JP6922518B2 - Non-combustible decorative board, manufacturing method of non-combustible decorative board - Google Patents

Description

The present invention relates to a non-combustible decorative board and a method for producing the same.

In the current Building Standard Law, the non-combustible performance of materials used for ceilings and walls is stipulated by the provision of interior restrictions. In addition, in special buildings where many people gather and large-scale buildings, fireproof building materials specified as non-combustible, semi-non-combustible, flame-retardant, etc. must be used for the interior (walls and ceilings).
The non-combustible decorative board used for the interior is required to have not only non-combustibility but also design and functionality such as color pattern, texture, and scratch resistance of the non-combustible decorative board. For this reason, the calorific value of the non-combustible decorative board tends to increase, and there is a problem that it is difficult to achieve the non-combustible standard after achieving the demand as a decorative board.

To solve this problem, there is a technique described in Patent Document 1.
Patent Document 1 describes a flame-retardant substrate mainly made of an inorganic material, a metal sheet in which innumerable pinhole-shaped ventilation holes are formed, a non-breathable non-combustible decorative plate, a flame-retardant substrate and a metal. A non-combustible decorative board including a sheet and an adhesive layer for adhering a metal sheet and a non-combustible decorative board is disclosed.
Further, in Patent Document 1, as an example of the ventilation holes formed in the metal sheet, the diameter is in the range of 0.01 mm or more and 0.5 mm or less, and the number is 1,000 to 1,000,000 pieces / m ^2. Is disclosed. As a result, in the technique described in Patent Document 1, when a strong heat is received from the outside due to a fire or the like, the gas generated from the inside of the flame-retardant substrate is released from the ventilation holes, so that damage to the metal sheet is suppressed. It is possible to achieve the effect of improving the fire protection performance.

Japanese Unexamined Patent Publication No. 2014-15509

However, in the technique described in Patent Document 1, if the diameter and number of ventilation holes are not properly set, the building standard law stipulates depending on the amount and momentum of gas generated from the inside of the flame-retardant substrate. There is a problem that it is difficult to achieve the non-combustible performance that has been achieved.
The present invention has been made by paying attention to the above-mentioned problems, and provides a non-combustible decorative board and a method for manufacturing the same, which can easily achieve the non-combustible performance specified in the Building Standards Act. With the goal.

In order to solve the above problems, one aspect of the present invention is a non-combustible decorative board in which a metal layer and a decorative layer are laminated in this order on one surface of a base material. The metal layer is formed with a plurality of holes penetrating the metal layer in the thickness direction, and the holes are formed linearly.
Further, in order to solve the above problems, one aspect of the present invention is a method for manufacturing a non-combustible decorative board in which a metal layer and a decorative layer are laminated in this order on one surface of a base material, and holes are provided. It includes a part forming step and a smoothing step. The hole forming step is a step of linearly forming a plurality of holes penetrating the metal layer in the thickness direction in the metal layer and cutting the metal layer into a plurality of holes. The smoothing step is a subsequent step of the hole forming step, and is a step of smoothing the metal layer by crushing the uneven portion formed on the metal layer in the hole forming step.

According to one aspect of the present invention, when gas is generated from the inside of the base material due to a fire or the like, the metal layer opens from the hole, so that the amount of gas released corresponding to the gas generation rate can be secured. This makes it possible to suppress damage to the metal layer.
Therefore, when the non-combustible decorative plate receives strong heat from the outside due to a fire or the like, the non-combustible effect can be efficiently exhibited by suppressing damage to the metal layer. This makes it possible to provide a non-combustible decorative board and a method for manufacturing a non-combustible decorative board, which can easily achieve the non-combustible performance specified in the Building Standard Law.

It is sectional drawing which shows the non-combustible decorative board of 1st Embodiment of this invention. It is a top view of a metal layer. It is an enlarged view of a hole part. It is a figure which shows the manufacturing method of the non-combustible decorative board. It is a figure which shows the manufacturing method of the non-combustible decorative board. It is a figure which shows the manufacturing method of the non-combustible decorative board. It is a figure which shows the manufacturing method of the non-combustible decorative board. It is a figure which shows the manufacturing method of the non-combustible decorative board. It is a figure which shows the modification of this invention. FIG. 9 is an enlarged view of a range represented by reference numeral X in FIG. It is a figure which shows the modification of this invention. It is a figure which shows the modification of this invention. It is a figure which shows the modification of this invention. It is a top view of the metal layer provided in the non-combustible decorative board of the 2nd Embodiment of this invention. It is an enlarged view of a hole part. It is a figure which shows the manufacturing method of the non-combustible decorative board.

