently selected from the group consisting of an ethylene-acrylic acid copolymer and an ionomer is laminated on each of the front and back surfaces to a thickness of 20 to 50 μm, and two layers of a flame retardant are provided. The decorative veneer sheet obtained by adding each to the adhesive resin layers and limiting the content of the flame retardant in each adhesive resin layer to 15% or less by weight is obtained. , While having a sufficiently high flame retardance to have the statutory quasi-incombustibility performance, the adhesive force between the sheet elements is maintained at a satisfactory high level, and a moderate flexibility as a decorative veneer sheet, The present invention has been found to be an excellent product having various advantages, such as having flexibility and further suppressing corrosion of the aluminum foil irrespective of the content of the flame retardant.

This eliminates the need for flame retarding treatment of veneer, paper, etc., and eliminates the problem of discoloration and the like. In addition, there is an advantage that a wide range of flame retardants including phosphoric acid can be applied. In addition, the present inventor used two kinds of adhesive resins to which a flame retardant was previously added, and according to a general extrusion laminating method and a hot pressing method, the decorative veneer sheet, that is, the flame retardant was contained. The present inventors have found that it is possible to manufacture (particularly, mass-produce) a decorative veneer sheet in which the specified specific adhesive resin layer is laminated on both sides of an aluminum foil, and have completed the present invention.

Accordingly, the present invention relates to a paper or non-woven fabric;
A first adhesive resin layer having a thickness of 20 to 50 μm; a thickness of 1
Aluminum foil of 0 to 30 μm; thickness of 20 to 5
A decorative adhesive veneer sheet in which a second adhesive resin layer of 0 μm; paper or non-woven fabric; an adhesive layer; The resin layer and the second adhesive resin layer are each composed of a resin layer independently selected from the group consisting of an ethylene-acrylic acid copolymer and an ionomer, and the flame retardant is the first adhesive resin layer and The present invention relates to a flame-resistant precious wood decorative sheet, characterized in that each layer of the second adhesive resin layer contains 15% or less in weight ratio.

Furthermore, the present invention also relates to a decorative board made of a fire-resistant precious wood, in which the above-mentioned decorative sheet for a fire-proof precious wood is adhered on a wood-based, inorganic-based or metal-based base material.

Further, the decorative sheet and the decorative board of the flameproof precious wood according to the present invention can be manufactured by the following process. The production process comprises the steps of adding a first adhesive resin and a second adhesive resin each independently selected from the group consisting of an ethylene-acrylic acid copolymer and an ionomer to an amount of 15% or less by weight, respectively. (A) first, according to the extrusion lamination method, a paper or nonwoven fabric; a layer of the first adhesive resin having a thickness of 20 to 50 μm; an aluminum foil having a thickness of 10 to 30 μm; 2
Forming a laminate of 0 to 50 μm of said second adhesive resin; paper or non-woven fabric, then applying an adhesive on the paper or non-woven fabric on the top of said laminate; Veneers are overlaid thereon and then hot-pressed together, or (b) meanwhile, according to the extrusion lamination method, paper or nonwoven; said first adhesive layer having a thickness of 20 to 50 μm A resin layer; an aluminum foil having a thickness of 10 to 30 μm; a laminate consisting of the second adhesive resin layer having a thickness of 20 to 50 μm; Agent layer; producing a veneer backing sheet of paper or non-woven fabric, and then hot-pressing the laminate and veneer backing sheet.

Further, the present invention further comprises a step of attaching the decorative sheet for a flame-resistant wood produced according to the above-mentioned method onto a wood-based, inorganic-based or metal-based substrate. The present invention also relates to a method for manufacturing a decorative board.

(Summary of the Present Invention) The present invention does not merely aim at flame retardancy by blending a flame retardant into a resin layer in a decorative veneer sheet. Generally, in order to further enhance the flame retardancy of the decorative veneer sheet, it is considered that a larger amount of the flame retardant should be contained in the resin layer. But,
A large amount of a flame retardant significantly reduces the adhesive strength between the components of the veneer veneer sheet, and in severe cases, easily peels off between the resin layer and the paper / non-woven fabric in the same sheet, thus increasing the laminated structure. No longer maintained. In addition, a large amount of flame retardant
It also promotes the corrosion of aluminum foil in decorative veneer sheets. Therefore, in order to make the decorative veneer sheet more flame-retardant and prevent corrosion, especially in order to ensure the statutory non-flammable performance, an appropriate amount of a flame retardant is added to the upper resin layer of the aluminum foil and the lower part. It is led that it is a more preferable embodiment to mix each with the resin layer on the side.

It should be noted that, as described above, the decrease in the adhesive strength between the components of the veneer veneer sheet due to the blending of the flame retardant depends on the type of the resin layer to which the flame retardant is added. Is significantly different from one another. When the resin layer is a polyethylene veneer or a polypropylene layer conventionally used in this type of veneer veneer sheet, the adhesive strength between the components of the veneer veneer sheet rapidly decreases due to the incorporation of the flame retardant. With only 5% by weight of flame retardant,
Adhesion under normal conditions is almost halved compared to the case where no flame retardant is added, and further addition of a flame retardant significantly reduces the adhesion, and the separation between the resin layer and paper / non-woven fabric tends to occur. . When left in a high-temperature and high-humidity atmosphere, the peeling becomes more and more easy. In this case, when the blending amount of the flame retardant is relatively large, the decorative veneer sheet cannot maintain the laminated structure. Therefore, if a polyethylene layer or a polypropylene layer is employed as the resin layer, it is not possible to achieve extremely high flame retardancy that satisfies the statutory quasi-nonflammability performance.
The present invention has solved the above-mentioned disadvantages by applying an adhesive resin independently selected from the group consisting of an ethylene-acrylic acid copolymer and an ionomer as a resin layer in a decorative veneer sheet. is there. That is, the present invention can achieve extremely high flame retardancy satisfying the statutory quasi-incombustibility by applying these adhesive resins,
This is to maintain the adhesive strength between the decorative veneer sheet elements at a sufficiently high level.

