JP3161975B2 - 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 non-combustible decorative board mainly used as an interior material for various uses.

[0002]

2. Description of the Related Art Many conventional non-combustible decorative panels are made of inorganic materials, which have many problems in workability, impact resistance, and safety to the human body due to the inclusion of asbestos. It is difficult to maintain its shape after a combustion test (surface combustion test, base material combustion test according to Ministry of Construction Notification No. 1828, hereinafter referred to as nonflammability test), and its reliability as a nonflammable decorative board is high. It was not obtained.

[0003]

SUMMARY OF THE INVENTION The present invention provides a non-combustible decorative board which is excellent in non-combustibility and has little dimensional change, warpage deformation and the like in the above situation.

[0004]

Means for Solving the problems] The present invention is a porous sheet substrate made of a non-aircraft-fiber consists phenolic resin and aluminum hydroxide, the composition ratio of Korira is 5-8 wt%
Two or more core material sheet materials coated with a composition that is 95 to 92% by weight, and a sheet substrate made of inorganic fibers inserted between these core material sheet materials. A sheet material for a reinforcing layer having a content of 40 to 400% and a thickness of 0.5 mm or less and an organic substance amount of 300 g on the front surface or the front and back surfaces of the core material layer sheet material. / M ² or less and a laminated non-combustible decorative sheet, which is laminated and integrated.

[0005] In the present invention, the porous sheet substrate made of inorganic fibers is not particularly limited. However, in order to apply a mixture of a phenol resin and aluminum hydroxide and impregnate the inside of the substrate, , Glass fiber non-woven fabric,
In particular, a glass fiber nonwoven fabric having a basis weight of 30 to 100 g / m ² is preferable. Because the basis weight of the glass fiber nonwoven fabric of insufficient strength is less than 30 g / m ^2, it may have difficulty in handling at the time of coating the formulation onto a glass fiber non-woven fabric, or molded or the like, 100 g / m ² If the ratio exceeds the above, the adhesion between the layers may be insufficient at the time of molding. The inorganic fiber base material used for the sheet material for the reinforcing layer obtained by impregnating the melamine resin is a glass nonwoven fabric having a basis weight of 30 to 100 g / m ² or a glass woven fabric having a basis weight of 45 to 220 g / m ^2. It is preferably used.

[0006] In the case of a composition comprising a phenol resin and aluminum hydroxide, a composition comprising 5 to 60% by weight of a phenol resin and 95 to 40% by weight of aluminum hydroxide makes the obtained decorative board flame-retardant. 8 phenolic resins
If the weight percentage is less than or equal to the weight percent, it conforms to the Notification of Ministry of Construction No. 1828 “Designating Noncombustible Materials”. If the phenolic resin is less than 5% by weight, the phenolic resin cannot sufficiently function as a binder, so that there is a problem in handling the core material sheet material and in the interlayer strength after molding, which is not preferable.

[0007] This composition is coated as it is or diluted with a diluent such as water or alcohol at a weight ratio of 9 to 30 with respect to a porous sheet substrate made of inorganic fibers. If it is less than 9 times, the adhesion and surface finish are not sufficient, and if it exceeds 30 times, there are disadvantages such as easy collapse during handling of the core material layer sheet material.

As the phenol resin, a resol-type phenol resin using ammonia or an amine catalyst such as triethylamine is usually used, but is not limited thereto.

On the other hand, it is preferable that aluminum hydroxide having a large particle diameter and a particle having a small particle diameter are mixed and used, and the aluminum hydroxide is packed closest. When a material having a small particle size is used alone, the uniformity of the core material layer sheet material or the decorative plate can be ensured, but the workability at the time of mixing the mixture is difficult. When a material having a large particle size is used alone, it is difficult to handle the obtained core material layer sheet material, and at the same time, a decrease in nonflammability due to a decrease in the particle surface area is observed. The close-packing of aluminum hydroxide with different particle diameters improves the wettability of the compound when preparing the sheet material for the core layer, as well as the workability when mixing the compound, the handling of the sheet, and the incombustibility. Etc. are also favorable and are preferred.

The decorative layer sheet material to be superimposed on the front surface or the front and back surfaces of the core material layer sheet material has a basis weight of 40 to 40 made of pulp, linter, synthetic fiber, glass fiber or the like.
Melamine resin 60 to 120 g / m ² sheet or paper
An impregnated sheet (or paper) impregnated with a mixture consisting of 95%, aluminum hydroxide or 40 to 5% of silica is used. The impregnation of this formulation is 10 or less per sheet or paper.
0 to 400% by weight. The melamine resin may be used in which a normal modifier is added in an amount of 0.1 to 20%.
An acidic curing agent can be appropriately compounded.

The decorative layer sheet material is laminated and integrated as a decorative layer on the front surface or the front and back surfaces of the core layer sheet material. Is desirably 300 g / m ² or less. Those exceeding this range make it difficult to pass the nonflammability test. Also, it may be difficult to pass the nonflammability test for a molded product having a total thickness of less than 3 mm.

[0012] The sheet material for the core layer prepared as described above is laminated on a plurality of sheets, the sheet material for the decorative layer is laminated on the front surface or the front and back surfaces, and heated and pressed to form the nonflammable decorative plate of the present invention. . At the time of molding, a mirror-finished plate, an embossed plate, an embossed film, or the like is overlaid, and the surface is finished to a mirror finish, an emboss finish, or the like.

