JP3680184B2

JP3680184B2 - Incombustible cosmetics

Info

Publication number: JP3680184B2
Application number: JP4561596A
Authority: JP
Inventors: 藤芳廣斎
Original assignee: Hokuetsu Paper Mills Ltd
Current assignee: Hokuetsu Paper Mills Ltd
Priority date: 1996-02-08
Filing date: 1996-02-08
Publication date: 2005-08-10
Anticipated expiration: 2016-02-08
Also published as: JPH09208282A

Description

【０００１】
【発明の属する技術分野】
本発明は不燃化粧材に関し、更に詳しくは、高度の不燃性を有し、かつ曲面下地に対して良好な施工性を有し、さらに意匠性に優れた不燃化粧材に関する。
【０００２】
【従来の技術】
従来より、現場施工時に曲面下地に対応できる不燃化粧材として柔軟性を有し屈曲自在な不燃裏打材上にケイ酸カルシウム板等の不燃基材を接着し、該不燃基材の表面に溝を所定間隔で形成し、かつ溝底が前記した不燃裏打材に至るように施したもの等が知られており、かかる不燃化粧材は表面に溝を有するため意匠性にも優れるという利点もある。
【０００３】
【発明が解決しようとする課題】
しかるに、上述した不燃裏打材上に不燃基材を接着し、該不燃基材の表面に溝を所定間隔で形成し、かつ溝底が不燃裏打材に至るように施す方法は、▲１▼不燃裏打材と不燃基材との接着工程が必要であり、加工工程が繁雑である。▲２▼不燃裏打材と不燃基材を接着するのに有機系接着剤を使用することが多いため、不燃性の悪化を来たしやすい。▲３▼柔軟性を有し、屈曲自在な不燃裏打材としてはガラスクロス、各種無機繊維系不織布、アラミド繊維シ−トなどが用いられるがかかる不燃裏打材は一般に極めて高価である、などの難点を有する。
【０００４】
従って、前記した不燃裏打材を用いることなしに曲面下地に対する施工性が良好で、かつ意匠性に優れ、高度の不燃性を有する不燃化粧材を構成することができれば極めて好適である。しかし、従来慣用のケイ酸カルシウム板の類を用いて前記した不燃裏打材なしにかかる要件を満たす不燃化粧材を得ることは困難であった。すなわち、ケイ酸カルシウム板の類は柔軟性に乏しいため切削加工で溝等の凹部を形成しても曲面下地に適用しようとすると切削で板厚が薄くなった部位に割れを生じやすい。また、ケイ酸カルシウム板の類のかかる柔軟性に乏しいという特性は表面試験において熱応力等による亀裂を発生しやすい原因にもなっており、切削加工で板厚の薄くなった部位は一段と表面試験での亀裂を発生しやすくなり所定の不燃性を確保できない。さらに、ケイ酸カルシウム板の類は柔軟性に乏しく、切削加工に際し、割れを生じやすく裏打材なしには良好な切削加工適性を確保できないし、仮に切削加工できたとしても、切削で板厚が薄くなった部位は非常に割れやすく、運搬、現場施工時などに支障を来たす危険が大きい。このように、ケイ酸カルシウム板の類は基材そのものの柔軟性に乏しいため切削加工で溝等の凹部を形成しても屈曲自在な不燃裏打材の補助なしには曲面下地への良好な施工適性及び高度の不燃性を与えることは実用上困難であった。
【０００５】
そこで、本発明者は、かかる課題を解決すべく多数次の実験を行った結果、多量の含水無機化合物もしくは多量の含水無機化合物と炭酸塩／セルロ−ス繊維／無機繊維／合成高分子という構成で各成分を特定量含有する不燃基材を用いて所定の凹部を形成せしめることにより、不燃裏打材を用いることなしに曲面下地に対する施工性が良好で、かつ意匠性に優れ、高度の不燃性を有する不燃化粧材を得ることができることをつきとめ本発明を完成した。
【０００６】
【課題を解決するための手段】
本発明に係る不燃化粧材は含水無機化合物を固形分で６０〜９５重量％と、セルロ−ス繊維を固形分で２〜３０重量％と、無機繊維を固形分で０．５〜２０重量％と、合成高分子を固形分で１〜２０重量％とを含有するシ−ト状の不燃基材の片面に深さが０．５ｍｍ以上で最大開口幅が１〜３０ｍｍの複数の凹部を有し、該凹部の底部での前記した不燃基材の厚さが０．５〜２ｍｍであり、該凹部の頂部での前記した不燃基材の厚さが２〜１０ｍｍであり、かつ、該凹部を有する側の不燃基材表面の投影面積に占める該凹部の最大投影面積を５０％以上としたものである。
【０００７】
また、本発明に係る不燃化粧材は含水無機化合物と炭酸塩を固形分で合計６０〜９５重量％と、セルロ−ス繊維を固形分で２〜３０重量％と、無機繊維を固形分で０．５〜２０重量％と、合成高分子を固形分で１〜２０重量％とを含有し、かつ含水無機化合物／炭酸塩が固形分重量比で５０／５０より含水無機化合物過多側であるシ−ト状の不燃基材の片面に、深さが０．５ｍｍ以上で最大開口幅が１〜３０ｍｍの複数の凹部を有し、該凹部の底部での前記した不燃基材の厚さが０．５〜２ｍｍであり、該凹部の頂部での前記した不燃基材の厚さが２〜１０ｍｍであり、かつ、該凹部を有する側の不燃基材表面の投影面積に占める該凹部の最大投影面積を５０％以上としたものである。
【０００８】
【発明の実施の形態】
上記した含水無機化合物としては水酸化アルミニウム、水酸化マグネシウム、水酸化カルシウム、２水和石こう及びアルミン酸化カルシウム等を挙げることができる。これらの化合物は何れも分子内に結晶水を持ち化学的に類似した構造を有する。また、含水無機化合物はその種類によって分解温度及び吸熱量に幾分差があるが、高温加熱時に分解して吸熱作用により不燃化効果を示すという点では全く共通している。従って、基本的に前記した含水無機化合物の何れを用いてもよいが、入手価格等の経済性をも考慮すると水酸化アルミニウムが最適である。
【０００９】
本発明で使用する炭酸塩としては、炭酸カルシウム、炭酸マグネシウム、炭酸バリウム、炭酸ストロンチウム、炭酸ベリリウム、炭酸亜鉛等の中から少なくとも１種類を選択して使用する。これらの炭酸塩はその種類により分解温度等に幾分差があるが、高温加熱時に分解して吸熱作用により難燃効果を示すという点では全く共通している。従って、基本的に前記した炭酸塩の何れを用いてもよいが、価格の面から炭酸カルシウムが最適である。なお、炭酸塩配合によるもう１つの重要な効果として本発明者が特開平５−１１２６５９号公報等で指摘したところの発煙量低減効果を挙げることができる。
【００１０】
本発明に係る不燃基材中の含水無機化合物あるいは含水無機化合物と炭酸塩の合計の含有率範囲は固形分で６０〜９５重量％、好ましくは、７０〜９５重量％である。その含有率が、６０重量％未満では十分な不燃性が得られない。反対に９５重量％を超えた場合は含水無機化合物あるいは含水無機化合物と炭酸塩の合計量の過多により十分な機械的強度が得られず、特に凹部底部での不燃基材の厚さの薄くなった部分での強度が不足し不適である。また、含水無機化合物／炭酸塩の含有重量比率は固形分で５０／５０よりも含水無機化合物過多側としなければならない。５０／５０より含水無機化合物過少側とした場合、不燃性が低下することがあり不適である。
【００１１】
上記したセルロ−ス繊維としては針葉樹系あるいは広葉樹系の化学パルプ、機械パルプ、セミケミカルパルプ等の木材パルプあるいは木綿パルプ、麻パルプ、各種古紙などの中から選ばれる１種類あるいは２種類以上を併用して使用すればよい。木材パルプは供給量及び品質が安定しており価格も比較的安価であることから最も使いやすいセルロ−ス繊維原料である。木綿パルプ及び麻パルプは供給量が不安定であり価格も高価であるが、本発明におけるような含水無機化合物あるいは含水無機化合物と炭酸塩を多量に含有する不燃基材においては、必要に応じて該木綿パルプあるいは麻パルプを使用することにより該不燃基材の機械的強度の低下、特に凹部底部での該不燃基材の厚さの薄くなった部分での機械的強度の低下を最小限にとどめることができる。
【００１２】
本発明に係る不燃基材中のセルロ−ス繊維の含有率範囲は固形分で２〜２０重量％である。その含有率が２重量％未満では基材中のセルロ−ス繊維の過少により十分な抄紙性あるいは機械的強度（特に凹部底部での不燃基材の厚さの薄くなった部分での機械的強度）が得られない。また該不燃基材の柔軟性も乏しくなり曲面下地に対する施工性も不十分となる。反対に２０重量％を超えた場合は有機物質の過多により十分な不燃性を得ることができない。