Further, it should be considered whether or not the decorative veneer sheet having such an adhesive resin layer laminated on both sides of the aluminum foil has a quasi-nonflammable performance stipulated by blending a flame retardant. Is related to the thickness of the adhesive resin layer to which the flame retardant is added and the thickness of the aluminum foil. When the thickness of the adhesive resin layer in the decorative veneer sheet is increased, the thickness is about 40 μm.
Up to this point, satisfactory flame retardancy is ensured, but when it is thicker, the flame retardancy starts to decrease and the thickness of the adhesive resin layer exceeds 50 μm, despite the increased amount of the flame retardant added. As a result, it becomes impossible to ensure the statutory non-combustible performance. On the other hand, even if the thickness of the adhesive resin layer is about 20 μm, high flame retardancy can be obtained, and the quasi-nonflammability performance specified by law can be ensured. However, if it is thinner, the total amount of flame retardant that can be added decreases. Not only does the flame retardancy decrease, but it becomes impossible to impart sufficient flexibility to the entire decorative veneer sheet. From this viewpoint, in the present invention, the thicknesses of the first adhesive resin layer and the second adhesive resin layer are each limited to the range of 20 μm to 50 μm.

Further, regarding the thickness of the aluminum foil,
If the thickness is as large as 10 μm, the aluminum foil can exhibit a high non-combustible action enough to achieve the legally quasi-noncombustible performance. However, if the thickness of the aluminum foil exceeds 30 μm, the decorative veneer sheet becomes extremely poor in flexibility, becomes a rigid sheet that is difficult to bend, and is not suitable as a surface decorative material. Therefore, in the present invention, the thickness of the aluminum foil is limited to the range of 10 μm to 30 μm.

The inventor of the present invention has found that, when the above-mentioned specific adhesive resin layer and aluminum foil each having a thickness in the above-mentioned range are employed, the adhesive strength between the elements of the decorative veneer sheet and Under conditions where corrosion of the aluminum foil is not a problem, the flame retardant can be blended in each of the two adhesive resin layers up to 15% by weight. It has been confirmed that high flame retardancy that satisfies the performance can be achieved.

Accordingly, the decorative veneer sheet according to the present invention has a flame retardant-containing adhesive resin layer (thickness of 20 to 20).
50 μm) / Aluminum foil (10-30 μm thickness) /
A resin layer having a laminated structure of a flame retardant-containing adhesive resin layer (thickness: 20 to 50 μm), and each independently selected from the group consisting of an ethylene-acrylic acid copolymer and an ionomer as the adhesive resin layer. In addition, it is required to limit the content of the flame retardant in each adhesive resin layer to 15% or less by weight.

The paper or nonwoven fabric used in the present invention is
It is a laminated element for buffering the unevenness of the base to prevent the decorative sheet from floating, and for concealing the brightness of the inner aluminum foil. Examples of the paper or nonwoven fabric used in the present invention include Japanese paper, Western paper (high quality paper, medium quality paper, etc.), kraft paper, tissue paper or resin impregnated paper, and
All fibrous sheets, such as various nonwoven fabrics such as polyethylene nonwoven fabric and polyester / pulp nonwoven fabric, are included.
The basis weight of the paper or nonwoven fabric, 15~100g / ^{m 2,} preferably 20 to 50 g / ^{m 2.}

The aluminum foil is used as a laminated element in order to give the decorative sheet an appropriate rigidity to suppress the dimensional change, warping and warpage of the veneer, and to give the decorative sheet a high dimensional stability. It is. In the present invention, the aluminum foil refers to a pure metal of aluminum or an alloy thereof. The thickness of the foil is 10 to 30 μm. 10μ
If it is less than m, the flame retardancy satisfying the quasi-incombustibility required by law cannot be achieved. On the other hand, if it exceeds 30 μm, the flexibility of the veneer veneer sheet becomes extremely poor and it becomes difficult to bend. Therefore, the present invention requires the above thickness range.

The first and second adhesive resin layers in the decorative veneer sheet have the following functions. (A) Since the adhesive strength is high, the aluminum foil in the decorative veneer sheet can be integrally bonded to paper / nonwoven fabric. (B) In a laminated structure including an aluminum foil and a paper / nonwoven fabric, moisture in the outside air penetrates into the paper / nonwoven fabric and thereafter migrates to the aluminum foil, thereby causing corrosion of the aluminum foil. Since the resin layer is interposed between the aluminum foil and the paper / nonwoven fabric, the transfer of moisture is blocked, and therefore, the occurrence of corrosion of the aluminum foil can be prevented. (C) Since the resin layer has a high flexibility, by making this a laminated element of the decorative veneer sheet, the decorative veneer sheet is given an appropriate flexibility to absorb the unevenness of the base during construction, The sheet itself is provided with appropriate flexibility and bendability (the property that the veneer does not crack and the grain expands when bent), and facilitates bending. (D) Further, together with the aluminum foil, warping and warpage of the veneer are suppressed.