The first embodiment of the present invention will be described below with reference to the drawings. In the description of the drawings referred to in the following description, the same or similar parts are designated by the same or similar reference numerals. However, it should be noted that the drawings are schematic, and the relationship between the thickness and the plane dimensions, the ratio of the thickness of each layer, etc. are different from the actual ones. Therefore, the specific thickness and dimensions should be determined in consideration of the following explanation. In addition, it goes without saying that the drawings include parts having different dimensional relationships and ratios from each other.

Further, the first embodiment shown below exemplifies a non-combustible decorative board for embodying the technical idea of the present invention, and the technical idea of the present invention describes the materials of the constituent parts and their components. The shape, structure, arrangement, etc. are not specified as follows. The technical idea of the present invention can be modified in various ways within the technical scope specified by the claims stated in the claims. Further, the directions of "left and right" and "up and down" in the following description are merely definitions for convenience of explanation, and do not limit the technical idea of the present invention. Therefore, for example, if the paper surface is rotated 90 degrees, "left and right" and "up and down" are read interchangeably, and if the paper surface is rotated 180 degrees, "left" becomes "right" and "right" becomes "left". Of course, it becomes.

(First Embodiment)
Hereinafter, the first embodiment of the present invention will be described with reference to the drawings.
(composition)
The configuration of the non-combustible decorative board 1 will be described with reference to FIGS. 1 to 3.
The non-combustible decorative board 1 shown in FIG. 1 is a board used for the interior (wall, ceiling) of a building (for example, a house).
The non-combustible decorative board 1 includes a base material 2, a first adhesive layer 4, a metal layer 6, a second adhesive layer 8, a decorative layer 10, and a reinforcing layer 20.
Further, in the non-combustible decorative board 1, as shown in FIG. 1, the first adhesive layer 4, the metal layer 6, the second adhesive layer 8 and the decorative layer 10 are laminated in this order on one surface of the base material 2. The reinforcing layer 20 is laminated on the other surface of the base material 2. The one surface of the base material 2 is the upper surface of the base material 2 in FIG. The other surface of the base material 2 is the lower surface of the base material 2 in FIG.

(Structure of base material 2)
The detailed configuration of the base material 2 will be described with reference to FIG.
The base material 2 is formed by using a volcanic vitreous multi-layer plate.
The volcanic vitreous multi-layer plate is an inorganic multi-layer plate having high fire resistance, and for example, a plate material conforming to JIS A5440 can be used. Examples of the plate material conforming to JIS A5440 include "Dailite FA" manufactured by Daiken Corporation and "Omar" manufactured by Iwakura Chemical Industry Co., Ltd.

(Structure of First Adhesive Layer 4)
The detailed configuration of the first adhesive layer 4 will be described with reference to FIG.
The first adhesive layer 4 is arranged between the base material 2 and the metal layer 6.
The first adhesive layer 4 is a layer for adhering the base material 2 and the metal layer 6.
Further, the first adhesive layer 4 is formed by drying, for example, an aqueous emulsion adhesive composition containing an aqueous emulsion resin and a cross-linking agent.
In the first embodiment, as an example, a case where the first adhesive layer 4 is formed by using an aqueous emulsion adhesive will be described.

As the aqueous emulsion resin, for example, vinyl acetate resin such as ethylene-vinyl acetate, acrylic resin, urethane resin, polyester resin, and epoxy resin can be used. Further, as the cross-linking agent, for example, an agent having an isocyanate group in the molecule and imparting a cross-linked structure by a chemical reaction can be used.
Since the aqueous emulsion adhesive composition does not use an organic solvent, it has a low impact on the environment.

The aqueous emulsion adhesive composition is applied by a known method such as gravure coating, bar coating, spray coating, roll coating, reverse roll coating, and comma coating. The coating amount of the aqueous emulsion adhesive composition ^{is preferably set within the range of 10 [g / m 2} ] or more and 60 [g / m ² ] or less in terms of solid content, and is preferably 20 [g / m ^2]. ] Or more and 50 [g / m ² ] or less is more preferable.
Further, a thickener may be added to the aqueous emulsion adhesive composition. As the thickener, for example, a water-soluble resin can be used. In particular, it is preferable to use an acrylic thickener, a cellulose derivative, a polyether-based thickener, or a urethane-modified polyether-based thickener.

