JP3081985B2 - Non-combustible decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a nonflammable decorative panel having excellent strength and workability for use in building interiors, housing equipment and the like.

[0002]

2. Description of the Related Art Conventionally, as a non-combustible decorative board using an inorganic base material, an inorganic board such as an asbestos cement calcium silicate board is coated with a colored paint, or a thermosetting resin decorative sheet is applied to the inorganic board. Were laminated and heated and pressed.

As described in JP-A-51-20980, a method of using a substrate containing a thermosetting resin includes a method of using a thermosetting resin such as a phenol resin as a binder for an inorganic material such as aluminum hydroxide. A non-combustible decorative plate formed by mixing a resin to form a sheet, further laminating a thermosetting resin decorative sheet, and heating and press-forming. Alternatively, a non-combustible material obtained by laminating and integrating a decorative layer forming layer material on a core material forming material composed of a sheet substrate made of inorganic fibers, aluminum hydroxide and a phenol resin and the phenol resin compounded to 8% by weight or less. Cosmetic material (Japanese Unexamined Patent Publication No.
0).

[0004]

However, many non-combustible decorative boards using an inorganic base material such as an asbestos cement calcium silicate board contain asbestos as a reinforcing material of the base material, and human body such as carcinogenicity of the asbestos. In addition, there is a problem that adverse effects on the steel sheet are adversely affected, and since the steel sheet is hard and brittle, it is easily broken during handling, and there is a problem in workability. Also,
Defects such as irregularities on the substrate are likely to appear on the surface, and the appearance of the cut surface is not beautiful, and the appearance and design are not always satisfactory.

[0005] A non-combustible decorative board formed by mixing a thermosetting resin as a binder with an inorganic material such as aluminum hydroxide to form a sheet, laminating thermosetting resin decorative sheets, and heating and pressing to form a sheet. In order to have non-combustibility as a non-combustible or semi-combustible material, the mixing ratio of the inorganic material to the resin must be increased, and sufficient strength such as impact resistance cannot be obtained.

A decorative layer molding layer material is laminated and integrated on a core material molding material comprising an inorganic fiber sheet substrate, aluminum hydroxide and a phenol resin, wherein the phenol resin is compounded to 8% by weight or less. With the non-combustible cosmetic material,
Although performance as a non-combustible material is obtained, sufficient strength is hardly obtained, and water resistance is poor. Therefore, it is not always suitable for applications such as a wet toilet, a washroom, and a bathroom.

The present invention has been made as a result of intensive studies in order to solve the above-mentioned problems of non-combustible materials. The present invention has non-combustibility as a non-combustible material or quasi-non-combustible material and has strength, workability and water resistance. Physical properties such as surface,
An object of the present invention is to provide a nonflammable decorative board having a beautiful appearance with both cut surfaces.

[0008]

The present invention relates to a phenolic tree.
The resin composition consisting of fat and filler is contained in the glass fiber nonwoven fabric.
Dipped, dried prepregs are used as a base material by stacking multiple sheets.
Cosmetic on which at least one surface of the base material is resin-treated on decorative paper
Sheets are laminated and formed into a non-combustible decorative board that is hot-pressed
More preferably, the filler is aluminum hydroxide.
Phenolic resin and aluminum hydroxide
% By weight to 70 to 90% by weight.
Melamine resin impregnated into dried paper and dried prepreg
It is a non-combustible decorative board molded in the manner described above.

The non-combustible decorative board of the present invention is a non-combustible material corresponding to a non-combustible material based on Article 108-2 of the Building Standards Law Implementation Examples and a quasi-non-combustible material based on Article 1, item 5 of the same. It refers to a board.

In the present invention, the basis weight of the glass fiber nonwoven fabric is preferably 30 to 150 g / m ² . When the amount is 30 g / m ² or less, a strength sufficient to withstand handling and load in the resin liquid impregnation and drying steps cannot be obtained. If it is 150 g / m ² or more, the impregnating property of the resin liquid is reduced, and it is easy to cause interlayer peeling of the core.

The resin liquid impregnated in the glass fiber is made non-flammable by preparing a resin composition comprising 10 to 30% by weight of a phenol resin as a non-volatile content and 70 to 90% by weight of a filler mainly composed of inorganic particles. If the phenolic resin is more than 30% by weight, it is difficult to obtain the incombustibility of the decorative board. In addition, the flowability of the resin composition in the above is reduced, and it is difficult to obtain sufficient strength and water resistance as a decorative board.

Further, the decorative sheet laminated on the surface has nonflammability due to the organic component being 300 g / m ² or less, and is required as a decorative board surface when the decorative sheet has a thickness of 0.5 mm or less. Finished, in which physical properties can be obtained, preferably a titanium paper having a basis weight of 20 to 200 g / m ^2, impregnated with melamine resin-called decorative paper, decorative laminate of interest by thermocompression molding the dried prepreg Can be manufactured. Especially 30 to 120
When a decorative paper having a basis weight of g / m ² is used, handleability, physical properties,
Preferred results are obtained in terms of appearance, nonflammability, and the like. As the decorative paper, a paper on which a pattern such as wood grain is printed as necessary is used.