In general, the above-mentioned properties (a) to (d) are deteriorated by the incorporation of a flame retardant into the resin layer, and in particular, the adhesive strength and the corrosion of the aluminum foil become remarkable. The present invention provides the above (a) by applying a resin layer independently selected from the group consisting of an ethylene-acrylic acid copolymer (EAA) and an ionomer as the adhesive resin layer.
(D) as much as possible. In addition, this limitation is that, in the case of a decorative veneer sheet using a polyethylene or polypropylene layer conventionally used as a resin layer, the above-described performance is significantly deteriorated, but the decorative veneer sheet using the adhesive resin layer in the above group is remarkable. The plate sheet is based on a novel finding by the present inventors that the deterioration progresses very slowly.

The first and second adhesive resin layers used in the present invention may be the same or different, and each resin layer may be a single layer or a multilayer. Its thickness is 2
0 to 50 μm. When the thickness is less than 20 μm, sufficient flexibility cannot be provided to the entire decorative veneer sheet.
If it exceeds 50 μm, the flame retardancy is reduced, and the statutory quasi-noncombustibility cannot be achieved. Therefore, in the present invention, the thickness of the adhesive resin layer is limited to the above range.

A feature of the present invention is a laminated structure in which an adhesive resin layer containing a flame retardant is interposed on both sides of an aluminum foil in order to make the entire decorative veneer sheet flame-retardant and flame-retardant. It has to have. The flame retardant is contained in both the first adhesive resin layer and the second adhesive resin layer in an amount of 15% or less by weight. Examples of the flame retardant that can be used in the present invention include antimony trioxide, phosphoric acid type, and halogen type.

Also, in the present invention, the precious wood veneer may be, for example, 0.05 to 3.0 mm from various precious woods.
And preferably a thickness of 0.10 to 0.4 mm. The grain of the precious wood veneer is not particularly limited, and may be any of a straight grain, an additional straight grain, a board grain, and a knob-like heather.

Further, the type of precious wood veneer is not particularly limited, but examples of preferable tree types are as follows. :Japanese cypress,
Nara, Keyaki, Cherry, Yu, Black persimmon, Tochi, Katsura, Maple, Sophora, Kusunoki, etc .: Rosewood, teak, mahogany, Kokutan (black bed), rosewood (rosewood), bird's eye maple, American black walnut, claro walnut, lathenu Walnut, Queensland Walnut, Zebrawood, Mangasilo, Brazilian Rose, Karin (Karin), Versimon, Silver Rose, Palma, Redwood, Purplewood, Silky Oak, Thai Wanks, Cherry, Magnolia, Black Leo (Dao), White Leo ,
Saberi, bubinka, makore, madrone, mirutor,
Maple, Assin, Inbuyer etc.

The adhesive layer is a laminated element for adhering the veneer veneer and paper or nonwoven fabric. The type of adhesive used in the present invention is not particularly limited because the adhesion between veneer and paper or nonwoven fabric is relatively easy. For example, ethylene vinyl acetate resin (EVA) adhesive, vinyl acetate-acrylic A polymer adhesive, an aqueous vinyl urethane-based adhesive, an acrylic adhesive, or the like can be advantageously used.

The decorative board made of flame-resistant wood according to the present invention has a decorative sheet made of fire-resistant wood made of the above-mentioned components as a surface material, and is adhered to a thick base material. As such a substrate, advantageously, a wood-based substrate (eg, plywood, MDF, particle board honeycomb board, etc.), an inorganic-based substrate (eg, gypsum board, light calcium board, asbestos pearlite board) Etc.) or a metal-based substrate (eg, an aluminum plate, an iron plate, etc.).

The decorative sheet for flame retardant precious wood of the present invention comprises:
It can be manufactured in two stages, that is, a stage of compounding a flame retardant and a stage of lamination molding. In the former step, a predetermined amount (1% by weight) is used.
(5% or less) flame retardant is added to both the first adhesive resin and the second adhesive resin. Also,
In the latter stage, there are the following two methods which are advantageous in manufacturing.

One method is as follows: (a) First, according to the extrusion laminating method, it is composed of paper or nonwoven fabric; the first adhesive resin layer; aluminum foil; the second adhesive resin layer; Forming a laminate, and then applying an adhesive on the paper or nonwoven on top of the laminate,
The method is to overlay a veneer veneer on it and then glue them together.

Another method is as follows: (b) On the other hand, according to the extrusion laminating method, a laminate comprising paper or nonwoven fabric; the first adhesive resin layer; an aluminum foil; and the second adhesive resin layer. A body is formed and, on the other hand, a veneer backing sheet made of a nameplate veneer; an adhesive layer; paper or nonwoven fabric is produced by laminating, and the laminate and the veneer backing sheet are hot-press bonded. That is the method.

In addition, the decorative board for flame retardant wood according to the present invention further comprises a step of sticking the decorative sheet for fire retardant wood produced according to the above method onto a wood-based, inorganic-based or metal-based substrate. It is manufactured through

[0040]

According to the present invention, since the flame retardant is blended in the adhesive resin layer in the decorative wood decorative sheet, not only the flame retardancy is imparted to the decorative sheet itself, but also the particularly high content accompanying the blending. Inconveniences and disadvantages when blending are eliminated. That is, since it is not necessary to perform the flame retarding treatment on the precious wood veneer on the surface of the decorative sheet, the problem of discoloration of the veneer which has conventionally occurred due to the treatment does not occur at all. Further, since it is not necessary to perform a flame-retardant treatment on the paper or non-woven fabric immediately below the veneer in the decorative sheet, the problem of poor adhesion between the veneer and the paper, which is conventionally observed by the treatment, does not occur.

In particular, in the present invention, an adhesive resin layer containing a flame retardant (thickness 20 to 50 μm) / aluminum foil (thickness 10
~ 30 μm) / adhesive resin layer containing flame retardant (thickness 20 ~
50 μm) and a resin layer independently selected from the group consisting of an ethylene-acrylic acid copolymer and an ionomer is applied as an adhesive resin layer. The content of flame retardant is 1 by weight
Since it is limited to 5% or less, flame retardancy (flame resistance) is improved, and quasi-non-flammability performance as a building material can be achieved. Nevertheless, it is maintained at a good level, and the aluminum foil and the paper / nonwoven fabric in the decorative veneer sheet are firmly bonded and integrated. In addition, due to the interposition of the adhesive resin layer, even under the condition in which a water-absorbing flame retardant is present in the shell, the transfer of moisture from the outside to the aluminum foil is well blocked, thereby preventing corrosion of the aluminum foil. The occurrence is prevented. Furthermore, by laminating the adhesive resin layer, regardless of the content of the flame retardant,
The precious wood decorative sheet retains its original flexibility and is given appropriate flexibility and bendability.

[0042]

Embodiments of the present invention will be described below with reference to the drawings.

Example 1 This example relates to a flameproof precious wood decorative sheet. This is, as shown in FIG. 1, a paper or nonwoven fabric 1 (basis weight 30 g / m2).
^A first adhesive resin layer 2 (ionomer layer having a thickness of 40 μm); an aluminum foil 3 (thickness of 15 μm); a second adhesive resin layer 4 (an ionomer layer having a thickness of 40 μm); paper or Non-woven fabric 5 (medium-weight paper of 30 g / m ² basis weight); adhesive layer 6 (vinyl acetate acrylic copolymer adhesive); precious wood veneer 7 (0.24 mm thick veneer) laminated in order from the bottom layer This is a decorative sheet that is integrally formed by pressure bonding.

In this embodiment, it is characteristic that antimony trioxide and a bromine-based flame retardant are the first flame retardants.
Is contained in both the second adhesive resin layer 4 and the second adhesive resin layer 2.

The decorative sheet of this example was manufactured according to the following procedure. Combination of flame retardant Antimony trioxide and bromine-based flame retardant, each in an appropriate amount,
The first adhesive resin 2 and the second adhesive resin 4 containing a flame retardant were prepared by adding the mixture into an ionomer and then thoroughly mixing the mixture by roll milling or the like until the mixture became homogeneous.

As one process, as shown in FIG. 3, a paper 1 having a basis weight of 30 g / m ² ; a first adhesive resin layer 2 made of the above-mentioned ionomer (having a thickness of 40 μm) was first prepared according to the extrusion lamination method as shown in FIG.
m); an aluminum foil 3 having a thickness of 15 μm; a second adhesive resin layer 4 made of the ionomer (40 μm in thickness);
A laminate 10 made of paper 5 having a basis weight of 30 g / m ² is formed (FIG. 3A), and then an appropriate amount of a vinyl acetate acrylic copolymer adhesive 6 is applied onto the paper 5 on the surface of the laminate 10. (FIG. 3
(B)) Then, a 0.24 mm thick veneer 7 was overlaid thereon (FIG. 3 (C)), and the whole was hot-pressed to complete a fireproof precious wood decorative sheet. (FIG. 3 (D)).

Further, the decorative sheet of this example was manufactured by another lamination molding process. As shown in FIG. 4, on the one hand, the basis weight is 30 g / m ² according to the extrusion lamination method.
Paper 1; first adhesive resin layer 2 of the ionomer (40 μm in thickness); aluminum foil 3 of 15 μm in thickness; second adhesive resin layer 4 of the ionomer
(Thickness: 40 μm) to form a laminate 11 (FIG. 4)
(A)) and, on the other hand, by bonding (110 ° C. × 7
kg / cm ² × 3 minutes hot pressing), thickness 0.2
A single veneer backing sheet 12 made of a 4 mm oak veneer 7; a vinyl acetate acrylic copolymer adhesive 6; a paper 5 having a basis weight of 30 g / m ² was produced (FIG. 4 (B)). The sheet backing sheet 12 is placed in a hot / cold continuous pressing machine, and these are placed at 125 ° C. × 7 kg / cm ² × 15.
Min, and while continuing to maintain the same press pressure, press-clamping is continued until the temperature is reduced to room temperature by forced cooling (FIG. 4 (C)).
The surface of the veneer plate 7 was polished with a 40, and then the surface was coated with a polyurethane resin paint (solid content applied amount: 10 g / m ² ), thereby producing a flame-resistant precious wood decorative sheet 8 (FIG. 4C). )).

Example 2 This example relates to a decorative board made of flame-retardant precious wood. As shown in FIG. 2, this is a decorative board in which the flame-resistant precious wood decorative sheet 8 of Example 1 is stuck on a wooden base material 9 (plywood, MDF, etc.). Therefore, in this embodiment, it is characteristic that antimony trioxide and a bromine-based flame retardant are blended in each of the inner layers 2 and 4 of the decorative sheet as the surface material.