[0013]

The present invention will be specifically described below with reference to examples and comparative examples .

Example 1 95% by weight of aluminum hydroxide (25% by weight with an average particle diameter of 100 μm) was added to a glass fiber nonwoven fabric having a basis weight of 75 g / m ² , a specific gravity of 0.23 g / cm ³ , and an organic binder amount of 11%. A mixture of 75% by weight having an average particle diameter of 8 μm) and 5% by weight of a resol-type phenol resin was applied to obtain a core material sheet material (5) having an impregnation ratio of 20 times. Next, a melamine resin containing a curing agent is applied to a glass woven fabric having a basis weight of 210 g / m ² and an organic binder amount of 0.08%, and an impregnation rate of 40%.
To obtain a sheet material (6) for a reinforcing layer. Sheet material for reinforcing layer (5) One sheet material for reinforcing layer (6) was inserted between the second and third sheets of the four sheets, and the same sheet material for decorative layer as in Example 1 ( 2) and the sheet material (3) for the decorative layer was laminated one by one on the front and back of the sheet material (5) for the core layer.
Under the same conditions as in Example 1 to obtain a non-combustible decorative plate (7) having a thickness of 3.6 mm.

Comparative Example 1 A grammage of 75 g / m ² and a specific gravity of 0.
Aluminum hydroxide 8 having an average particle size of 10 μm was added to a glass fiber nonwoven fabric having an organic binder amount of 11% and an organic binder amount of 23 g / cm ³ .
8% by weight of a blend of resol type phenolic resin and 12% by weight of a coating material, and a sheet material for a core material layer with an impregnation ratio of 20 times
I got Four sheets of the core layer sheet material (8), Example 1
The decorative layer sheet material (2) and the decorative layer sheet material (3), which are the same as described above, are stacked one by one on the front and back, and hot-pressed under the same conditions as in Example 1 to give a decorative plate having a thickness of 3.5 mm. (9) was obtained.

The characteristics of the non-combustible decorative panels (4) and (7) obtained in the above Examples and the decorative panel (9) obtained in Comparative Example were evaluated, and the results are shown below.

[0017]

[Table 1]

(Test Method) Substrate Burning Test: According to Notification No. 1828 of the Ministry of Construction. Surface burning test: According to Ministry of Construction Notification No. 1828. Judgment 1 = Existence of harmful deformation in fire prevention, generation of gas extremely harmful in evacuation, etc. Judgment 2 = Melting over the entire thickness of the test specimen, 10 minutes of the thickness of the crack reaching the back surface, where the width of the crack is the full thickness Judgment 3 = Existence of residual flame for 30 seconds or more after the end of heating, Judgment 4 = Exhaust temperature curve of the test specimen (refer to the curve shown by the recording thermometer specified in No. 2) The standard temperature curve (the curve obtained by adding 50 degrees to the exhaust gas temperature for each elapsed time after adjusting the heating furnace specified in No. 1-2 of the item 1, and connecting them together) Judgment 5 = The smoke emission coefficient C _A per unit area determined by the following equation is 30 or less, C _A = 24 log ₁₀ I ₀ / I In this equation, I ₀ and I represent the following numerical values, respectively. And I ₀ : Light intensity at the start of heating test (unit lux) I: Minimum value of light intensity during heating test (unit lux)

[0019]

According to the decorative plate of the present invention, a composition comprising a porous sheet base material such as a non-woven fabric made of inorganic fibers such as glass fibers and a phenolic resin and aluminum hydroxide has a phenolic resin content of 8% or less. 0.5 m thick on the surface or front and back of the core material layer material coated
m and a decorative layer having an organic content of 300 g / m ² or less are laminated and integrated, so that the amount of heat generated during combustion and the amount of smoke generated are suppressed to extremely small amounts. At the same time, there is almost no shape destruction after combustion, and the material is certified as a noncombustible material conforming to Ministry of Construction Notification No. 1828. Further, since a decorative layer sheet material similar to a conventional decorative plate can be used for the decorative layer, the decorative layer can be freely selected from a wide variety of colors and patterns and used as a non-combustible material for various uses.

[Brief description of the drawings]

FIG. 1 shows a sheet material for reinforcing layer (6) inserted between a sheet material for core layer (5) and a sheet material for decorative layer (2) and a sheet material for decorative layer on the front and back surfaces of the sheet material for core layer (5). Sectional drawing of the noncombustible decorative board (7) which carried out lamination molding of (3).

FIG. 2 is a cross-sectional view of a decorative plate (9) in which decorative layer sheet materials (2) and (3) are laminated and formed on the front and back surfaces of a core material layer sheet material (8).

Continuation of front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (1)

(57) [Claims] 1. A porous sheet substrate comprising inorganic fibers, comprising a phenol resin and aluminum hydroxide,
Two or more core material sheet materials coated with a composition having a composition ratio of 5 to 8% by weight to 95 to 92% by weight, and between these core material sheet materials. Inserted,
A melamine resin is applied to a sheet substrate made of inorganic fibers, and the content of the melamine resin is 40 to 400%. A non-combustible decorative plate comprising a decorative layer sheet material having an organic substance amount of 300 g / m ² or less, which is laminated and integrated below.