JP6624209B2 - Noncombustible decorative board - Google Patents

Description

  The present invention relates to a nonflammable decorative board.

  As the non-combustible decorative board, there is a non-combustible melamine decorative board which is widely used as a kitchen panel material, and a non-combustible melamine decorative board of a decorative board specification using a glass fiber base material and aluminum hydroxide fine powder is mainly used.

  A melamine decorative board using a general melamine resin has a high surface hardness and is not suitable for use in post-form (secondary molding) processing such as bending. However, in recent years, melamine resins for postforms that are suitable for bending applications have been developed, and decorative boards for postforms using the same can be heated and bent, and have been used for doors and the like. Furthermore, various combinations of melamine decorative boards according to applications have been manufactured by using kraft paper impregnated with a phenolic resin, aluminum or the like for the backing of the melamine decorative board. For example, Patent Literature 1 discloses a melamine decorative board in which aluminum is combined with a surface layer made of melamine resin-impregnated paper using melamine resin for postform.

  However, in the melamine decorative board disclosed in Patent Document 1, in order to bond the melamine decorative layer and aluminum, a kraft paper layer impregnated with a phenol resin is required. Since the thickness of the melamine decorative board is increased, it is difficult to reduce the thickness of the melamine decorative board, and the bendability is also limited. In the decorative board specification, the product thickness is large, it cannot exhibit flexibility even under heating, and it has high rigidity, so it will not be easily put into practical use in the field where nonflammability and bending workability are required at the same time. is there.

JP 2001-96702 A

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a non-combustible decorative board excellent in non-combustibility, capable of coping with thinning, and excellent in bending workability at room temperature.

Such an object is achieved by the following inventions (1) to (5).
(1) A non-combustible decorative plate having a structure in which a surface layer and a core material layer are laminated,
The surface layer is made of a thermoplastic resin film as a design surface, the basis weight of the surface layer is 40 g / m ² or more and 300 g / m ² or less, the core layer is Ri Do aluminum layer, and wherein A core material layer having a thickness of 0.1 mm or more, wherein the thermoplastic resin contains a polyvinyl chloride resin, and the surface layer and the core material layer do not pass through a two-component reaction type polyurethane resin adhesive; Wherein the core material layer does not have a polyvinyl chloride resin layer on the surface opposite to the surface layer, and has a bending workability with a minimum bending radius at 25 ° C. of 10 mmR or less. A non-combustible decorative plate characterized by the following.
(2) a structure in which the surface layer and the core material layer are laminated via an adhesive layer composed of a thermoplastic adhesive sheet having a basis weight of 200 g / m ² or less, and The non-combustible decorative board according to (1), wherein the total basis weight with the plastic adhesive sheet is 350 g / m ² or less.
(3) The non-combustible decorative plate according to (1) or (2), wherein the overall thickness is 0.5 mm or less .

  ADVANTAGE OF THE INVENTION According to this invention, it is excellent in nonflammability, can respond to thinning, and can obtain the nonflammable decorative board excellent in bending workability at normal temperature.

It is a conceptual diagram showing an example of the structure of the nonflammable decorative board of this invention. It is a conceptual diagram showing an example of the structure of the nonflammable decorative board of this invention. It is a conceptual diagram explaining an example of the manufacturing method of the nonflammable decorative board of this invention.

The non-combustible decorative plate of the present invention is a decorative plate having a structure in which a surface layer and a core material layer are laminated, and the surface layer is formed of a thermoplastic film or sheet serving as a design surface or a surface layer material including wallpaper. The basis weight of the surface layer material is 40 g / m ² or more and 300 g / m ² or less, and the core material layer is constituted by a core material material composed of an aluminum layer. This makes it possible to obtain a non-combustible decorative board that is excellent in non-combustibility, can be made thinner, and has excellent bending workability at normal temperature.