The decorative board made of flame-retardant precious wood of this embodiment is shown in FIG.
As shown in (D), the fireproof precious wood decorative sheet 8 manufactured according to the above-described process was attached on a wood-based substrate 9 to complete the process.

Both the decorative sheet of Example 1 and the decorative plate of Example 2 had high flame retardancy and exhibited satisfactory fire protection performance. This was also confirmed from the results of the following Test Examples 1 and 2.

Test Example 1 Surface Burning Test of Decorative Sheet A surface burning test was performed on the fireproof precious wood decorative sheet of Example 1 in accordance with the notification of the Ministry of Construction of Fire Protection Materials and JIS A1321. As a base material to be tested, an asbestos pearlite board (10 mm thick) of a legally incombustible material and a gypsum board (9 mm thick) of a legally quasi-incombustible material were used, and the decorative sheet of Example 1 was adhered thereon. , A specimen was prepared. Two specimens were prepared for each substrate. In addition, a vinyl acetate emulsion adhesive was used at a coating amount (solid content) of 40 g / m ² for attaching the decorative sheet and the base material.
The test results are shown in the following table.

[0046]

[Table 1]

From this table, it can be seen that both the test specimen in which the decorative sheet was adhered on the non-combustible base material and the test specimen in which the decorative sheet was adhered on the quasi-non-combustible base material have quasi-noncombustible performance. Therefore, it is recognized that the decorative sheet of Example 1 is a wall covering material exhibiting semi-flammable performance.

Test Example 2 : Comparative test on surface burning of decorative sheet For each decorative sheet, notice of Ministry of Construction and J
A surface burning test according to IS A 1321 was performed as follows, and the fire protection performance was compared.

Each of the decorative sheets A, B and C having the following laminated structure was manufactured three by three for each sheet and subjected to the above-mentioned test. Decorative sheet A; (top layer) veneer / adhesive layer / paper / untreated adhesive resin layer / aluminum foil / untreated adhesive resin layer / paper (bottom layer) Decorative sheet B; (top layer) veneer / Adhesive layer / paper / adhesive resin layer containing flame retardant / aluminum foil / untreated adhesive resin layer / paper (bottom layer) Decorative sheet C; (top layer) veneer / adhesive layer / paper / containing flame retardant Adhesive resin layer / Aluminum foil / Adhesive resin layer containing flame retardant / Paper (bottom layer)

The materials used for the above decorative sheets are as follows:
It is as follows. Veneer: birch wood Air-dry weight 109g / m² Surface coating
Uncoated paper: basis weight 30 g / m²  Adhesive layer: Vinyl acetate adhesive applied amount (solid
Min) 20 g / m²  Untreated adhesive resin layer: No flame retardant added
Adhesive film of len-acrylic acid copolymer resin (40
Aluminum foil: Thickness 15μ Adhesive resin layer containing flame retardant: Antimony trioxide and aluminum
Rom-based flame retardants containing 12% by weight in total
Tylene-acrylic acid copolymer resin adhesive film (4
0μ thickness)

A gypsum board (9 mm thick) of a legally quasi-incombustible material was employed as a substrate for the surface burning test, and the decorative sheets A, B and C were adhered thereon, respectively. Three were created for each type. In addition, a vinyl acetate emulsion adhesive was used at a coating amount (solid content) of 40 g / m ² for attaching the decorative sheet and the base material. The test results are shown in the following table.

[0057]

[Table 2] In addition, the standard value of the performance of quasi-incombustibility is the temperature time area
<100, smoke emission coefficient CA <60, residual flame time = 0.
From this table, by containing an appropriate amount of flame retardant in the adhesive resin layer, the decorative sheet exhibits the statutory quasi-incombustibility,
In addition, it can be seen that the fire prevention performance is further improved if it is contained in the upper and lower adhesive resin layers.

Test Example 3 : Relationship between moisture barrier performance of adhesive resin layer and content of flame retardant 1) The following table shows bromo-based flame retardants composed of EAA (ethylene-acrylic acid copolymer). Various adhesive resins blended in the added amounts were prepared, and each of the resins was extruded into paper (basis weight 30 g /
m ³ ) and an aluminum foil (thickness: 15 μm) to produce a laminate of paper / adhesive resin layer containing a flame retardant / aluminum foil. 2) Test method A lump of absorbent cotton impregnated with a 1% aqueous solution of sodium carbonate is placed on the paper surface of the above-mentioned laminate, and then the lump of absorbent cotton is covered with a watch glass to suppress evaporation of water. This was left as it was at room temperature for 12 hours. Thereafter, the watch glass was removed, and the laminate was washed with water and dried at room temperature. 3) Evaluation After that, the surface of the aluminum foil of the obtained laminate was observed, and whether or not the adhesive resin layer of each laminate had good or poor moisture blocking performance was determined by the presence or absence of corrosion marks. Was determined. The occurrence of corrosion marks means that the performance of moisture barrier is insufficient, while the absence of corrosion marks means that the performance of moisture barrier is sufficiently good. The results are shown in the table below.