In the present invention, the resin as a component of the resin composition used for impregnating the glass fiber nonwoven fabric is a resol type phenol resin having a formaldehyde to phenol molar ratio of 1.0 to 2.0, and a filler. Are powders of aluminum hydroxide, calcium carbonate, silica, etc., and are fine particles having a diameter of 30 μm, preferably 1 to 5 μm.
When the particle size is μm, the impregnation property of the glass fiber nonwoven fabric is improved. By using aluminum hydroxide as the filler component, a nonflammable effect can be obtained more easily.

The amount of the resin composition adhered to the glass fiber nonwoven fabric is preferably 83 to 94% by weight as a non-volatile content.
When the content is 83% by weight or less, the adhesive strength between the layers of the base material, the bending strength, the impact value, and the like decrease. If the content is 94% by weight or more, the drying property of the prepreg deteriorates.

The volatile content of the prepreg is preferably 1 to 5% by weight, and if it is 5% by weight or more, the warp becomes large, and if it is 1% by weight or less, the flow property at the time of molding and the interlayer adhesion strength of the base material decrease.

As a method for forming a non-combustible decorative board, a prepreg obtained by impregnating a glass fiber nonwoven fabric with a resin composition and drying is laminated to a desired thickness to form a base material for a decorative board.
A decorative layer sheet is placed on at least one side, and is heated and pressed by a hot press molding machine between the plates to cure and integrate to obtain a nonflammable decorative plate.

When the decorative layers are provided on both surfaces of the substrate, the thickness and weight of the glass fiber nonwoven fabric, the amount of the resin composition adhered, and the like are substantially the same, so that the occurrence of warpage of the decorative plate is suppressed.

[0018]

EXAMPLES The parts and percentages given below are parts by weight and percentages by weight. Examples 1 to 4 As Examples 1 to 4, the resin compositions shown in Table 1 were prepared using a basis weight of 6
Non-volatile content of 600 g non-woven glass non-woven fabric of 0 g / m ²
/ M ² prepreg 7 obtained by impregnating and drying to a coating weight
Was a base material was laminated sheets, on both sides of the substrate, as a sheet constituting the decorative layer, so that the adhesion amount of the melamine resin is 55 g / m ² non-volatiles in the titanium paper having a basis weight of 55 g / m ² Prepregs dried by drying so that the volatile content becomes 8%, sandwiched between matte stainless steel plates having a thickness of 3 mm, and inserted between hot plates of a hot press machine at a temperature of 150 ° C. and pressure. After heating and pressurizing at 80 kg / cm ² for 20 minutes, it was cooled for 20 minutes in the pressurized state and decompressed to obtain a decorative board.

COMPARATIVE EXAMPLES 1-2 Using the same glass nonwoven fabric as that used in Examples 1-4 for the resin compositions shown in Table 1, a decorative plate was prepared under substantially the same production conditions as in Examples 1-4. Manufactured. Table 2 shows the physical property test and nonflammability test results of the decorative boards of Examples 1 to 4 and Comparative Examples 1 and 2.

Test method The thickness, boiling resistance, dimensional change, and flexural strength were determined by JI.
The test was performed according to the thermosetting resin decorative board test method specified in SK6902. For non-combustible materials, the non-combustible materials shall be subjected to a base material test and a surface test in accordance with the provisions of Article 108-2 of the Ordinance of the Building Standards Act. , Perforation test, gas hazard test, and model box test.

[0021]

[Table 1] The mixing ratios indicate parts.

[0022]

[Table 2]

[0023]

The incombustible decorative board of the present invention is lighter and tougher than conventional decorative boards based on inorganic board materials, does not break during handling, and has good workability such as cutting and drilling. It is excellent and has a beautiful cut surface and excellent design. In addition, since the base material does not contain alkaline substances, the decorative layer on the front surface does not deteriorate or the adhesive layer on the back surface does not deteriorate even when used for a long time. It is excellent. Furthermore, it is a material that can achieve fire prevention performance that passes the test as a non-combustible material or a quasi-non-combustible material, and is a material suitable for applications subject to interior restrictions.

──────────────────────────────────────────────────続 き Continued on front page (51) Int.Cl. ⁷ Identification code FI B32B 33/00 B32B 33/00 C08J 5/24 CFB C08J 5/24 CFB

Claims (3)

(57) [Claims] A phenolic resin of 10 to 30% by weight and 7
A resin composition comprising 0 to 90% by weight of a filler is
Weaving nonwoven fabrics and stacking multiple dried prepregs
Material, and at least one side of the substrate is impregnated with resin in decorative paper
The treated decorative sheets are laminated and hot pressed
A non-combustible decorative board characterized by the above. 2. The method according to claim 1, wherein the filler is aluminum hydroxide.
Cosmetic sheet impregnated titanium paper with melamine resin and dried
The non-combustible decorative board according to claim 1, wherein 3. The particle size of aluminum hydroxide is 30 μm.
The nonflammable decorative board according to claim 2, which is: