JP4354003B2 - Incombustible decorative board - Google Patents

Description

  The present invention relates to a non-combustible decorative board.

Conventionally, decorative panels imparted with fireproofing and nonflammability have been known, and the core layer containing an organic resin as a flammable organic component as a binder component has reduced the organic component content in order to ensure nonflammability performance. .
Japanese Patent Laid-Open No. 51-20980 Japanese Patent Laid-Open No. 08-207201

  Therefore, the delamination strength of the molded product is weak, and chipping at the cut edge during cutting, decorative layer peeling, cornering during construction, dents and cracks may occur.For example, when used around a kitchen or stove Interlayer puncture due to radiant heat may occur.

  The present invention has been studied in view of such a situation, and has the following characteristics in order to ensure non-flammable performance and high adhesion to the surface decorative layer and the strength of the molded product. And

That is, the present invention is a non-combustible decorative board in which a resin-impregnated underlay layer is interposed between a core layer and a decorative coated paper, and the resin-impregnated underlay layer has a basis weight of 10 to 100 g / m ² . The base material is impregnated so that the content of the organic component is 50 to 300% by the calculation method represented by Equation 1, and the core layer is formed of the organic component and the inorganic filler on the glass fiber nonwoven fabric base material. A non-combustible decorative board comprising a prepreg impregnated so that the content of the organic component is 3 to 20% by a calculation method represented by Formula 2.

  The present invention comprises a prepreg in which a core layer is impregnated with a slurry comprising an organic component and an inorganic filler in a glass fiber nonwoven fabric, and a resin-impregnated underlay layer is interposed between the decorative layer and the core layer, Nonflammability performance can be maintained, and adhesion with a higher surface decorative layer and strength of a molded product can be realized. In addition, there is no chipping during cutting, peeling of the decorative layer, cornering during construction, dents and cracks, and when used around a stove, there is no generation of interlayer puncture due to radiant heat. Hereinafter, the present invention will be described in detail.

The core layer comprised by this invention consists of a prepreg which made the inorganic fiber nonwoven fabric impregnate the organic component and the inorganic filler, and glass fiber, rock wool, carbon fiber etc. are mentioned as an inorganic fiber. Examples of the organic component include phenol-formaldehyde resins, amino-formaldehyde resins, urethane resins, and other flame retardant resins. Examples of inorganic fillers include aluminum hydroxide, magnesium hydroxide, calcium carbonate, and silica. It is done. The basis weight of the inorganic fiber nonwoven fabric is preferably in the range of 10 to ²⁰⁰ g / m2.

  Among inorganic fillers, those with an average particle size in the range of 0.5 to 200 μm can be impregnated into inorganic fiber nonwoven fabrics, and those containing crystal water such as aluminum hydroxide and magnesium hydroxide decompose at high temperatures. It is optimal in terms of nonflammability because it absorbs heat and binds water.

The slurry solids retention rate to the inorganic fiber nonwoven fabric (%) according to the calculating method shown by the number 3, preferably in the range 500 to 3000%.

The resin-impregnated underlay layer interposed between the decorative layer and the core layer is preferably 50 to 300% by the calculation method shown in Equation 1 on paper having a basis weight of 10 to 100 g / m ² , and in the prepreg, Equation 2 It is preferable to set it as 3 to 20% by the calculation method shown by these. Thus, by reducing the organic component of the core layer and increasing the amount of the organic component contained in the resin-impregnated underlay layer from that of the prepreg, it has nonflammability and improves the adhesion between the decorative layer and the core layer. Can be secured. That is, when the upper limit is exceeded, the organic component increases, the nonflammability performance decreases, and when the lower limit is not reached, the adhesion is inferior and delamination becomes easy. In addition, when the basis weight of the underlay base material is less than 10 g / m ^2, it is easy to cut during impregnation and workability is poor, and when it exceeds 100 g / m ² , nonflammability tends to be poor.

  Phenol resins are obtained by reacting phenols and aldehydes at a ratio of 1 to 3 moles of aldehydes with 1 mole of phenolic hydroxyl group under a basic catalyst or an acidic catalyst. Phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, bisphenol F and the like. Examples of aldehydes include formaldehyde, paraformaldehyde, glyoxal, trioxal and the like. In addition, those modified with a modifying agent that promotes plasticization such as paratoluene sulfonamide, tung oil, phosphoric esters, glycols, etc. can be applied as necessary, and basic catalysts include alkali metals such as sodium and potassium, And oxides and hydroxides of alkaline earth metals such as magnesium and calcium, amines such as triethylamine and triethanolamine, and ammonia. Examples of acidic catalysts include paratoluenesulfonic acid and hydrochloric acid.

  Amino-formaldehyde resins include initial condensates obtained by reacting amino compounds such as melamine, urea, benzoguanamine, and acetoguanamine with formaldehyde, etherification with lower alcohols such as methyl alcohol and butyl alcohol, and paratoluene. Those modified with a reactive modifier that promotes plasticization such as sulfonamide can be applied, and among them, a melamine-formaldehyde resin excellent in durability is preferable.

  Examples of the urethane resin include prepolymers, adducts, block isocyanates, and the like made from compounds having an isocyanate group such as tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate.

  A decorative layer is formed on at least one side of the core layer, and as a forming method, a method in which the core layer and the resin-impregnated underlay layer are laminated and integrated, and then a coating method is applied, Examples include a method of integrally forming the core layer, a method of integrally forming the decorative coated paper, the resin-impregnated underlay layer, and the core layer, and a method of transferring the decorative layer using a transfer foil.