【００１３】
上記した無機繊維としては、ガラス繊維、ロックウ−ル繊維、セラミック繊維、炭素繊維などの中から少なくとも１種類を選択して使用する。
本発明に係る不燃基材中の無機繊維の含有率範囲は０．５〜２０重量％である。その含有率が０．５重量％未満では該不燃基材より得た不燃化粧材が表面試験において亀裂を発生しやすくなる。特に凹部底部の厚さの薄くなった部分において亀裂を発生しやすくなる。また、２０重量％を超えると十分な抄紙性が得られない。
【００１４】
上記した合成高分子としては、フェノ−ル樹脂、メラミン樹脂、エポキシ樹脂、尿素樹脂、不飽和ポリエステル樹脂などの熱硬化性樹脂（繊維状のものも含む）もしくはポリオレフィン樹脂、ポリエステル樹脂、アクリル樹脂、メタクリル樹脂、スチレン樹脂、塩化ビニル樹脂、酢酸ビニル樹脂等の熱可塑性樹脂（繊維状のものも含む）またはＳＢＲ、ＮＢＲ、ＭＢＲ等の合成ゴム等の中から少なくとも１種類を選択して使用する。これらの合成高分子はその種類により、硬化温度、溶融軟化温度等に幾分差があるが、加熱処理に伴う流動硬化作用あるいは軟化溶融固化作用により、不燃基材に各種成形賦形効果もしくは諸強度の発現効果または含水無機化合物等の脱落防止効果を与えるという点では全く共通している。従って基本的には、前記合成高分子のいずれを用いてもよいが入手価格等の経済性をも考慮するとフェノ−ル樹脂、ポリオレフィン樹脂等が最適である。
【００１５】
本発明に係る不燃基材中の合成高分子の含有率範囲は固形分で１〜２０重量％である。その含有率が１重量％未満では十分な機械的強度（特に凹部底部の不燃基材の厚さの薄くなった部分での機械的強度）が得られない。また、２０重量％を超えた場合は有機物質の過多により十分な不燃性を得ることができない。
【００１６】
本発明に係る不燃基材は上記配合のもとに含水無機化合物あるいは含水無機化合物と炭酸塩／セルロ−ス繊維／無機繊維／合成高分子という構成であればよくその製造法としては、湿式抄造法、乾式成形法などの任意の方法が適用可能であり、特定の製造法に限定するものではないが、以下において本発明の当該分野である湿式抄造法を適用した場合を例にとって製造法にも言及しながらさらに詳述する。
【００１７】
本発明に係る不燃化粧材は上記配合のもとに含水無機化合物あるいは含水無機化合物と炭酸塩の歩留を向上させるための各種歩留向上剤あるいは必要に応じて合成繊維、または着色のための合成染料等を含有していてもよい。また、用途によっては機械的強度もしくは後加工適性の改善を図るべく乾燥または湿潤紙力増強剤、サイズ剤、耐水化剤、撥水剤等を含有せしめるべきことは言うまでもない。
【００１８】
本発明に係る不燃基材に合成高分子を含有せしめる方法としては、合成高分子の液状物、繊維状物あるいは粒状物等を原料スラリ−中に内添したり、紙層形成後に塗布または含浸するなどすればよい。
含水無機化合物または炭酸塩を含有せしめる方法としては、含水無機化合物または炭酸塩を含有する塗料を基材に塗布あるいは含浸するなどの方法も考えられるが、所定の含有量を確保しあるいは厚さ方向での品質の均一化を図るためには原料スラリ−中に含水無機化合物または炭酸塩を粉体状あるいはスラリ−状にて内添する方法が最も好ましい。
この場合、含水無機化合物、炭酸塩、セルロ−ス繊維、無機繊維及び合成高分子の添加方法及び添加順序等は任意であり、必要に応じて叩解処理等を施してもよい。
【００１９】
こうして得た原料スラリ−を用いて、本発明に係る不燃基材を製造するには、通常の抄造法によればよい。すなわち、通常の長網、円網あるいは傾斜網等の抄造網上に前記スラリ−を供給し、濾過、脱水した後、圧搾、乾燥すればよい。また、必要により各種コンビネ−ション網や、多槽円網及び各種ラミネ−タ−などにより紙層を２層以上重ね合わせてもよい。
【００２０】
こうして得た不燃基材を用いて本発明の不燃化粧材を製造するには、不燃基材にたとえば熱圧プレス成形、高周波加熱成形、予熱−コ−ルドプレスなどの従来慣用の熱成形を単独であるいは２種以上組み合わせて適用し不燃基材中の熱硬化性樹脂あるいは熱可塑性樹脂を硬化もしくは軟化溶解、再固化せしめるなどした後、切削加工等により所定の凹部を成形せしめるか、不燃基材を所定の金型等を用いて熱圧成形することにより、不燃基材中の熱硬化性樹脂あるいは熱可塑性樹脂の硬化もしくは軟化溶解、再固化と所定の凹部の形成を同時に行うかなどすればよい。
また、必要に応じて、熱成形後あるいは切削加工前もしくは切削加工後などにおいて化粧紙、突板、レザ−、合成樹脂膜の貼合、各種塗料の吹付け、塗布、印刷などしてもよい。場合によっては、不燃基材と化粧紙、突板、レザ−等の接着もしくは貼合と所定の凹部の形成を金型等による一体熱圧成形等により同時に行うことも可能である。
【００２１】
本発明に係る不燃化粧材の有する凹部は、深さが０．５ｍｍ以上、最大開口幅が１〜３０ｍｍでなければならない。深さが０．５ｍｍ未満あるいは最大開口幅が１ｍｍ未満では表面の凹形状による意匠性向上効果に乏しい。最大開口幅が３０ｍｍを超えた場合、凹部底部での不燃基材の厚さの薄くなる部分の面積が大きくなりやすく表面試験において当該部位に亀裂を生じやすくなり不適である。
【００２２】
本発明に係る不燃化粧材の有する凹部は該凹部の底部での不燃基材の厚さが０．５〜２ｍｍでなければならない。かかる厚さが０．５ｍｍ未満では当該部位の機械的強度が弱くなり切削加工、運搬、あるいは現場施工時などにおいて、割れるなどの不具合を発生しやすく、加えて表面試験において当該部位に亀裂を生じやすくなり不適である。また、かかる厚さが２ｍｍを超えると、不燃成形体の柔軟性が乏しくなり、曲面下地に対する施工性が不十分となる。
【００２３】
本発明に係る不燃化粧材の有する凹部は、該凹部の頂部での不燃基材の厚さが２〜１０ｍｍでなければならない。２ｍｍ未満では表面試験において亀裂を生じやすく不適である。また１０ｍｍを超えると、凹部頂部近傍もしくは凹部の形成されていない部位と凹部底部近傍との厚さの違いが大きくなり過ぎ、運搬あるいは現場施工時などにおいて凹部頂部近傍及び凹部の形成されていない部位を構成する不燃基材の重量による応力が凹部底部近傍の不燃基材の厚さの薄くなった部位に作用し当該部位が割れる、あるいは破断するなどの不具合を発生しやすくなる。
【００２４】
本発明に係る不燃化粧材の有する凹部は、該凹部を有する面において当該表面に占める該凹部の最大投影面積が５０％以上でなければならない。５０％未満では、不燃化粧材の全面積に占める凹部底部近傍の不燃基材の厚さが薄くなった部位の占める割合が過少となり、不燃化粧材の柔軟性が乏しくなり、曲面下地に対する施工性が不十分となる。
【００２５】
本発明に係る不燃化粧材の有する凹部は互いに平行となるようにするのが、切削で凹部を形成する場合にはやりやすく、また円柱状もしくは部分円柱状等の曲面下地への施工性の向上を図る上では好ましい。ただし、円すい形状もしくは球状あるいは卵形状等の多様な曲面下地に対する施工性を向上せしめるには凹部を互いに平行にするよりも、それぞれの曲面下地の曲面形状に合わせて多様な凹部の配置が考えられる。実際、ＮＣ切削機あるいは、金型による熱圧成形による凹部形成によればかなり複雑な形状で、かつ複雑な配置の凹部の形成も可能である。
【００２６】
本発明に係る不燃化粧材は、不燃基材中に含有される含水無機化合物と無機繊維あるいは含水無機化合物と炭酸塩と無機繊維により十分な不燃性能を確保することができる。ただし、難燃剤の使用を妨げるものではない。使用可能な難燃剤としては、有機リン化合物、含リン含窒素有機化合物、スルファミン酸塩、無機リン酸塩、含ハロゲン化合物及びアンチモン系化合物等を挙げることができる。また、本発明に係る不燃基材中の必須有機物質であるセルロ−ス繊維及び合成高分子に対して、より効果的な難燃化作用を発揮せしめるという観点から、炭化促進作用を有する難燃剤を使用するのが一層効果的である。
【００２７】
難燃剤を含有せしめるには、難燃剤の液状物あるいは粒状物等を原料スラリ−中に内添せしめるか、抄造工程中もしくは抄造後または成形後に塗布または含浸するなどすればよい。また、難燃剤の使用量はごく少量（多くても固形分で１０％以下）にすべきある。難燃剤含有率が１０重量％を超えた場合、高温加熱時に難燃剤の分解に伴う発煙や有害ガスの発生等を伴うことがあり、むしろ逆効果となることがあるからである。