Hereinafter, the nonflammable decorative board of the present invention will be described in detail with reference to the drawings.
As an example of the configuration of the non-combustible decorative board of the present invention, FIG. 1 shows a configuration of a non-combustible decorative board 12 having a structure in which a surface layer 15 and a core layer 16 are laminated. FIG. 2 shows a configuration of a non-combustible decorative plate 13 having a structure in which a surface layer material 15 and a core material layer 16 are laminated via an adhesive layer 17 made of a thermoplastic adhesive sheet. FIG. 3 shows an example of a method of manufacturing the nonflammable decorative board 12 as an example of a method of manufacturing the nonflammable decorative board. In the case of the non-combustible decorative board 12 shown in FIG. 3, the surface layer material 15A and the core material layer material 16A are overlapped, formed by heating and pressing, and laminated. Although not shown, in the case of the non-combustible decorative plate 13, the surface layer material 15A, the thermoplastic adhesive sheet 17A, and the core material layer material 16A are laminated in this order, and they are laminated by heating and pressing. It can be obtained by: Hereinafter, each layer constituting the nonflammable decorative board of the present invention will be described.

<1. Surface layer>
The surface layer 15 is composed of a surface layer material 15A, and this surface layer material 15A is disposed on the design surface (exposed surface) side of the nonflammable decorative plate 12 of the present invention. The surface layer material 15A is made of a thermoplastic film or sheet or wallpaper on which a design is formed. Thereby, designability and workability such as bending can be imparted.

  The material of the surface layer material 15A is not particularly limited, but is preferably biaxially stretched polyethylene terephthalate (PET), amorphous PET, polybutylene terephthalate (PBT), non-crystalline PET film, polyester film, acrylic film, polycarbonate film. And a polyolefin-based film such as polypropylene (PP) and polyethylene (PE), and, if necessary, polyvinyl chloride (PVC) and wallpaper. The wallpaper is a sheet made of cloth, paper, or synthetic resin used as an interior finishing material for building walls and ceilings, and a commonly used sheet can be used.

The basis weight of the surface layer material 15A is preferably 40 g / m ² or more and 300 g / m ² or less, and more preferably 80 g / m ² or more and 150 g / m ² or less. When the grammage is less than the lower limit, there is a possibility that the design property is deteriorated or the use is difficult due to the problem of wrinkles. On the other hand, when the grammage exceeds the upper limit, it is not preferable because it may cause a decrease in nonflammability, a decrease in productivity, and an increase in cost.
<2. Core layer>
The core layer 16 is made of a core layer material 16A made of an aluminum layer. Thereby, heat resistance, nonflammability, rigidity, and the like can be imparted to the nonflammable decorative board of the present invention. As the aluminum layer used here, an aluminum foil or an aluminum plate can be used.

  The thickness of the core layer 16 is preferably 0.07 mm or more, and more preferably 0.1 mm or more. Thereby, sufficient heat resistance and nonflammability can be imparted to the decorative plate. The upper limit of the thickness is not particularly limited, but as the thickness increases, the heat resistance and the incombustibility improve, but the thickness and weight of the incombustible decorative board increase, and the cost increases. Above, it is preferable to set it within the permissible range, preferably 0.5 mm or less, more preferably 0.3 mm or less.

  It is preferable that the core layer material 16A has a surface on which the surface layer material 15A is laminated, which is subjected to a primer treatment with an epoxy resin, a urethane resin, or the like. Thereby, the adhesive strength between the surface layer material 15A and the core material layer material 16A can be further improved.

<3. Adhesive layer>
The adhesive layer 17 is composed of a thermoplastic adhesive sheet 17A. Thereby, the surface layer 15 and the core material layer can be securely bonded. As the thermoplastic adhesive sheet 17A, a polyamide-based, polyolefin-based, polyurethane-based film or sheet can be used in addition to a polyester film or sheet.

<4. Non-combustible decorative board>
The non-combustible decorative board 12 is obtained by laminating the above-described surface layer material 15A and core material layer material 16A, and forming the laminate by heating and pressing. The conditions for heating and pressing the non-combustible decorative plate 12 are not particularly limited. For example, the temperature is 130 ° C. or more, 200 ° C. or less, the pressure is 0.2 MPa or more, 8 MPa or less, the time is 0.1 minute or more, Minutes or less. In addition, when the non-combustible decorative plate 12 is heated and pressed, a mirror-finished plate can be placed on the first design surface side of the surface layer material 15A to achieve a mirror-finished surface. Thereby, embossing can be performed.