[0059]

[Table 3]

From this table, it can be seen that when the blending amount of the flame retardant is about 20% or more, the inherent moisture-blocking performance of the adhesive resin layer (water that has intruded from the outside is prevented from further penetrating into the inside and the aluminum It can be seen that the occurrence of corrosion of the aluminum foil is remarkably reduced, and the occurrence of corrosion of the aluminum foil is observed. Therefore, it is concluded that the blending amount of the flame retardant in the adhesive resin layer should be limited to 15% (or more, 16 to 18%).

Test Example 4 : -Relationship Between Adhesive Strength of Adhesive Resin Layer and Flame Retardant Content- A decrease in the adhesive strength of a flame-resistant precious wood decorative sheet reduced the strength and flexibility of the sheet. It degrades flexibility and bendability. Poor bending aptitude does not allow the grain of the veneer to follow and expand when bent, resulting in cracks, thus making it especially difficult to bend and adhere to curved surfaces. Therefore,
It is important to know the relationship between the adhesive strength and the content of the flame retardant, and this test example examined this relationship.

1) Test Flame-Retardant Precious Wood Decorative Sheet Composition Thinner paper (basis weight 30 g / m ² ) / first adhesive resin layer (brominated flame retardant in the amount shown in the table below) was compounded from the bottom layer. Resin layer, thickness 40 μm) / aluminum foil (15 μm)
m) / Second adhesive resin layer (resin layer containing the same amount of bromo-based flame retardant as the first adhesive resin layer, thickness of 40 μm)
/ Thin paper (basis weight 30 g / m ² ) / adhesive layer (vinyl acetate adhesive, applied amount (dry) 20 g / m ² ) / precious wood veneer (birch straight grain veneer, thickness 0.25 mm) It has a laminated structure. As the first and second adhesive resin layers, a flame-retardant precious wood decorative sheet made of ethylene-acrylic acid copolymer (EAA) and low-density polyethylene (LDPE)
Two types of flameproof precious wood decorative sheets made of these were prepared, and were subjected to this test.

Production method The production was carried out according to the method of the present invention, and the hot-pressure bonding was carried out according to the following procedure. The obtained laminate was placed in a hot-cold continuous press machine, and was placed at 125 ° C. × 7 kg.
Heat-pressing is performed under the condition of / cm ² × 15 minutes, then, while maintaining the same press pressure, forced cooling is performed, and pressing is continued until the temperature is reduced to room temperature.

2) Measurement of Adhesive Strength Strips each having a width of 15 mm (length of the strip is parallel to the grain direction of the veneer) by punching or cutting from the two types of test flame-resistant decorative wood decorative sheets. ) Is made and a knife is used to make a tear at the tip of the strip between the second adhesive resin layer and the paper on its upper side, forcing about half of the strip from there. The test piece for 180 degree peeling strength measurement (separated into two pieces at one end side) was produced by peeling off to the length portion. -Measurement 1. -Each of the two specimens produced (three specimens of each kind) is allowed to stand in a room at room temperature for 24 hours, and then, for each specimen taken out, in accordance with general test standards; Normal 180 degree peeling strength (g / 15m
m) was measured. The in-layer peel strength (paper-to-paper peel strength) of the paper itself used for the test flame-resistant precious wood decorative sheet is 1800 g / 15 mm on average. Measurement 2. -Each of the two types of test specimens (three test specimens of each type) was placed in a chamber adjusted to an atmosphere of 40 ° C and a relative humidity of 95% for 7 days.
The sample was left for 3 days in an atmosphere with a relative humidity of 55%, and thereafter, each of the test pieces taken out was measured. The normal 180 ° peeling strength (g / 15 mm) was measured in the same manner as described above.

3) Results The above measurement 1. And measurement 2. The results are shown in the following table.
In this table, the peeling strength represents the average value of the normal 180 ° peeling strength in three tests. FIG.
Is the measurement 1. 6 is a graph showing the results of the measurement. 6 is a graph showing the result of the above.

[0066]

[Table 4]

From the table and the graph, the following can be understood. In the case of a fireproof precious wood decorative sheet composed of a low-density polyethylene layer as an adhesive resin layer, the adhesive force between the adhesive resin layer and the paper adjacent thereto is rapidly reduced by the addition of a flame retardant, and is difficult to achieve. With only 5% by weight of flame retardant,
The adhesive strength is almost halved as compared with the case where the flame retardant is not blended, and when the blending amount of the flame retardant is further increased, the adhesive strength is remarkably reduced, and the peeling easily occurs between the adhesive resin layer and the paper.
In particular, when the decorative sheet is exposed to a high-temperature and high-humidity atmosphere, the adhesive strength is significantly reduced even when the decorative sheet is then returned to an ordinary temperature and humidity environment and dried. Separation easily occurs between the sheets, and particularly when the blending amount of the flame retardant is large, the decorative sheet cannot maintain the laminated structure. On the other hand, in the case of a fireproof nameplate decorative sheet made of an ethylene-acrylic acid copolymer layer as the adhesive resin layer, the adhesive strength between the adhesive resin layer and paper adjacent thereto is difficult. The addition of a small amount (about 5% by weight) of the flame retardant hardly decreases, and even when the blending amount of the flame retardant is further increased, the progress of the decrease in the adhesive force is very slow, and the flame retardant is added in an amount of 20% by weight. When blended, a decrease in adhesive strength starts to be noticeable, and peeling occurs between the adhesive resin layer and the paper. Therefore, an ethylene-acrylic acid copolymer layer is applied as the adhesive resin layer, and the compounding amount of the flame retardant therein is 15% (or 16 to 18 which is larger than this).
%) Is concluded that it should be limited to:

Test Example 5 : -Surface Burning Test of Flame-Retardant Precious Wood Decorative Sheet- For each of the flame-retardant precious wood decorative sheets, a surface fire test according to the notification of the Ministry of Construction of Fire Protection Materials and JIS A1321 was carried out as follows. I tried to compare.