【００２８】
【作用】
本発明の重要点は、多量の含水無機化合物あるいは含水無機化合物と炭酸塩を含有し、かつセルロ−ス繊維、無機繊維及び合成高分子の所定量を含有するシ−ト状の不燃基材の片面に特定の凹部を有する化粧材により、従来必要不可欠であった不燃裏打材を用いなくとも高度の不燃性と曲面下地に対する良好な施工性を得ることができる点にある。
以下、後述する実施例での実験結果に基づき説明する。
【００２９】
まず、不燃性について説明する。多量の含水無機化合物と炭酸塩を含有し、かつセルロ−ス繊維、無機繊維及び合成高分子の所定量を含有する厚さ２．４ｍｍのシ−ト状の不燃基材について表面試験を実施したところ、亀裂を生じ所定の不燃性に達しなかった（比較例４）。次に、前記したシ−ト状の不燃基材と同一組成を有する不燃基材に図６で示すような凹部（１０ｍｍ間隔で互いに平行する深さ５．５ｍｍ、最大開口幅１０ｍｍのノコ切り刃形状）を形成せしめた本発明に係る化粧材について表面試験を実施したところ、凹部底部での厚さが１．５ｍｍしかないにもかかわらず亀裂の発生がなく所定の不燃性能が得られた（実施例６）。
これに対し、市販のケイ酸カルシウム板を用いて図１６に示すような凹部（１０ｍｍ間隔で互いに平行する深さ５．６ｍｍ、最大開口幅１０ｍｍ、凹部底部の厚さ１．８ｍｍのノコ切り刃形状）を形成せしめた場合は、表面試験で著しい亀裂を生じ所定の不燃性が得られなかった（比較例６）。すなわち、従来のケイ酸カルシウム板の類に本発明に係る凹部を形成せしめた場合、不燃裏打材なしでは所定の不燃性能を得ることができないのである。
【００３０】
さて、それではなぜ本発明の化粧材は不燃裏打材なしでも高度の不燃性が得られるのかという点については次のように推定される。
本発明の化粧材を高温加熱した時、凹部頂部近傍あるいは凹部の形成されていない部位を構成する不燃基材中の含水無機化合物あるいは含水無機化合物と炭酸塩がより効果的に熱分解され凹部底部の厚さの薄い部位での不燃性能の悪化を補い全体として優れた不燃性が引き出されるとともに、特定組成、特定形状の凹部により本発明の化粧材が柔軟性に富むため、高温加熱時の熱応力が加熱部位近傍に集中せず分散され、全体的に熱応力の発生が緩和される結果、凹部底分の厚さを０．５〜２ｍｍときわめて薄くしても係る部位に亀裂を生ずることなく、不燃裏打材を用いなくとも優れた不燃性能が得られるものと考えられる。
【００３１】
次に曲面下地に対する施工性について説明する。
本発明の不燃化粧材の主構成成分は含水無機化合物あるいは含水無機化合物と炭酸塩であるが、比較的少量のセルロ−ス繊維、無機繊維及び合成高分子を含有しているため、特に、係るセルロ−ス繊維と合成高分子により木質材的素地が付加され、かつ、凹部形状（頂部での厚さ、底部での厚さ、深さ、最大開口幅及び最大投影面積）を本発明で特定する所定形状とすることにより、凹部底部の厚さを０．５〜２ｍｍときわめて薄くしても必要最低限の強度を維持しつつ、良好な柔軟性が発現する結果、不燃裏打材を用いずに曲面下地材用不燃化粧材として実用に供し得る優れた曲面施工性が得られるものと考えられる。
【００３２】
【実施例】
次に本発明を以下の実施例に基づいてさらに具体的に説明する。
本実施例中の各項目の測定は次の方法によった。
▲１▼不燃性：ＪＩＳＡ−１３２１の表面試験による
▲２▼曲面施工性：４０，５０，６０，７０，８０，１００，１２０，１５０，２００，３００，４００，６００，８００，１０００ｍｍなる曲率半径を有する成形合板を用いて模擬下地を構成し、この模擬下地に試験体（３０ｃｍ×３０ｃｍ）をあてがい破断あるいはひび割れ等の施工上の不具合を発生しなかった最も小さい曲率半径をもって評価した。
【００３３】
実施例１
市販の針葉樹系末晒硫酸塩パルプとガラス繊維（繊維径３μｍである。以下同じ）をパルパ−にて離解し、これに水酸化アルミニウム粉体（平均粒径５．７μｍである。以下同じ）、炭酸カルシウム粉体（平均粒径１．５μｍである。以下同じ）及び粉体状フェノ−ル樹脂（平均粒子径３０μｍである。以下同じ）を添加し十分に分散混合後、長網／ワインドアップロ−ル構成の巻取板紙抄紙機にて紙層を３０層積層させて抄紙し圧搾、乾燥し、さらに熱プレスにて加熱処理（温度１７５℃、圧力２０ｋｇ／ｃｍ² 、時間１０分）し大きさが９１０ｍｍ×１８２０ｍｍの不燃基材を得た。この不燃基材中の各成分の含有率（重量％）は含水無機化合物８８．３、炭酸塩１．９、セルロ−ス繊維４．１、無機繊維２．０、合成高分子３．７である。
次に該不燃基材の片面を切削機にて切削処理し、図１に示すような凹部（６ｍｍ間隔で互いに平行する深さ２．７ｍｍ、最大開口幅６ｍｍの波形）を有する化粧材Ａを得た。化粧材Ａについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００３４】
実施例２
実施例１で得た熱プレス後の不燃基材の片面を切削機にて切削処理し、図２に示すような凹部（６ｍｍ間隔で互いに平行する深さ３ｍｍ、最大開口幅６ｍｍの波形）を有する化粧材Ｂを得た。化粧材Ｂについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００３５】
実施例３
実施例１で得た熱プレス後の不燃基材の片面を切削機にて切削処理し、図３に示すような凹部（６ｍｍ間隔で互いに平行する深さ２．７ｍｍ、最大開口幅６ｍｍのノコ切り刃形状）を有する化粧材Ｃを得た。化粧材Ｃについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００３６】
実施例４
実施例１で得た熱プレス後の不燃基材の片面にウレタン系接着剤を用いて厚さ０．２ｍｍの天然木突板を接着し、次に該突板面を切削機にて切削処理し、図４に示すような凹部（１０ｍｍ間隔で互いに平行する深さ３．５ｍｍ、最大開口幅７ｍｍのＶ溝）を有する化粧材Ｄを得た。化粧材Ｄについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００３７】
実施例５
実施例１で得た熱プレス前の不燃基材を用いて金型による成形（金型温度１７５℃、圧力４０ｋｇ／ｃｍ² 、時間１０分）を行い、図５に示すような凹部（６ｍｍ間隔で互いに平行する深さ２．７ｍｍ、最大開口幅６ｍｍのノコ切り刃形状）を有する化粧材Ｅを得た。化粧材Ｅについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００３８】
実施例６
実施例１において不燃基材中の各成分の含有率（重量％）を含水無機化合物７２．２、炭酸塩６．１、セルロ−ス繊維８．４、無機繊維５．１、合成高分子８．２に変えた以外は実施例１と同様にして得た熱プレス前の不燃基材を尿素・メラミン系接着剤を併用して２枚積層し熱プレスにて加熱処理（温度１７５℃、圧力２０ｋｇ／ｃｍ² 、時間１０分）し、大きさが９１０ｍｍ×１８２０ｍｍの２層が強固に固着した不燃基材を得た。
次に該不燃基材の片面を切削機にて切削処理し、図６に示すような凹部（１０ｍｍ間隔で互いに平行する深さ５．５ｍｍ、最大開口幅１０ｍｍのノコ切り刃形状）を有する化粧材Ｆを得た。化粧材Ｆについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００３９】
実施例７
実施例６において不燃基材中の各成分の含有率（重量％）を含水無機化合物５１．７、炭酸塩２３．７、セルロ−ス繊維１０．３、無機繊維５．２、合成高分子９．１に変え、熱プレス時の積層枚数を３枚とした以外は実施例６と同様にして得た熱プレス後の３層が強固に固着した不燃基材の片面を切削機にて切削処理し、図７に示すような凹部（１２ｍｍ間隔で互いに平行する深さ８．１ｍｍ、最大開口幅１２ｍｍの波形）を有する化粧材Ｇを得た。化粧材Ｇについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
【００４０】
実施例８
実施例６において水酸化アルミニウム粉体に代えて水酸化マグネシウム粉体（平均粒子径１０μｍである。以下同じ）を用い、粉体状フェノ−ル樹脂に代えて繊維状ポリエチレン樹脂（市販のポリエチレン系合成パルプである。以下同じ）を配合した以外は実施例６と同様にして得た熱プレス後の２層が強固に固着した不燃基材の片面を切削機にて切削処理し、図８に示すような凹部（１０ｍｍ間隔で互いに平行する深さ５．５ｍｍ、最大開口幅１０ｍｍのノコ切り刃形状）を有する化粧材Ｈを得た。化粧材Ｈについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