  Further, the non-combustible decorative plate 13 is obtained by laminating the surface layer material 15A, the thermoplastic adhesive sheet 17A, and the core layer material 16A in this order, and then heating and press-molding and laminating them. The conditions for heating and pressing the non-combustible decorative board 13 are not particularly limited. For example, the same conditions as those for heating and pressing the non-combustible decorative board 12 can be used.

The non-combustible decorative plates 12 and 13 of the present invention can be bent at room temperature (normally 25 ° C.) with a minimum bending radius of 10 mmR or less, but is not particularly limited. The minimum bending radius R is defined as a minimum value at which 100% non-defective products can be obtained without causing defects such as cracks even if cold bending performed in one direction is repeatedly performed along a mold having a curved portion having a radius R. Means a radius R of the form
Hereinafter, an example of a reference embodiment of the present invention will be described.
<1> A non-combustible decorative plate having a structure in which a surface layer and a core material layer are laminated, wherein the surface layer is formed of a thermoplastic film or sheet serving as a design surface or a surface layer material formed of wallpaper, and the surface The non-combustible decorative board, wherein the basis weight of the layer material is 40 g / m ² or more and 300 g / m ² or less, and the core layer is made of a core layer material made of an aluminum layer.
<2> The surface layer and the core layer have a structure in which the surface layer and the core layer are laminated via an adhesive layer composed of a thermoplastic adhesive sheet having a basis weight of 200 g / m ² or less. The non-combustible decorative plate according to <1>, wherein the total basis weight with the plastic adhesive sheet is 350 g / m ² or less.
<3> The non-combustible decorative plate according to <1> or <2>, wherein the overall thickness is 0.5 mm or less.
<4> The non-combustible decorative plate according to any one of <1> to <3>, wherein the thickness of the core material layer is 0.1 mm or more.
<5> The non-combustible decorative plate according to any one of <1> to <4>, which has a bending property of a minimum bending radius at 25 ° C of 10 mmR or less.

  Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples, but the present invention is not limited thereto.

(Example 1)
A polyethylene film (manufactured by Dai Nippon Printing Co., Ltd.) on which a design surface having a basis weight of 200 g / m ² was formed as a surface layer material, and a surface having been subjected to primer treatment with a urethane resin as a core material layer material, having a thickness of 0.1 mm. The aluminum foil of the above, the primer-treated surface of the aluminum foil on the surface side opposite to the design surface of the surface layer material is overlapped, and heated and pressed at 140 ° C. and 2 MPa for 40 minutes to form a 0.3 mm thick A decorative plate (1) was obtained.

(Example 2)
A wallpaper having a basis weight of 100 g / m ² (manufactured by Dai Nippon Printing Co., Ltd.) was used as the surface layer material, and a 0.1 mm-thick aluminum foil whose surface was subjected to a primer treatment with urethane resin was used as the core material layer material. A primer-treated surface of aluminum foil is superimposed on the surface opposite to the design surface of the layer material, and heated and pressed at 140 ° C. and 2 MPa for 40 minutes to obtain a decorative plate (2) having a thickness of 0.2 mm. Was.

(Example 3)
As the surface material, a 50 μm-thick thermoplastic polyester adhesive film (manufactured by Toa Gosei Co., Ltd.) using a polyvinyl chloride resin sheet (manufactured by Sumitomo 3M Limited) on which a design surface having a basis weight of 200 g / m ² is formed. Is inserted between a phosphoric acid-treated aluminum foil having a thickness of 0.1 mm, placed in a hot-hot press at a hot plate temperature of 160 ° C., heated and pressed at a pressure of 0.5 MPa for 2 minutes, taken out, and immediately taken out. By cooling and pressing with a low-pressure cold press, a decorative plate (3) having a thickness of 0.35 mm was obtained.