Three decorative sheets C ^* , D, and E having the following laminated structure were manufactured for each sheet, and were subjected to the above test. Decorative sheet C ^* ; (top layer) Veneer / adhesive layer / paper / adhesive resin layer containing 12% flame retardant / aluminum foil / adhesive resin layer containing 12% flame retardant / paper (bottom layer) Decorative sheet D; (top layer) veneer / adhesive layer / paper / adhesive resin layer containing 12% flame retardant ^* / paper (bottom layer) decorative sheet E; (top layer) veneer / adhesive layer / paper / none Adhesive resin layer of treatment / Aluminum foil / Adhesive resin layer containing 24% bromide flame retardant / Paper (bottom layer)

The materials used for each of the decorative sheets are as follows:
It is as follows. Veneer: Birch material Air-dry weight 112g / m² Surface coating
Uncoated paper: basis weight 30 g / m²  Adhesive layer: Vinyl acetate adhesive applied amount (solid
Min) 20 g / m²  Aluminum foil: Thickness 15μ Adhesive resin layer containing 12% flame retardant: Brom-based flame retardant is heavy
40% thick ethylene-A containing 12% by weight
Crylic acid copolymer adhesive film Adhesive resin layer containing 12% flame retardant^*: Brom-based flame retardant
80 μm thick ethylene containing 12% by weight
Acrylic acid copolymer adhesive film Untreated adhesive resin layer: No flame retardant added 4
0 μ thick ethylene-acrylic acid copolymer adhesive film Adhesive resin layer containing 24% flame retardant: heavy bromo flame retardant
Ethylene-A having a thickness of 40 .mu.
Crylic acid copolymer adhesive film

A gypsum board (9 mm thick) of legally quasi-noncombustible material was used as a base material for the surface combustion test, and the decorative sheets C ^* , D and E were adhered thereon, respectively. Were prepared for each type. In addition, a vinyl acetate emulsion adhesive was used at a coating amount (solid content) of 40 g / m ² for attaching the decorative sheet and the base material. The test results are shown in the following table.

[0072]

[Table 5] In addition, the standard value of the performance of quasi-incombustibility is the temperature time area tdθ
<100, smoke emission coefficient CA <60, residual flame time = 0.

The following is understood from this table. The flame retardant precious wood decorative sheet C ^* is a flame retardant-containing adhesive resin layer /
It is a decorative sheet having a three-layer structure of an aluminum foil / adhesive resin layer containing a flame retardant, and satisfies the quasi-incombustible performance standards at all three measurement points. On the other hand, the flame-resistant precious wood decorative sheet D has a three-layer structure such as a decorative sheet (decorative sheet C ^*) having a structure in which only an adhesive resin layer containing a flame retardant and no aluminum foil is interposed. Orazu, i.e., the thickness of the adhesive resin layer makeup a thickness twice the thickness of the resin layer in the sheet C ^*, form a material structure than the decorative sheet C ^* to remove the aluminum foil.) In the combustion test, the gypsum board, especially the surface paper, burned violently, and tdθ> 100 at all three measurement points.
And does not meet the quasi-noncombustibility standard. Further, the decorative sheet E having a flameproofing precious wood has a three-layer structure of an untreated adhesive resin layer / aluminum foil / an adhesive resin layer containing a flame retardant (a three-layer structure like a decorative sheet C ^* ). However, the flame retardant is contained only in one of the adhesive resin layers, and the content thereof is twice as much as the content in the decorative sheet C ^* ). >
Since it is 100, the quasi-noncombustibility performance test is rejected similarly to the decorative sheet D. In addition, the quasi-incombustibility is exhibited in the flameproof precious wood decorative sheet C ^* in the first place.
Adhesive resin layer (containing a flame retardant) and aluminum foil delay the penetration of flame into the paper / nonwoven fabric on the back side of the sheet and the surface paper of the gypsum board, and the second adhesive resin layer (flame retardant) Is contained in the veneer sheet, the adhesive layer, and the mechanism of delaying combustion of the paper / nonwoven fabric, promoting carbonization, and forming a heat insulating layer. Therefore, the adhesive resin layer / aluminum foil /
By providing a three-layer laminated structure of an adhesive resin layer and incorporating a flame retardant into each of the adhesive resin layers, a decorative sheet having a structure in which an aluminum foil is not interposed in the adhesive resin layer is provided. In addition, the fire-retardant performance is remarkably improved as compared with a decorative sheet having a three-layer laminated structure but a structure in which a flame retardant is contained only in one of the adhesive resin layers. The nature precious wood decorative sheet can satisfactorily exhibit the statutory non-combustibility performance.

Test Example 6 : Influence of the Thickness of Adhesive Resin Layer and Aluminum Foil on Fire Protection Performance of Flame-Resistant Precious Wood Decorative Sheet Regarding the sheets and the various fire-resistant precious wood decorative sheets having different thicknesses of aluminum foil, surface fire tests according to the notification of the Ministry of Construction of fire prevention materials and JIS A 1321 were performed as follows, and their fire protection performances were compared. .