【００４１】
実施例９
実施例１において炭酸カルシウム粉体を添加しない以外は実施例１と同様にして得た熱プレス後の不燃基材の片面を切削機にて切削処理し、図９に示すような凹部（６ｍｍ間隔で互いに平行する深さ３．１ｍｍ、最大開口幅６ｍｍの波形）を有する化粧材Ｉを得た。化粧材Ｉについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
【００４２】
実施例１０
実施例１においてガラス繊維に代えてロックウ−ル繊維（繊維長７ｍｍである。以下同じ）を用いた以外は実施例１と同様にして得た熱プレス後の不燃基材の片面を切削機にて切削処理し、図１０に示すような凹部（６ｍｍ間隔で互いに平行する深さ２．８ｍｍ、最大開口幅６ｍｍの波形）を有する化粧材Ｊを得た。化粧材Ｊについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
【００４３】
実施例１１
実施例６においてガラス繊維に代えてロックウ−ル繊維を用いた以外は実施例６と同様にして得た熱プレス後の２層が強固に固着した不燃基材の片面を切削機にて切削処理し、図１１に示すような凹部（１０ｍｍ間隔で互いに平行する深さ５．４ｍｍ、最大開口幅１０ｍｍのノコ切り刃形状）を有する化粧材Ｋを得た。化粧材Ｋについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
【００４４】
上記実施例１〜４及び６〜１１において切削処理は割れ、かけ等の発生なく行うことができた。また上記実施例１〜１１で得た大きさが９１０ｍｍ×１８２０ｍｍの化粧材Ａ〜Ｋはいずれも２人で支障なく持ち運ぶことができ現場施工に際しても問題はなかった。
【００４５】
比較例１
実施例１においてガラス繊維を配合しない以外は実施例１と同様にして得た熱プレス後の不燃基材の片面を切削機にて切削処理し、図１２に示すような凹部（６ｍｍ間隔で互いに平行する深さ３．１ｍｍ、最大開口幅６ｍｍの波形）を有する化粧材Ｌを得た。化粧材Ｌについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
【００４６】
比較例２
実施例１で得た熱プレス後の不燃基材の片面を切削機にて切削処理し、図１３に示すような凹部（６ｍｍ間隔で互いに平行する深さ３．２ｍｍ、最大開口幅６ｍｍの波形）を有する化粧材Ｍを得た。化粧材Ｍについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
化粧材Ｍを持ち上げると凹部底部の厚さの薄い部分が破断しやすく実際上２人で持ち運ぶことは困難であった。
【００４７】
比較例３
実施例６で得た熱プレス後の２層が強固に固着した不燃基材の片面を切削機にて切削処理し、図１４に示すような凹部（８ｍｍ間隔で互いに平行する深さ４ｍｍ、最大開口幅８ｍｍの波形）を有する化粧材Ｎを得た。化粧材Ｎについて、不燃性及び曲面施工性を測定し、その結果を、切削処理前の不燃基材中の各成分の含有率とともに表１に示した。
【００４８】
比較例４
実施例６で得た熱プレス前の不燃基材を熱プレスにて加熱処理（温度１７５°Ｃ、圧力２０kg／ｃｍ² 、時間１０分）し、さらにサンダ−掛け処理し大きさが９１０ｍｍ×１８２０ｍｍで厚さ２．４ｍｍの基材を得た。該基材について、不燃性及び曲面施工性を測定し、その結果を、サンダ−掛け前の不燃基材中の各成分の含有率とともに表１に示した。
【００４９】
比較例５
市販の大きさ９１０ｍｍ×１８２０ｍｍで厚さ１０ｍｍのケイ酸カルシウム板を用いて３０ｃｍ×３０ｃｍの大きさに切り出し、該３０ｃｍ×３０ｃｍの大きさのケイ酸カルシウム板の片面を切削機にて切削処理し、図１５に示すような凹部（８ｍｍ間隔で互いに平行する深さ３．９ｍｍ、最大開口幅８ｍｍの波形）を有する化粧材Ｏを得た。化粧材Ｏについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。
化粧材Ｏは凹部底部の厚さの薄い部分がわずかの衝撃でも割れやすく実際上扱えるものではなかった。なお、大きさ９１０ｍｍ×１８２０ｍｍのままで化粧材Ｏと同様の凹部を形成すべく切削機で切削処理したところ、割れを生じ、かかる大きさでは実際上切削処理を行うことができなかった。
【００５０】
比較例６
凹部形状を代えた以外は比較例５と同様にして図１６に示すような凹部（１０ｍｍ間隔で互いに平行する深さ５．６ｍｍ、最大開口幅１０ｍｍのノコ切り刃形状）を有する化粧材Ｐを得た。化粧材Ｐについて、不燃性及び曲面施工性を測定し、その結果を表１に示した。化粧材Ｐは凹部底部の厚さの薄い部分がわずかの衝撃でも割れやすく実際上扱えるものではなかった。なお、大きさ９１０ｍｍ×１８２０ｍｍのままで化粧材Ｐと同様の凹部を形成すべく切削機で切削処理したところ、割れを生じ、かかる大きさでは実際上切削処理を行うことができなかった。
【００５１】
【発明の効果】
本発明の不燃化粧材は含水無機化合物あるいは含水無機化合物と炭酸塩／セルロ−ス繊維／無機繊維／合成高分子という構成で各成分を特定量含有するシ−ト状の不燃基材の片面に所定形状の凹部を形成せしめたので、高度の不燃性を有し、かつ曲面下地に対する良好な施工性を有し、さらに意匠性にも優れた不燃化粧材が得られる。
【００５２】
本発明に係る不燃化粧材は切削加工性が良好で耐割裂性の点でケイ酸カルシウム板に比して優位性を有するとともに、従来必要不可欠であった不燃裏打材を用いることなしに切削加工適性及び曲面下地への良好な施工性を有し、また、ＪＩＳＡ−１３２１の表面試験に合格できる高度の不燃性を確保でき、かつ、所定の大きさの不燃化粧材を支障なく持ち運びあるいは現場施工できるという利点を有する。
【００５３】
加えて、不燃基材中に熱硬化性樹脂、熱可塑性樹脂などの合成高分子を所定量含有せしめることとしたので、必ずしも切削によらずとも熱圧成形などによっても各種形状の凹部を形成せしめることができ、かつ必要に応じて２層以上の不燃基材を互いに強固に熱圧着せしめることも可能である。
さらに、各種形状の凹部を有する本発明の不燃化粧材を内壁の化粧材等に用いることにより、吸音特性等の音響性能の面にも効果的な作用を期待できる。
【図面の簡単な説明】
【図１】本発明により得られた波形の凹部を有する化粧材の断面図である。
【図２】本発明により得られた波形の凹部を有する化粧材の断面図である。
【図３】本発明により得られたノコ切り刃形状の凹部を有する化粧材の断面図である。
【図４】本発明により得られたＶ溝形状の凹部を有する化粧材の断面図であり、突板を接着した場合を示す。
【図５】本発明により得られたノコ切り刃形状の凹部を有する化粧材の断面図である。
【図６】本発明により得られたノコ切り刃形状の凹部を有する化粧材の断面図である。
【図７】本発明により得られた波形の凹部を有する化粧材の断面図である。
【図８】本発明により得られたノコ切り刃形状の凹部を有する化粧材の断面図である。
【図９】本発明により得られたノコ切り刃形状の凹部を有する化粧材の断面図である。
【図１０】本発明により得られた波形の凹部を有する化粧材の断面図である。
【図１１】本発明により得られたノコ切り刃形状の凹部を有する化粧材の断面図である。
【図１２】波形の凹部を有する化粧材の断面図である。
【図１３】波形の凹部を有する化粧材の断面図であり、凹部底部での厚さを本発明で特定する範囲外とした場合を示す。
【図１４】波形の凹部を有する化粧材の断面図であり、凹部底部での厚さを本発明で特定する範囲外とした場合を示す。
【図１５】波形の凹部を有する化粧材の断面図である。
【図１６】波形の凹部を有する化粧材の断面図である。
【符号の説明】
１化粧材
２凹部
３突板
４接着剤
【表１】

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a non-combustible decorative material, and more particularly to a non-combustible decorative material having a high degree of non-combustibility, good workability for a curved base, and excellent design properties.
[0002]
[Prior art]
Conventionally, a non-combustible base material such as a calcium silicate plate is bonded onto a flexible and flexible non-combustible backing material as a non-combustible decorative material that can be applied to a curved base during field construction, and a groove is formed on the surface of the non-combustible base material. Known are those formed at predetermined intervals and provided such that the bottom of the groove reaches the above-mentioned noncombustible backing material. Such a noncombustible decorative material also has an advantage that it has excellent design properties because it has grooves on the surface.
[0003]
[Problems to be solved by the invention]
However, the method of adhering a non-combustible base material on the above-described non-combustible backing material, forming grooves on the surface of the non-combustible base material at predetermined intervals, and applying the groove bottom to the non-combustible backing material is as follows: An adhesion process between the backing material and the non-combustible substrate is necessary, and the processing process is complicated. (2) Since an organic adhesive is often used to bond the incombustible backing material and the incombustible substrate, the incombustibility tends to be deteriorated. (3) Glass cloth, various inorganic fiber nonwoven fabrics, aramid fiber sheets, etc. are used as flexible and flexible incombustible backing materials, but such incombustible backing materials are generally very expensive. Have
[0004]
Therefore, it is extremely preferable that a non-combustible decorative material having good workability with respect to a curved base and having excellent design properties and high non-combustibility can be formed without using the above-described non-combustible backing material. However, it has been difficult to obtain a non-combustible cosmetic material that satisfies the requirements without using the non-combustible backing material by using a conventional calcium silicate plate. In other words, since the calcium silicate plates are poor in flexibility, even if recesses such as grooves are formed by cutting, cracks are likely to occur in portions where the plate thickness has been reduced by cutting when applied to a curved substrate. In addition, the low flexibility of the calcium silicate plate is a cause of cracking due to thermal stress in surface testing, and the surface test is more effective when the thickness is reduced by cutting. It is easy to generate cracks in the case, and the predetermined nonflammability cannot be ensured. In addition, calcium silicate plates are not very flexible, and they are prone to cracking during cutting, and good cutting suitability cannot be ensured without a backing material. The thinned part is very easy to break, and there is a great risk of causing troubles during transportation and construction at the site. In this way, calcium silicate plates are poor in flexibility of the substrate itself, so even if grooves such as grooves are formed by cutting, it can be applied to a curved substrate without the aid of a flexible noncombustible backing material. It has been practically difficult to provide suitability and high nonflammability.
[0005]
Therefore, the present inventor has conducted a number of experiments to solve such problems, and as a result, a configuration of a large amount of water-containing inorganic compound or a large amount of water-containing inorganic compound and carbonate / cellulose fiber / inorganic fiber / synthetic polymer. By using a non-combustible base material containing a specific amount of each component to form a predetermined recess, the workability of the curved substrate is good without using a non-combustible backing material, and it has excellent design and high non-combustibility. The present invention was completed by finding out that a non-combustible cosmetic material having the above can be obtained.
[0006]
[Means for Solving the Problems]
The incombustible decorative material according to the present invention comprises 60 to 95% by weight of water-containing inorganic compound, 2 to 30% by weight of cellulose fiber, and 0.5 to 20% by weight of inorganic fiber in solid content. And a sheet-shaped non-combustible base material containing 1 to 20% by weight of a synthetic polymer as a solid content and having a plurality of recesses having a depth of 0.5 mm or more and a maximum opening width of 1 to 30 mm. The thickness of the incombustible substrate at the bottom of the recess is 0.5 to 2 mm, the thickness of the incombustible substrate at the top of the recess is 2 to 10 mm, and the recess The maximum projected area of the concave portion occupying the projected area of the surface of the non-combustible substrate on the side having slag is 50% or more.
[0007]
In addition, the incombustible decorative material according to the present invention is a total of 60 to 95% by weight of water-containing inorganic compound and carbonate, 2 to 30% by weight of cellulose fiber in solids, and 0% of inorganic fiber in solids. 0.5 to 20% by weight and 1 to 20% by weight of the synthetic polymer in a solid content, and the water-containing inorganic compound / carbonate is on the excess side of the water-containing inorganic compound in a solid content weight ratio of 50/50. -On one side of the G-shaped non-combustible substrate, there are a plurality of recesses having a depth of 0.5 mm or more and a maximum opening width of 1 to 30 mm, and the thickness of the non-combustible substrate at the bottom of the recess is 0 0.5 mm to 2 mm, and the thickness of the incombustible substrate at the top of the recess is 2 to 10 mm, and the maximum projection of the recess occupies the projected area of the surface of the incombustible substrate on the side having the recess The area is 50% or more.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Examples of the above-mentioned water-containing inorganic compound include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, dihydrate gypsum and calcium aluminate. These compounds all have crystal water in the molecule and have a chemically similar structure. In addition, the hydrous inorganic compounds have some differences in decomposition temperature and endothermic amount depending on the type, but they are completely the same in that they decompose upon high temperature heating and exhibit an incombustible effect by endothermic action. Therefore, basically any of the water-containing inorganic compounds described above may be used, but aluminum hydroxide is most suitable in consideration of economics such as an acquisition price.
[0009]
As the carbonate used in the present invention, at least one selected from calcium carbonate, magnesium carbonate, barium carbonate, strontium carbonate, beryllium carbonate, zinc carbonate and the like is used. These carbonates have some differences in decomposition temperature depending on their types, but they are quite common in that they decompose upon high temperature heating and exhibit a flame retardant effect due to endothermic action. Therefore, basically any of the carbonates described above may be used, but calcium carbonate is optimal from the viewpoint of cost. In addition, the smoke generation amount reducing effect pointed out by the present inventor in Japanese Patent Application Laid-Open No. 5-112659 can be given as another important effect obtained by the carbonate compounding.
[0010]
The total content range of the water-containing inorganic compound or the water-containing inorganic compound and the carbonate in the incombustible substrate according to the present invention is 60 to 95% by weight, preferably 70 to 95% by weight in terms of solid content. If the content is less than 60% by weight, sufficient incombustibility cannot be obtained. On the other hand, when it exceeds 95% by weight, sufficient mechanical strength cannot be obtained due to the excessive amount of the water-containing inorganic compound or the water-containing inorganic compound and the carbonate, and the thickness of the non-combustible base material becomes particularly thin at the bottom of the recess. Insufficient strength in the areas where it is not suitable. Moreover, the content weight ratio of the water-containing inorganic compound / carbonate must be on the side containing more water-containing inorganic compound than 50/50 in terms of solid content. If the water-containing inorganic compound is less than 50/50, the nonflammability may be lowered, which is inappropriate.
[0011]
As the above-mentioned cellulose fiber, one or two or more kinds selected from wood pulp such as softwood or hardwood chemical pulp, mechanical pulp, semi-chemical pulp, cotton pulp, hemp pulp and various waste papers are used in combination. And use it. Wood pulp is the most easy-to-use cellulose fiber material because its supply and quality are stable and its price is relatively low. Cotton pulp and hemp pulp are unstable in supply and expensive in price. However, in the non-combustible base material containing a large amount of water-containing inorganic compound or water-containing inorganic compound and carbonate as in the present invention, By using the cotton pulp or hemp pulp, the mechanical strength of the non-combustible base material is reduced, particularly at the bottom of the concave portion where the thickness of the non-combustible base material is reduced. You can stay.
[0012]
The content range of the cellulose fiber in the incombustible substrate according to the present invention is 2 to 20% by weight in solid content. If the content is less than 2% by weight, sufficient paper-making property or mechanical strength (particularly the mechanical strength at the portion where the thickness of the non-combustible base material is reduced at the bottom of the recess) due to insufficient cellulose fiber in the base material. ) Is not obtained. In addition, the non-combustible base material is poor in flexibility, and the workability with respect to the curved base becomes insufficient. On the other hand, if it exceeds 20% by weight, sufficient nonflammability cannot be obtained due to an excess of organic substances.
[0013]
As the above-mentioned inorganic fiber, at least one kind is selected and used from glass fiber, rock wool fiber, ceramic fiber, carbon fiber and the like.
The content range of the inorganic fiber in the incombustible substrate according to the present invention is 0.5 to 20% by weight. If the content is less than 0.5% by weight, the non-combustible decorative material obtained from the non-combustible base material tends to crack in the surface test. In particular, cracks are likely to occur at the portion where the thickness of the bottom of the recess is reduced. On the other hand, if it exceeds 20% by weight, sufficient papermaking properties cannot be obtained.
[0014]
Examples of the synthetic polymer include thermosetting resins (including fibrous ones) such as phenol resins, melamine resins, epoxy resins, urea resins, unsaturated polyester resins, polyolefin resins, polyester resins, acrylic resins, At least one selected from thermoplastic resins (including fibrous ones) such as methacrylic resin, styrene resin, vinyl chloride resin, and vinyl acetate resin, or synthetic rubber such as SBR, NBR, and MBR is used. These synthetic polymers have some differences in curing temperature, melt softening temperature, etc., depending on their types. This is quite common in that it provides the effect of strength or the effect of preventing the removal of water-containing inorganic compounds. Therefore, basically, any of the above synthetic polymers may be used, but phenol resin, polyolefin resin and the like are optimal in view of economics such as availability.