The blending amount of the thickener is set so that an appropriate viscosity can be obtained according to the coating method. For example, it is set in the range of 0.001% by mass or more and 5.0% by mass or less with respect to the total mass of the aqueous emulsion adhesive composition. This is because when the blending amount is larger than 5.0% by mass, the viscosity becomes high and it becomes difficult to reduce the coating amount.
By blending a thickener in the aqueous emulsion adhesive composition, thixotropy can be obtained, so that the coating suitability can be improved and the coating amount can be reduced. By reducing the coating amount, the residual moisture content of the first adhesive layer 4 should be less than 30% by mass and the moisture content should be less than 10.0 [g / m ² ] by drying for a short time. This makes it possible to increase the production speed of the non-combustible decorative plate 1.
Further, conventionally, in order to impart good nonflammability, aluminum hydroxide is blended in the aqueous emulsion adhesive composition, but by reducing the coating amount, the blending amount of aluminum hydroxide can be reduced. Therefore, it is possible to reduce the cost.

(Structure of metal layer 6)
The detailed configuration of the metal layer 6 will be described with reference to FIGS. 1 and 3 with reference to FIGS. 2 and 3.
The metal layer 6 is a layer for imparting nonflammability to the noncombustible decorative plate 1.
The non-combustibility imparted to the non-combustible decorative board 1 conforms to ISO5660-1. Specifically, in the fire resistance test method based on Article 2-9 of the Building Standards Act and Article 108-2 of the Construction Standards Act Construction Ordinance and the heat generation test by the cone calorimeter tester according to the performance evaluation standard, the following conditions are met. It is nonflammable and satisfies the conditions represented by (A) to (C).
Condition (A): A condition in which the total calorific value for 20 minutes after the start of heating is 8 [MJ / m ² ] or less.
Condition (B): A condition in which the maximum heat generation rate does not exceed ^{200 [KW / m 2] continuously for 10 seconds or more for 20 minutes after the start of heating.}
Condition (C): A condition in which there are no harmful cracks or holes in fire protection for 20 minutes after the start of heating.

As the material of the metal layer 6, for example, aluminum foil, copper foil, silver foil, iron foil, and stainless steel foil can be used. In particular, aluminum foil is preferable in consideration of workability and corrosion resistance.
In the first embodiment, as an example, a case where the material of the metal layer 6 is an aluminum foil will be described. As a result, in the first embodiment, the structure of the metal layer 6 is set so that it can be easily processed and corrosion can be suppressed.
The thickness of the metal layer 6 is preferably in the range of 5 [μm] or more and 50 [μm] or less, and more preferably in the range of 7 [μm] or more and 30 [μm] or less.

In the first embodiment, as an example, a case where the thickness of the metal layer 6 is set in the range of 0.01 [mm] or more and 0.05 [mm] or less will be described.
Further, a plurality of holes 30 are formed in the metal layer 6.
The plurality of holes 30 are formed in a linear shape and penetrate the metal layer 6 in the thickness direction of the metal layer 6.
In the first embodiment, a case where the hole portion 30 is formed in a straight line having a long side 30Sa and a short side 30Sb will be described. In the following description and in FIGS. 2 and 3, the hole portion 30 formed in the metal layer 6 is represented by the reference numeral “30S”.
The length La of the long side 30Sa is in the range of 2 [mm] or more and 20 [mm] or less along the first direction preset in the metal layer 6.

In the first embodiment, a case where the first direction is set to the transport direction (flow direction) of the base material sheet (not shown) which is the original fabric of the base material 2 will be described.
Further, in the first embodiment, a case where the length La is set to 10 [mm] will be described.
The distance L1 between the two holes 30S adjacent to each other along the first direction is within the range of 1 [mm] or more and 30 [mm] or less.
In the first embodiment, the case where the interval L1 is set to 20 [mm] will be described.
The distance L2 between the two holes 30S adjacent to each other along the second direction orthogonal to the first direction is within the range of 10 [mm] or more and 30 [mm] or less.

In the first embodiment, a case where the interval L2 is set to 15 [mm] will be described.
The length Lb of the short side 30Sb is in the range of 0.01 [mm] or more and 0.05 [mm] or less.
Further, as shown in FIG. 2, the plurality of hole portions 30S are arranged in a hexagonal lattice (checkerboard pattern) in a plan view (plan view of the noncombustible decorative plate 1 and plan view of the metal layer 6).
Further, the opening area of the hole 30S when the metal layer 6 is viewed from the side of the first adhesive layer 4 is the same as the opening area of the hole 30S when the metal layer 6 is viewed from the side of the second adhesive layer 8. That is, the hole portion 30S is formed in a shape in which the opening area does not change.

(Structure of Second Adhesive Layer 8)
The detailed configuration of the second adhesive layer 8 will be described with reference to FIG.
The second adhesive layer 8 is arranged between the metal layer 6 and the decorative layer 10.
The second adhesive layer 8 is a layer for adhering the metal layer 6 and the decorative layer 10, and is formed by using any one of an aqueous emulsion adhesive, a reactive hot melt adhesive, and an adhesive. do.
In the first embodiment, a case where the second adhesive layer 8 is formed by using a reactive hot melt adhesive will be described.
As the reactive hot melt adhesive, for example, a reactive hot melt adhesive containing urethane resin as a main component and imparting reaction system characteristics to the hot melt (for example, "Tyforce" manufactured by DIC Corporation) can be used. It is possible.

(Structure of decorative layer 10)
The detailed configuration of the decorative layer 10 will be described with reference to FIG.
The decorative layer 10 is a layer for imparting design to the non-combustible decorative board 1.
The material of the decorative layer 10 is not particularly limited, and a material using a resin sheet or the like as a base material can be used.
As the resin forming the resin sheet, for example, a polyester resin, a polyolefin resin, a polyurethane resin, or an acrylic resin can be used. Further, as the resin forming the resin sheet, for example, a polycarbonate resin, a polystyrene resin, a vinyl chloride resin, a vinyl acetate resin, and a vinyl chloride-vinyl acetate copolymer resin can be used.

As the polyester resin, for example, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or the like can be used. As the polyolefin-based resin, for example, polyethylene, polypropylene, polybutene, ethylene-propylene copolymer resin, ethylene-propylene-butene copolymer resin, olefin-based thermoplastic elastomer and the like can be used. As the polyurethane-based resin, for example, an acrylic-modified urethane-based resin, a polyester-modified urethane-based resin, a vinyl chloride-vinyl acetate copolymer-modified urethane-based resin, or the like can be used.

As the resin for forming the resin sheet, it is also possible to use two or more of the above-mentioned resins in combination.
Further, as the decorative layer 10, it is also possible to use a colored resin sheet and a transparent resin sheet formed by using the above-mentioned resin as a doubling sheet obtained by sandwiching a pattern. In this case, the resin used for the colored resin sheet and the transparent resin sheet may be the same resin or different resins. Further, as the resin used for the colored resin sheet and the transparent resin sheet, for example, a polyolefin-based resin is preferable.

When the resin used for the colored resin sheet and the transparent resin sheet are different, the combination of the resins is preferably a combination of polyethylene-polyethylene, polyethylene-polypropylene, and polypropylene-polypropylene. As the combination of resins, in addition to the above-mentioned combinations, a combination of polybutylene terephthalate-polypropylene, polybutylene terephthalate-polyethylene, or polybutylene terephthalate-polybutylene terephthalate is preferable.

In the doubling sheet, for example, the surface of the first resin sheet formed by using the above-mentioned resin is subjected to corona discharge treatment or the like to provide a primer layer, and further, a solid layer or a pattern layer is printed on the first resin sheet. Form. After that, the second resin sheet formed by using the above-mentioned resin can be formed by pressure-bonding by a lamination method. As the lamination method, for example, extrusion lamination, dry lamination, wet lamination, and thermal lamination can be used.
In the first embodiment, as an example, a case where the decorative layer 10 contains an olefin resin will be described.
The thickness of the decorative layer 10 is within the range of 0.06 [mm] or more and 0.18 [mm] or less.

(Structure of Reinforcing Layer 20)
The detailed configuration of the reinforcing layer 20 will be described with reference to FIG.
The reinforcing layer 20 is a layer for imparting nonflammability and strength to the noncombustible decorative board 1.
As the reinforcing layer 20, for example, double-sided thin paper-covered aluminum foil can be used.
The double-sided thin paper-covered aluminum foil is formed of a laminate including two sheets of tissue paper 22, 24 and a metal foil 26 arranged between the two sheets of tissue paper 22, 24.
Both the two sheets of tissue paper 22 and 24 are impregnated with a sealer agent.
As the material of the metal foil 26, for example, aluminum foil, copper foil, silver foil, iron foil, and stainless steel foil can be used. In particular, as the material of the metal foil 26, it is preferable to use an aluminum foil in consideration of workability and corrosion resistance.
The emissivity of the metal foil 26 is preferably 60% or more, and particularly preferably 70% or more from the viewpoint of nonflammability.