  As a means for painting, a resin liquid containing an unsaturated polyester resin colored with a pigment, a curing agent, for example, methyl ethyl ketone peroxide, and a curing accelerator, for example, cobalt naphthenate, on the core molded product. After coating, the coated surface is covered with a vinylon film, spread with a roller, and after the resin is cured, the vinylon film is peeled off.

  The unsaturated polyester resin contains an acid component containing an unsaturated dibasic acid and / or an acid anhydride thereof and other saturated acid and / or acid anhydride used as necessary, and a polyhydric alcohol. A dehydration-condensation reaction is carried out according to a conventional method at about 160 to 230 ° C., preferably 210 to 230 ° C. in an inert gas atmosphere such as argon, and a polymerizable monomer such as a styrene monomer is added.

As a method using resin-impregnated decorative paper, a resin-impregnated underlay layer having a high organic component content is interposed between a prepreg containing an organic component and an inorganic filler in an inorganic fiber nonwoven fabric and resin-impregnated decorative paper. Laminated and hot-press molded. As the resin-impregnated decorative paper, a resin liquid composed of a thermosetting resin such as amino-formaldehyde resin, diallyl phthalate resin, unsaturated polyester resin, and the like is used for a decorative plate. impregnation rate indicated by the number 4 in m ² of the decorative sheet can be applied those impregnated 80-300%. Hot pressing may be performed with a press such as a flat plate press or a continuous press.

As a method using coated paper, a resin-impregnated underlay having a high organic component content is provided between a prepreg containing an organic component and an inorganic filler in an inorganic fiber nonwoven fabric and a decorative coated paper having a coated resin layer formed on the surface. The layers are laminated with the layers interposed therebetween and hot-press molded. The resin-impregnated underlay layer is a thin paper substrate having a basis weight of 10 to 60 g / m ² , an amino-formaldehyde resin, a butyral resin, a phenol resin, an unsaturated polyester resin, a diallyl phthalate resin, a urethane resin, an epoxy resin, and an acrylic resin. In addition, a resin having adhesiveness such as vinyl acetate resin, EVA resin, or a mixture thereof impregnated with a content of 50 to 300% represented by Equation 1 can be applied. When the resin-impregnated decorative paper is provided only on one side of the core layer, a balance layer may be provided on the other side so as not to impair nonflammability in order to suppress warpage.

  EXAMPLES Hereinafter, although an Example is given and demonstrated in detail, this invention is shown more concretely and is not specifically limited.

Example 1
Core layer A slurry in which 95 parts of aluminum hydroxide is blended with 5 parts of phenol-formaldehyde resin in a glass fiber nonwoven fabric having a basis weight of 50 g / m ² has a slurry solid content fixing ratio of 1600% shown in Equation 3. Thus, prepreg (A ₂ ) was obtained by impregnation.

Resin-impregnated underlay layer A thin paper having a basis weight of 13 g / m ² is impregnated so that the melamine resin content is 250% by the calculation method of Equation 1, and a dried resin-impregnated underlay paper (B ₂ ) is obtained. It was.

Cosmetic layer A decorative coated paper having a basis weight of 23 g / m ² , containing titanium oxide, printed with a wood grain pattern, and provided with a 5 μm acrylic urethane hard coat layer on the printed surface was used.

Balance Layer A melamine-formaldehyde resin-impregnated balance paper (A ₄ ) was obtained by impregnating kraft paper having a basis weight of 40 g / m ^{2 with} a melamine-formaldehyde resin content of 120%.

Non-combustible decorative board In order from the bottom, 1 sheet of melamine resin-impregnated balance paper (A ₄ ), ₄ sheets of prepreg (A ₂ ), 1 sheet of resin-impregnated underlay paper (A ₁ ), 1 sheet of decorative coated paper Then, the non-combustible decorative board of the present invention was obtained by hot-pressure molding using a flat finish plate at 130 ° C. and 100 kg / cm ² for 90 minutes.

Comparative Example 1
In Example 1, it carried out similarly except not using resin impregnation underlay paper, and the laminated board of the comparative example 1 was obtained.

Comparative Example 2
The same procedure as in Example 1 was carried out except that the content of melamine resin in the resin-impregnated underlay paper was 42%, whereby a laminate of Comparative Example 2 was obtained.

The evaluation results are shown in Table 1.

The test method was as follows.
Nonflammability: JIS A 1321 “Evaluated based on building interior materials and construction method flame retardancy test method.
Adhesiveness: Cut with a rotary saw blade for woodworking and evaluated the cross section of the cut end.

FIG. 2 is a structural cross-sectional view of the incombustible decorative board of the present invention.

Explanation of symbols

1 resin-impregnated underlay layer 2 prepreg 3 decorative layer 4 balance layer 6 incombustible decorative plate

Claims (1)

In order from the bottom, the balance layer, the core layer, the resin-impregnated underlay layer, and the decorative layer are non-combustible decorative plates integrated with heat and pressure,
The balance layer is melamine resin impregnated balance paper,
The core layer is a prepreg impregnated on a glass fiber nonwoven fabric base so that a slurry comprising a phenol-formaldehyde resin and aluminum hydroxide is 3 to 20% by a calculation method represented by Formula 2. ,
The resin-impregnated underlay layer was impregnated with a melamine resin on a base material having a basis weight of 10 to 100 g / m ^{2 so} that the organic component content was 50 to 300% by the calculation method represented by Equation 1. With underlay paper impregnated with melamine resin,
The non-combustible decorative board, wherein the decorative layer is a decorative coated paper on which an acrylic urethane hard coat layer is formed .