[0015]
The content range of the synthetic polymer in the incombustible substrate according to the present invention is 1 to 20% by weight in solid content. If the content is less than 1% by weight, sufficient mechanical strength (particularly, mechanical strength at the portion where the thickness of the non-combustible substrate at the bottom of the recess is reduced) cannot be obtained. Moreover, when it exceeds 20 weight%, sufficient nonflammability cannot be obtained by the excess of an organic substance.
[0016]
The non-combustible base material according to the present invention may be composed of a water-containing inorganic compound or a water-containing inorganic compound and carbonate / cellulose fiber / inorganic fiber / synthetic polymer based on the above formulation. Any method such as a dry forming method can be applied, and the method is not limited to a specific manufacturing method, but the following is an example of a manufacturing method in which the wet papermaking method, which is the field of the present invention, is applied. Further details with reference to.
[0017]
The incombustible decorative material according to the present invention is a water-containing inorganic compound or various yield improvers for improving the yield of the water-containing inorganic compound and carbonate based on the above formulation, or a synthetic fiber if necessary, or for coloring. It may contain synthetic dyes and the like. In addition, it goes without saying that a dry or wet paper strength enhancer, a sizing agent, a water-resistant agent, a water-repellent agent and the like should be included in order to improve mechanical strength or suitability for post-processing depending on applications.
[0018]
As a method for incorporating a synthetic polymer into the non-combustible substrate according to the present invention, a liquid, fibrous or granular material of the synthetic polymer is internally added to the raw material slurry, or is applied or impregnated after the paper layer is formed. You can do it.
As a method of adding a water-containing inorganic compound or carbonate, a method of applying or impregnating a base material with a paint containing a water-containing inorganic compound or carbonate is also conceivable, but a predetermined content is ensured or thickness direction is considered. In order to achieve uniform quality, the most preferable method is to internally add a hydrous inorganic compound or carbonate in the form of powder or slurry into the raw material slurry.
In this case, the addition method and order of addition of the hydrous inorganic compound, carbonate, cellulose fiber, inorganic fiber, and synthetic polymer are arbitrary, and beating treatment may be performed as necessary.
[0019]
In order to produce the incombustible substrate according to the present invention using the raw material slurry thus obtained, a normal papermaking method may be used. That is, the slurry may be supplied on a papermaking net such as an ordinary long net, circular net or inclined net, filtered and dehydrated, and then compressed and dried. Further, if necessary, two or more paper layers may be overlapped by various combination nets, multi-tank circular nets, various laminators and the like.
[0020]
In order to produce the non-combustible decorative material of the present invention using the non-combustible base material thus obtained, the conventional non-combustible base material is subjected to conventional conventional thermoforming such as hot press molding, high-frequency heat molding, preheating-cold press alone. Alternatively, two or more types can be used in combination to cure, soften, dissolve, and re-solidify the thermosetting resin or thermoplastic resin in the incombustible substrate, and then form a predetermined recess by cutting or the like. What is necessary is just to perform hardening or softening melt | dissolution of the thermosetting resin or thermoplastic resin in a nonflammable base material, re-solidification, and formation of a predetermined recessed part simultaneously by carrying out hot-pressure molding using a predetermined metal mold | die etc. .
Further, if necessary, decorative paper, a veneer, a laser, a synthetic resin film may be bonded, various paints may be sprayed, applied, or printed after thermoforming, before cutting, or after cutting. In some cases, it is possible to simultaneously bond or bond a non-combustible substrate and decorative paper, a veneer, a laser, etc., and form a predetermined recess by integral hot pressing with a mold or the like.
[0021]
The concave portion of the nonflammable decorative material according to the present invention must have a depth of 0.5 mm or more and a maximum opening width of 1 to 30 mm. When the depth is less than 0.5 mm or the maximum opening width is less than 1 mm, the effect of improving the design property due to the concave shape on the surface is poor. When the maximum opening width exceeds 30 mm, the area of the portion where the thickness of the incombustible substrate becomes thin at the bottom of the recess tends to be large, which is unsuitable because cracks tend to occur in the surface test.
[0022]
The thickness of the noncombustible base material at the bottom of the concave portion of the nonflammable decorative material according to the present invention must be 0.5 to 2 mm. If the thickness is less than 0.5 mm, the mechanical strength of the part is weakened, and it is easy to cause problems such as cracking during cutting, transportation, or on-site construction. In addition, the part is cracked in the surface test. It becomes easy and unsuitable. Moreover, when this thickness exceeds 2 mm, the softness | flexibility of a nonflammable molded object will become scarce and the construction property with respect to a curved base will become inadequate.
[0023]
As for the recessed part which the incombustible decorative material which concerns on this invention has, the thickness of the incombustible base material in the top part of this recessed part must be 2-10 mm. If it is less than 2 mm, cracks are likely to occur in the surface test, which is inappropriate. Also, if it exceeds 10 mm, the difference in thickness between the vicinity of the top of the concave portion or the portion where the concave portion is not formed and the vicinity of the bottom of the concave portion becomes too large, and the portion near the top of the concave portion and the portion where the concave portion is not formed during transportation or construction on site The stress due to the weight of the incombustible base material constituting the material acts on the thinned portion of the incombustible base material in the vicinity of the bottom of the recess, so that a problem such as cracking or breaking of the part is likely to occur.
[0024]
As for the recessed part which the nonflammable decorative material which concerns on this invention has, the largest projected area of this recessed part which occupies for the said surface in the surface which has this recessed part must be 50% or more. If it is less than 50%, the proportion of the area where the thickness of the non-combustible base material near the bottom of the concave portion occupies the total area of the non-combustible decorative material becomes too small, the flexibility of the non-combustible cosmetic material becomes poor, and the workability for curved bases Is insufficient.
[0025]
The recesses of the non-combustible decorative material according to the present invention are made parallel to each other, which is easy to do when forming the recesses by cutting, and improves the workability on a curved base such as a columnar or partial columnar shape. It is preferable for the purpose. However, in order to improve the workability for various curved bases such as conical shape, spherical shape, or egg shape, it is possible to arrange various concave portions according to the curved shape of each curved base, rather than making the concave portions parallel to each other. . Actually, according to the formation of the concave portion by the NC cutting machine or the hot press molding using the mold, it is possible to form the concave portion having a considerably complicated shape and complicated arrangement.
[0026]
The incombustible decorative material according to the present invention can ensure sufficient incombustible performance by the water-containing inorganic compound and inorganic fiber or the water-containing inorganic compound, carbonate and inorganic fiber contained in the incombustible base material. However, this does not prevent the use of flame retardants. Examples of flame retardants that can be used include organic phosphorus compounds, phosphorus-containing nitrogen-containing organic compounds, sulfamate, inorganic phosphate, halogen-containing compounds, and antimony compounds. Moreover, the flame retardant which has a carbonization promotion effect | action from a viewpoint of exhibiting a more effective flame-retarding effect | action with respect to the cellulose fiber and synthetic polymer which are the essential organic substances in the nonflammable base material which concerns on this invention Is more effective.
[0027]
In order to contain the flame retardant, a liquid or granular material of the flame retardant may be internally added to the raw material slurry, or may be applied or impregnated during the paper making process, after paper making, or after molding. Also, the amount of flame retardant used should be very small (at most 10% in solids). This is because if the flame retardant content exceeds 10% by weight, it may be accompanied by fuming or harmful gas generation accompanying decomposition of the flame retardant during high temperature heating, which may be counterproductive.
[0028]
[Action]
The important point of the present invention is that the sheet-like non-combustible substrate contains a large amount of a water-containing inorganic compound or a water-containing inorganic compound and a carbonate, and contains a predetermined amount of cellulose fiber, inorganic fiber and synthetic polymer. A decorative material having a specific concave portion on one side is capable of obtaining a high degree of incombustibility and good workability for a curved base without using a non-combustible backing material that has been indispensable in the past.
Hereinafter, description will be made based on experimental results in Examples described later.
[0029]
First, nonflammability will be described. A surface test was conducted on a sheet-like non-combustible substrate having a thickness of 2.4 mm containing a large amount of a water-containing inorganic compound and carbonate, and containing predetermined amounts of cellulose fiber, inorganic fiber and synthetic polymer. However, cracks occurred and the predetermined nonflammability was not reached (Comparative Example 4). Next, a recess as shown in FIG. 6 (a saw blade with a depth of 5.5 mm parallel to each other at 10 mm intervals and a maximum opening width of 10 mm is formed on the incombustible base material having the same composition as the above-described sheet-like incombustible base material. When the surface test was performed on the decorative material according to the present invention in which a shape) was formed, cracks were not generated and a predetermined incombustible performance was obtained even though the thickness at the bottom of the recess was only 1.5 mm ( Example 6).