(Manufacturing method of non-combustible decorative board 1)
A method for manufacturing the non-combustible decorative board 1 will be described with reference to FIGS. 1 to 3 and FIGS. 4 to 8.
The method for producing the non-combustible decorative plate 1 is a method of forming the non-combustible decorative plate 1 in which the metal layer 6 and the decorative layer 10 are laminated in this order on one surface of the base material 2, and is a hole forming step. And a smoothing step which is a post-step of the hole forming step.
The hole forming step is a step of forming a plurality of holes 30S in the metal layer 6 by cutting the metal layer 6.
As a specific example of the hole forming step, for example, as shown in FIG. 4, the metal foil sheet 6S, which is the material of the metal layer 6, is cut into the target size of the hole 30S by using the slitter machine 50. It is possible to use a method of continuously forming SS.
The slitter machine 50 includes a disc-shaped notch blade 52 and a backup roller 54.

The disk-shaped notch blade 52 is a plurality of blades capable of making a notch SS having a target dimension of the hole 30S.
The backup roller 54 is a roller that rotates with the metal foil sheet 6S sandwiched between the disk-shaped notch blade 52 and conveys the metal foil sheet 6S.
In the hole forming step, as shown in FIG. 5, a notch SS having a target size of the hole 30S is formed by cutting the tip of the disk-shaped notch blade 52 into the metal foil sheet 6S. Therefore, as shown in FIG. 6, in the notch SS, the trace of the metal foil sheet 6S being cut is in a state in which the tip of the disk-shaped notch blade 52 is deeply inserted.

Therefore, as shown in FIG. 6, in the hole forming step, the uneven portion 56 is formed on the metal layer 6 (metal foil sheet 6S).
The smoothing step is a step of smoothing the metal layer 6 by crushing the uneven portion 56 formed on the metal layer 6 in the hole forming step.
As a specific example of the smoothing step, for example, as shown in FIG. 7, a portion of the metal foil sheet 6S having a notch SS is pressed by two roller members 58 from both sides of the metal foil sheet 6S. Thereby, as shown in FIG. 8, it is possible to use a method of crushing the uneven portion 56 to smooth the metal foil sheet 6S.

(Action)
The operation of the first embodiment will be described with reference to FIGS. 1 to 8.
In the non-combustible decorative plate 1 of the first embodiment, a plurality of holes 30S penetrating the metal layer 6 in the thickness direction are formed in the metal layer 6, and the holes 30S are formed linearly.
Therefore, when the non-combustible decorative plate 1 receives strong heat from the outside due to a fire or the like, the non-combustible effect of the metal layer 6 can be efficiently exhibited. Specifically, when gas is generated from the inside of the base material 2 due to a fire or the like, the metal layer 6 opens starting from the hole 30S, so that it is possible to secure the amount of gas released corresponding to the gas generation rate. Therefore, it is possible to suppress damage to the metal layer 6.

In addition to this, the distance L1 between the two adjacent holes 30S along the first direction is within the range of 1 [mm] or more and 30 [mm] or less, and the two adjacent holes along the second direction are adjacent to each other. The interval L2 of 30S is within the range of 10 [mm] or more and 30 [mm] or less. Therefore, since it is possible to secure a sufficient area of the metal layer 6 in the two adjacent holes 30S, it is possible to suppress the exposure of the base material 2 and to reduce the radiant heat generated in the event of a fire. It is possible to efficiently exert the preventive effect.

As described above, the non-combustible decorative plate 1 of the first embodiment efficiently exerts the non-combustible effect of the metal layer 6 when the non-combustible decorative plate 1 receives strong heat from the outside due to a fire or the like. It becomes possible. This makes it possible to easily achieve the non-combustible performance stipulated in the Building Standard Law.
The above-mentioned first embodiment is an example of the present invention, and the present invention is not limited to the above-mentioned first embodiment, and even if it is an embodiment other than this embodiment, it relates to the present invention. As long as it does not deviate from the technical idea, various changes can be made according to the design and the like.