When the thickness of the adhesive resin layer is 20, 30, 40,
5 kinds of flameproof precious wood decorative sheets of 50 and 60 μm (the thickness of the aluminum foil is all 15 μm), and the thickness of the aluminum foil is 0, 10, 15, 20, and 30 μm
The five types of fireproof precious wood decorative sheets (the thickness of the adhesive resin layer is 40 μm in total) were manufactured for each of the three types of sheets and subjected to the above test.

Any of these flame-resistant decorative wood decorative sheets can be used
Also have the following laminated configuration. (Top layer) Veneer / Adhesive layer / Paper / Adhesive tree containing flame retardant
Oil layer / Aluminum foil / Adhesive resin layer containing flame retardant / Paper
(Lower layer) The materials used for the above decorative sheet are as follows.
You. Veneer: birch wood Air-dry weight 106g / m² Surface coating
Uncoated paper: thin paper basis weight 30g / m²  Adhesive layer: Vinyl acetate adhesive applied amount (solid
Min) 20 g / m²  Adhesive resin layer containing flame retardant: Brom-based flame retardant in weight ratio
Ethylene-acrylic acid copolymer containing 12%
Adhesive film

A gypsum board (9 mm thick) of a legally quasi-incombustible material was used as a base material for the surface burning test, and the above-mentioned decorative sheet made of flame-resistant wood was stuck on each of the plaster boards. Three of each were created. In addition, a vinyl acetate emulsion adhesive was used at a coating amount (solid content) of 40 g / m ² for attaching the decorative sheet and the base material.

The results of the test are shown in the following table. FIG.
FIG. 8 is a graph showing the results for each of the fireproof precious wood decorative sheets having various thicknesses of the adhesive resin layer, and FIG.
It is a graph showing the result about each flame retardant precious wood decorative sheet in which the thickness of an aluminum foil differs.

[Table 6]

From the table and the graph, the following can be understood. When the thickness of the adhesive resin layer is about 40 μm or less, the tested fireproof precious wood decorative sheet shows almost the same high fire protection performance and conforms to the quasi-nonflammable standard, but its thickness is 40 μm. Exceeding the above, the fire prevention performance deteriorates and the quasi-incombustibility is not reached. Also, when the thickness of the aluminum foil is in the range of 10 μm to 30 μm, the aluminum foil exhibits extremely high fire protection performance that satisfies the quasi-nonflammable standard.

[0080]

As described above, according to the present invention,
A laminated veneer sheet in which the sheet surface is a precious wood veneer and an aluminum foil is included as its backing material, which is a laminated veneer sheet having high flame retardancy, and can exhibit the quasi-incombustibility of a fireproof material, In addition, there is provided a flame-resistant precious wood decorative sheet free from defects and problems such as a reduction in product value due to discoloration of the veneer and production defects due to deterioration in adhesiveness. In particular, according to the present invention, not only high flame retardancy (flammability) can be achieved by high blending of a flame retardant, but also the decrease in adhesion, corrosion, and flexibility due to the inclusion of the flame retardant The effect of not causing the deterioration of various performances such as reduction of the noise is obtained. Further, according to the present invention, there is provided a decorative board made of a fire-resistant precious wood having the above-described fire prevention effect and the like by using the decorative sheet of the fire-proof precious wood.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a flameproof precious wood decorative sheet according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view showing a fireproof precious wood decorative panel according to an embodiment of the present invention.

FIGS. 3 (A) to 3 (D) are views showing a manufacturing process of the flameproof precious wood decorative sheet of FIG. 1;

FIGS. 4 (A) to 4 (D) are views showing the steps of manufacturing the flameproof precious wood decorative sheet of FIG. 1 and the flameproof precious wood decorative board of FIG. 2;

FIG. 5 is a graph showing the relationship between the peeling strength and the content of the flame retardant 24 hours after standing indoors.

FIG. 6: 7 days in 40 ° C. × 95% RH → 25 ° C.
It is a graph which shows the relationship between the peeling strength after 3 days in x55% RH, and the content of a flame retardant.

FIG. 7 is a graph showing the relationship between the thickness of the flame-retardant-containing adhesive resin layer and the temperature-time area.

FIG. 8 is a graph showing the relationship between the thickness of the aluminum foil and the temperature time area.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Paper or nonwoven fabric 2 1st adhesive resin layer 3 Aluminum foil 4 2nd adhesive resin layer 5 Paper or nonwoven fabric 6 Adhesive layer 7 Precious wood veneer 8 Flameproof precious wood decorative sheet 9 Wood base 10 Laminate 11 laminated body 12 veneer backing sheet

Claims (2)

(57) [Claims] 1. Paper or non-woven fabric; thickness of 20 to 50 μm
m first adhesive resin layer; aluminum foil having a thickness of 10 to 30 μm; second adhesive resin layer having a thickness of 20 to 50 μm; paper or nonwoven fabric; adhesive layer; Wherein the first adhesive resin layer and the second adhesive resin layer are each independently formed from a group consisting of an ethylene-acrylic acid copolymer and an ionomer. And a flame retardant is added to each of the first adhesive resin layer and the second adhesive resin layer in a weight ratio of 15%.
% Or less. 2. A decorative board made of flame-retardant precious wood, characterized in that the decorative sheet of fire-preventive precious wood according to claim 1 is stuck on a wood-based, inorganic-based or metal-based substrate.