On the other hand, using a commercially available calcium silicate plate, a recess as shown in FIG. 16 (a saw blade with a depth of 5.6 mm parallel to each other at 10 mm intervals, a maximum opening width of 10 mm, and a thickness of the bottom of the recess of 1.8 mm) When the shape was formed, a remarkable crack was generated in the surface test, and the predetermined nonflammability was not obtained (Comparative Example 6). That is, when the recessed part based on this invention is formed in the kind of conventional calcium silicate board, a predetermined | prescribed incombustible performance cannot be obtained without an incombustible backing material.
[0030]
Now, the reason why the decorative material of the present invention can obtain a high degree of incombustibility even without an incombustible backing material is estimated as follows.
When the decorative material of the present invention is heated at a high temperature, the water-containing inorganic compound or the water-containing inorganic compound and carbonate in the incombustible base material constituting the vicinity of the top of the recess or the portion where the recess is not formed are more effectively thermally decomposed and the bottom of the recess As the overall non-flammability is derived by compensating the deterioration of the non-flammability performance at the thin part of the material, and the decorative material of the present invention is rich in flexibility due to the concave portion having a specific composition and specific shape, the heat during high-temperature heating As a result of stress being dispersed without concentrating in the vicinity of the heated part, the generation of thermal stress is alleviated as a result, even if the thickness of the bottom part of the recess is extremely thin, 0.5 to 2 mm, the part concerned is cracked. Therefore, it is considered that excellent incombustible performance can be obtained without using an incombustible backing material.
[0031]
Next, workability with respect to the curved base will be described.
The main component of the incombustible decorative material of the present invention is a water-containing inorganic compound or a water-containing inorganic compound and a carbonate, and since it contains a relatively small amount of cellulose fiber, inorganic fiber, and synthetic polymer, particularly Wood material base is added by cellulose fiber and synthetic polymer, and concave shape (thickness at the top, thickness at the bottom, depth, maximum opening width and maximum projected area) is specified by the present invention. By adopting a predetermined shape, the bottom of the recess is made as thin as 0.5 to 2 mm, while maintaining the necessary minimum strength and exhibiting good flexibility, so that non-combustible backing material is not used. It is considered that excellent surface workability that can be practically used as a non-combustible decorative material for curved base materials is obtained.
[0032]
【Example】
Next, the present invention will be described more specifically based on the following examples.
Measurement of each item in this example was performed by the following method.
(1) Nonflammability: According to the surface test of JIS A-1321
(2) Curved surface workability: 40, 50, 60, 70, 80, 100, 120, 150, 200, 300, 400, 600, 800, and 1000 mm, using a molded plywood having a curvature radius, A test specimen (30 cm × 30 cm) was applied to the simulated base, and the evaluation was performed with the smallest radius of curvature that did not cause any inconvenience in construction such as fracture or crack.
[0033]
Example 1
Commercially available softwood based bleached sulfate pulp and glass fiber (fiber diameter 3 μm, the same applies hereinafter) are disaggregated with a pulper, and aluminum hydroxide powder (average particle diameter is 5.7 μm, the same applies hereinafter). , Calcium carbonate powder (average particle size of 1.5 μm, the same applies hereinafter) and powdered phenol resin (average particle size of 30 μm, the same applies hereinafter), and after sufficiently dispersing and mixing, long mesh / wind 30 layers of paper layers are laminated on a roll-up paperboard machine with up-roll construction, and paper is pressed, dried, and heat-treated with a hot press (temperature 175 ° C., pressure 20 kg / cm). ² , 10 minutes), and a non-combustible base material having a size of 910 mm × 1820 mm was obtained. The content (% by weight) of each component in this incombustible substrate is as follows: water-containing inorganic compound 88.3, carbonate 1.9, cellulose fiber 4.1, inorganic fiber 2.0, and synthetic polymer 3.7. is there.
Next, one side of the non-combustible base material is cut with a cutting machine, and a decorative material A having recesses (waveforms having a depth of 2.7 mm parallel to each other at intervals of 6 mm and a maximum opening width of 6 mm) as shown in FIG. Obtained. The decorative material A was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0034]
Example 2
One side of the non-combustible base material after hot pressing obtained in Example 1 is cut with a cutting machine, and concave portions (a waveform having a depth of 3 mm parallel to each other at intervals of 6 mm and a maximum opening width of 6 mm) as shown in FIG. A decorative material B was obtained. The decorative material B was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0035]
Example 3
One side of the non-combustible substrate after hot pressing obtained in Example 1 was cut with a cutting machine, and a recess as shown in FIG. 3 (a saw having a depth of 2.7 mm parallel to each other at intervals of 6 mm and a maximum opening width of 6 mm). A decorative material C having a cutting edge shape was obtained. The decorative material C was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0036]
Example 4
A natural wood veneer with a thickness of 0.2 mm was bonded to one side of the non-combustible base material obtained in Example 1 using a urethane-based adhesive, and then the veneer surface was cut with a cutting machine. A decorative material D having recesses as shown in FIG. 4 (V-grooves having a depth of 3.5 mm and a maximum opening width of 7 mm parallel to each other at intervals of 10 mm) was obtained. The decorative material D was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0037]
Example 5
Molding with a mold using the incombustible base material before hot pressing obtained in Example 1 (mold temperature 175 ° C., pressure 40 kg / cm ² , Time 10 minutes) to obtain a decorative material E having concave portions (a saw blade shape having a depth of 2.7 mm parallel to each other at intervals of 6 mm and a maximum opening width of 6 mm) as shown in FIG. The decorative material E was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0038]
Example 6
In Example 1, the content (% by weight) of each component in the incombustible base material was determined as follows: hydrous inorganic compound 72.2, carbonate 6.1, cellulose fiber 8.4, inorganic fiber 5.1, synthetic polymer 8 Except for the change to 2, two non-combustible substrates before hot pressing obtained in the same manner as in Example 1 were laminated together using urea / melamine adhesive and heat-treated with a hot press (temperature 175 ° C., pressure 20kg / cm ² 10 minutes), and a non-combustible base material in which two layers having a size of 910 mm × 1820 mm were firmly fixed was obtained.
Next, one side of the non-combustible base material is cut with a cutting machine, and has a recess as shown in FIG. 6 (a saw blade shape having a depth of 5.5 mm parallel to each other at 10 mm intervals and a maximum opening width of 10 mm). Material F was obtained. The decorative material F was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0039]
Example 7
In Example 6, the content (% by weight) of each component in the incombustible base material was determined as follows: hydrous inorganic compound 51.7, carbonate 23.7, cellulose fiber 10.3, inorganic fiber 5.2, synthetic polymer 9 .1 was changed to 1 and the number of laminated layers at the time of hot pressing was changed to 3, and one side of the incombustible base material to which the three layers after hot pressing obtained in the same manner as in Example 6 were firmly fixed was cut with a cutting machine. Then, a decorative material G having recesses as shown in FIG. 7 (waveform with a depth of 8.1 mm parallel to each other at 12 mm intervals and a maximum opening width of 12 mm) was obtained. The decorative material G was measured for nonflammability and curved surface workability, and the results are shown in Table 1.
[0040]
Example 8
In Example 6, instead of aluminum hydroxide powder, magnesium hydroxide powder (average particle size is 10 μm; the same applies hereinafter), fibrous polyethylene resin (commercially available polyethylene-based resin) was used instead of powdered phenol resin. Except for blending synthetic pulp (the same applies hereinafter), one side of the non-combustible base material to which the two layers after hot pressing obtained in the same manner as in Example 6 were firmly fixed was cut with a cutting machine. A decorative material H having recesses as shown (a saw blade shape having a depth of 5.5 mm parallel to each other at intervals of 10 mm and a maximum opening width of 10 mm) was obtained. About the decorative material H, the nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
[0041]
Example 9
In Example 1, one side of the non-combustible base material after hot pressing obtained in the same manner as in Example 1 except that calcium carbonate powder was not added was cut with a cutting machine, and a recess as shown in FIG. Thus, a decorative material I having a waveform of a depth of 3.1 mm parallel to each other and a maximum opening width of 6 mm was obtained. About the decorative material I, nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
[0042]
Example 10
A non-combustible base material after hot pressing obtained in the same manner as in Example 1 except that rock wool fibers (fiber length: 7 mm; the same applies hereinafter) was used instead of glass fibers in Example 1 as a cutting machine. Then, a decorative material J having concave portions as shown in FIG. 10 (waveform with a depth of 2.8 mm parallel to each other at intervals of 6 mm and a maximum opening width of 6 mm) was obtained. About the decorative material J, nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
[0043]
Example 11
In Example 6, one side of the non-combustible base material to which the two layers after hot pressing firmly obtained in the same manner as in Example 6 were used except that rock wool fibers were used instead of glass fibers was cut with a cutting machine. Then, a decorative material K having recesses as shown in FIG. 11 (a saw blade shape having a depth of 5.4 mm parallel to each other at 10 mm intervals and a maximum opening width of 10 mm) was obtained. About the decorative material K, nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
[0044]
In the said Examples 1-4 and 6-11, the cutting process could be performed without generation | occurrence | production of a crack, a crack, etc. Further, the cosmetic materials AK having a size of 910 mm × 1820 mm obtained in Examples 1 to 11 can be carried by two people without any problem, and there was no problem in the field construction.