(Comparative Example 1)
Using a polyethylene film (manufactured by Dai Nippon Printing Co., Ltd.) on which a design surface having a basis weight of 500 g / m ² was formed as a surface layer material, and having a surface subjected to a primer treatment with a urethane resin as a core material layer material, having a thickness of 0.1 mm. The aluminum foil of the above, the primer-treated surface of the aluminum foil is superimposed on the second surface side of the surface layer material, and heated and pressed at 140 ° C. and 2 MPa for 40 minutes to form a decorative plate having a thickness of 0.6 mm. (4) was obtained.

(Comparative Example 2)
A decorative board (5) having a thickness of 0.4 mm was obtained in the same manner as in Example 1, except that a 0.2 mm-thick polyester non-woven fabric (Asahi Kasei Kogyo Co., Ltd., Spunbond "IEL") was used as the core material layer material. Was.

  The characteristics of the decorative boards (1) to (5) obtained in Examples 1, 2, and 3 and Comparative Examples 1 and 2 were evaluated. Table 1 shows the results.

(Test method)
1. Non-flammability test Business standard of the Japan Building Research Institute “Fire prevention performance test and evaluation method” 4.10 In the non-flammability performance test and evaluation method, (2) ii) Exothermic test and evaluation method of 4.10.2 and The test was conducted according to the gas hazard test / evaluation method of 4.10.3.
The above-mentioned items of the above-mentioned business standard “Fireproof performance test / evaluation business method” describe a performance evaluation method relating to the certification based on the provisions of Article 2, Item 9 (non-combustible materials) of the Building Standards Act.
2. Bend formability test In accordance with JIS K6902 bend formability test (Method A), outer and inner bends were formed at room temperature and 10 mmR, and the presence or absence of cracks on the decorative plate surface was confirmed.

In Comparative Example 1, the decorative film (4) was inferior in nonflammability because the weight of the thermoplastic film as the surface layer material was large and the organic component was increased.
In Comparative Example 2, the decorative sheet (5) was inferior in nonflammability because a polyester nonwoven fabric was used as the core layer material.
On the other hand, in the decorative plates (1), (2) and (3) obtained in Examples 1 to 3, the surface layer is composed of a surface layer material composed of a thermoplastic film or sheet or wallpaper, and the surface layer material The amount is 40 g / m ² or more and 300 g / m ² or less. Since the core layer is made of a core layer material made of an aluminum layer, it is excellent in noncombustibility, can be made thinner, and can be bent at normal temperature. Excellent workability.

  The decorative board of the present invention has good bending workability and nonflammability, and can respond to thinning. And, since a conventional thermoplastic film or wallpaper can be used for the surface layer, it can be freely selected from a variety of colors and patterns, and is widely used for applications such as walls subject to regulation of nonflammable materials in public facilities and the like. It is something that can be applied.

12 Non-combustible decorative board 13 Non-combustible decorative board 15 Surface layer 15A Surface layer material 16 Core material layer 16A Core material layer material 17 Adhesive layer 17A Thermoplastic adhesive sheet

Claims (3)

A non-combustible decorative plate having a structure in which a surface layer and a core material layer are laminated,
The surface layer is made of a thermoplastic resin film serving as a design surface,
The basis weight of the surface layer is 40 g / m ² or more and 300 g / m ² or less;
The core layer is Ri Do aluminum layer, and the thickness of the core material layer is at 0.1mm or more,
The thermoplastic resin contains a polyvinyl chloride resin,
The surface layer and the core material layer are not via a two-component reaction type polyurethane resin adhesive,
25 ° C. , which does not have a polyvinyl chloride resin layer on the surface of the core material layer opposite to the surface layer, and is measured according to the bending formability test (Method A) of JIS K6902. A non-combustible decorative board characterized by having a bending workability with a minimum bending radius of 10 mmR or less. A structure in which the surface layer and the core material layer are laminated via an adhesive layer formed of a thermoplastic adhesive sheet having a basis weight of 200 g / m ² or less;
Non-combustible decorative board according to claim 1 total basis weight of the thermoplastic adhesive sheet and the surface layer is 350 g / m ² or less.   The nonflammable decorative board according to claim 1 or 2, wherein the total thickness is 0.5 mm or less.

Images