[0045]
Comparative Example 1
In Example 1, one side of the incombustible base material after hot pressing obtained in the same manner as in Example 1 except that no glass fiber was blended was cut with a cutting machine, and recessed portions (as shown in FIG. A decorative material L having a parallel wave depth of 3.1 mm and a maximum opening width of 6 mm was obtained. About the decorative material L, nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
[0046]
Comparative Example 2
One side of the non-combustible substrate after hot pressing obtained in Example 1 was cut with a cutting machine, and a recess as shown in FIG. 13 (waveform with a depth of 3.2 mm parallel to each other at intervals of 6 mm and a maximum opening width of 6 mm). ) Was obtained. About the decorative material M, the nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
When the decorative material M is lifted, the thin part of the bottom of the recess is easily broken, and it was actually difficult for two people to carry it.
[0047]
Comparative Example 3
One side of the incombustible base material to which the two layers after hot pressing obtained in Example 6 were firmly fixed was cut with a cutting machine, and a recess as shown in FIG. 14 (depth of 4 mm parallel to each other at intervals of 8 mm, maximum) A decorative material N having a waveform with an opening width of 8 mm was obtained. About the decorative material N, nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before a cutting process.
[0048]
Comparative Example 4
The incombustible substrate before hot pressing obtained in Example 6 was heat-treated with a hot press (temperature 175 ° C., pressure 20 kg / cm). ² 10 minutes), and further subjected to sanding to obtain a substrate having a size of 910 mm × 1820 mm and a thickness of 2.4 mm. About this base material, nonflammability and curved surface workability were measured, and the result was shown in Table 1 with the content rate of each component in the nonflammable base material before sanding.
[0049]
Comparative Example 5
A commercially available size 910 mm × 1820 mm and a 10 mm thick calcium silicate plate is cut into a size of 30 cm × 30 cm, and one side of the 30 cm × 30 cm size calcium silicate plate is cut with a cutting machine. A decorative material O having recesses as shown in FIG. 15 (waveform having a depth of 3.9 mm parallel to each other at intervals of 8 mm and a maximum opening width of 8 mm) was obtained. About the decorative material O, the nonflammability and curved surface workability were measured, and the results are shown in Table 1.
In the case of the decorative material O, the thin portion at the bottom of the recess was easily broken even by a slight impact and was not practically handled. In addition, when it cut with the cutting machine in order to form the recessed part similar to the decorative material O with the magnitude | size of 910 mm x 1820 mm, a crack was produced and the cutting process could not actually be performed at such a size.
[0050]
Comparative Example 6
A decorative material P having recesses (a saw blade shape with a depth of 5.6 mm parallel to each other at 10 mm intervals and a maximum opening width of 10 mm) as shown in FIG. 16 is the same as in Comparative Example 5 except that the recess shape is changed. Obtained. The decorative material P was measured for nonflammability and curved surface workability, and the results are shown in Table 1. In the decorative material P, the thin portion at the bottom of the recess was easily broken even by a slight impact, and was not practically handled. In addition, when it cut with the cutting machine in order to form the recessed part similar to the decorative material P with the magnitude | size of 910 mm x 1820 mm, a crack was produced and the cutting process could not actually be performed at such a size.
[0051]
【The invention's effect】
The incombustible decorative material of the present invention is a water-containing inorganic compound or a water-containing inorganic compound and carbonate / cellulose fiber / inorganic fiber / synthetic polymer, on one side of a sheet-like incombustible base material containing a specific amount of each component. Since the concave portion having a predetermined shape is formed, a non-combustible decorative material having a high degree of incombustibility, good workability on a curved base, and excellent design properties can be obtained.
[0052]
The non-combustible decorative material according to the present invention has superiority to the calcium silicate plate in terms of good machinability and splitting resistance, and can be processed without using a non-combustible backing material that has been essential in the past. It has good suitability and good workability on curved bases, and it can secure a high degree of non-combustibility that can pass the surface test of JIS A-1321. It has the advantage that it can be constructed.
[0053]
In addition, since a predetermined amount of a synthetic polymer such as a thermosetting resin or a thermoplastic resin is included in the non-combustible base material, recesses of various shapes can be formed not only by cutting but also by hot pressing. In addition, if necessary, two or more layers of non-combustible substrates can be firmly thermocompression bonded together.
Furthermore, by using the incombustible decorative material of the present invention having concave portions of various shapes for the decorative material of the inner wall, an effective action can be expected in terms of acoustic performance such as sound absorption characteristics.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a decorative material having corrugated recesses obtained according to the present invention.
FIG. 2 is a cross-sectional view of a decorative material having corrugated recesses obtained according to the present invention.
FIG. 3 is a cross-sectional view of a decorative material having a saw blade-shaped concave portion obtained by the present invention.
FIG. 4 is a cross-sectional view of a decorative material having a V-groove-shaped recess obtained by the present invention, showing a case where a veneer is bonded.
FIG. 5 is a cross-sectional view of a decorative material having a saw blade-shaped concave portion obtained by the present invention.
FIG. 6 is a cross-sectional view of a decorative material having a saw blade-shaped concave portion obtained by the present invention.
FIG. 7 is a cross-sectional view of a decorative material having corrugated recesses obtained according to the present invention.
FIG. 8 is a cross-sectional view of a decorative material having a saw blade-shaped concave portion obtained by the present invention.
FIG. 9 is a cross-sectional view of a decorative material having a saw blade-shaped concave portion obtained by the present invention.
FIG. 10 is a cross-sectional view of a decorative material having corrugated recesses obtained according to the present invention.
FIG. 11 is a cross-sectional view of a decorative material having a saw blade-shaped concave portion obtained by the present invention.
FIG. 12 is a cross-sectional view of a decorative material having corrugated recesses.
FIG. 13 is a cross-sectional view of a decorative material having a corrugated recess, and shows the case where the thickness at the bottom of the recess is outside the range specified by the present invention.
FIG. 14 is a cross-sectional view of a decorative material having a corrugated recess, and shows the case where the thickness at the bottom of the recess is outside the range specified by the present invention.
FIG. 15 is a cross-sectional view of a decorative material having corrugated recesses.
FIG. 16 is a cross-sectional view of a decorative material having corrugated recesses.
[Explanation of symbols]
1 Cosmetic material
2 recess
3 Veneer
4 Adhesive
[Table 1]

Claims

60 to 95% by weight of water-containing inorganic compound, 2 to 30% by weight of cellulose fiber, 0.5 to 20% by weight of inorganic fiber in solid content, and synthetic polymer in solid content The sheet-shaped non-combustible base material containing 1 to 20% by weight has a plurality of recesses having a depth of 0.5 mm or more and a maximum opening width of 1 to 30 mm on one side. The thickness of the incombustible substrate is 0.5 to 2 mm, the thickness of the incombustible substrate at the top of the recess is 2 to 10 mm, and the surface of the incombustible substrate on the side having the recess The non-combustible decorative material, wherein the maximum projected area of the concave portion in the projected area is 50% or more.

A total of 60 to 95% by weight of water-containing inorganic compound and carbonate, 2 to 30% by weight of cellulose fiber and 0.5 to 20% by weight of solid content of inorganic fiber, On one side of a sheet-like incombustible base material containing 1 to 20% by weight of a molecule in solid content, and the water-containing inorganic compound / carbonate is in excess of the water-containing inorganic compound in a solid content weight ratio of 50/50 , Having a plurality of recesses having a depth of 0.5 mm or more and a maximum opening width of 1 to 30 mm, and the thickness of the incombustible base material at the bottom of the recesses is 0.5 to 2 mm, The thickness of the noncombustible base material at the top is 2 to 10 mm, and the maximum projected area of the concave portion in the projected area of the nonflammable base material surface on the side having the concave portion is 50% or more. Incombustible cosmetic material.

The incombustible cosmetic material according to claim 2, wherein the carbonate is calcium carbonate.

The incombustible cosmetic material according to claim 1, 2 or 3, wherein the hydrous inorganic compound comprises at least one selected from aluminum hydroxide, magnesium hydroxide, calcium hydroxide, dihydrate gypsum and calcium aluminate.

The incombustible cosmetic material according to claim 1, 2, 3, or 4, wherein the synthetic polymer comprises at least one selected from a thermosetting resin, a thermoplastic resin, and a synthetic rubber.

The non-combustible cosmetic material according to claim 1, 2, 3, 4, or 5, wherein the inorganic fiber comprises at least one selected from glass fiber, rock wool fiber, and ceramic fiber.