(Effect of the first embodiment)
The non-combustible decorative board 1 of the first embodiment can achieve the effects described below.
(1) A metal layer 6 and a decorative layer 10 are laminated in this order on one surface of the base material 2, and the metal layer 6 has a plurality of holes penetrating the metal layer 6 in the thickness direction. 30S is formed. In addition to this, the hole 30S is formed linearly.
Therefore, when gas is generated from the inside of the base material 2 due to a fire or the like, the metal layer 6 opens starting from the hole 30S, so that it is possible to secure the amount of gas released corresponding to the gas generation rate. .. As a result, when the non-combustible decorative plate 1 receives strong heat from the outside due to a fire or the like, the non-combustible effect of the metal layer 6 can be efficiently exhibited.
As a result, it becomes possible to provide the non-combustible decorative board 1 capable of easily achieving the non-combustible performance specified in the Building Standard Law.

(2) The hole portion 30S is formed in a straight line having a long side 30Sa and a short side 30Sb. In addition to this, the length La of the long side 30Sa is in the range of 2 [mm] or more and 20 [mm] or less along the first direction, and the interval L1 is in the range of 1 [mm] or more and 30 [mm] or less. The interval L2 is within the range of 10 [mm] or more and 30 [mm] or less.
As a result, it is possible to secure a sufficient area of the metal layer 6 in the two adjacent holes 30S, so that it is possible to suppress the exposure of the base material 2 and to reduce the radiant heat generated in the event of a fire. It is possible to efficiently exert the preventive effect.

(3) The length Lb of the short side 30Sb is within the range of 0.01 [mm] or more and 0.05 [mm] or less.
As a result, it is possible to secure a sufficient area of the metal layer 6 in the two adjacent holes 30S, so that it is possible to suppress the exposure of the base material 2 and to reduce the radiant heat generated in the event of a fire. It is possible to efficiently exert the preventive effect.
(4) The thickness of the metal layer 6 is within the range of 0.01 [mm] or more and 0.05 [mm] or less.
As a result, the thickness of the metal layer 6 can be reduced, and the weight of the non-combustible decorative plate 1 can be reduced.

(5) A plurality of holes 30S are arranged in a hexagonal lattice in a plan view.
As a result, the plurality of holes 30S can be evenly arranged on the metal layer 6, and the nonflammable effect of the metal layer 6 can be exhibited on average with respect to the noncombustible decorative plate 1.
(6) The thickness of the decorative layer 10 is within the range of 0.06 [mm] or more and 0.18 [mm] or less.
As a result, it is possible to reduce the maximum heat generation rate after the start of heating.

(7) The first adhesive layer 4 arranged between the base material 2 and the metal layer 6 is formed by using an aqueous emulsion adhesive. In addition to this, a second adhesive layer 8 arranged between the metal layer 6 and the decorative layer 10 is formed using any one of an aqueous emulsion adhesive, a reactive hot melt adhesive and an adhesive. ing.
As a result, since the first adhesive layer 4 is formed without using an organic solvent, it is possible to reduce the environmental load and the amount of heat generated by the non-combustible decorative plate 1 with respect to heating from the decorative layer 10 side. It is possible to suppress the increase. In addition to this, since moisture can be easily removed from the hole 30S, it is possible to shorten the curing time after the decorative layer 10 is bonded, and it is possible to shorten the time required for manufacturing the non-combustible decorative plate 1. Become. Further, when it is formed by using any one of the reactive hot melt adhesive and the pressure-sensitive adhesive, the decorative layer 10 is provided because the moisture drying time is not required to exert the adhesive force unlike the water-based adhesive. It is possible to shorten the curing period after bonding.

(8) The base material 2 is formed by using a volcanic vitreous multi-layer plate.
As a result, it becomes easy to impart nonflammability to the base material 2.
(9) Double-sided thin paper-covered aluminum having a reinforcing layer 20 laminated on the other surface of the base material 2 having a metal foil 26 arranged between two sheets of tissue paper 22, 24 and two sheets of tissue paper 22, 24. It is made of foil.
As a result, the reinforcing layer 20 can impart non-combustibility and strength to the non-combustible decorative plate 1, so that the non-combustible decorative plate 1 can be improved and the non-combustible decorative plate 1 can be improved. It is possible to suppress warpage and improve dimensional stability.

(10) Both of the two thin paper sheets 22 and 24 are impregnated with a sealer agent.
As a result, it is possible to impart the effect of strengthening the interlayer strength and the sealing effect to the thin paper sheets 22 and 24.
Further, according to the method for producing the non-combustible decorative board 1 of the first embodiment, the effects described below can be obtained.

(11) A method for manufacturing a non-combustible decorative plate 1 in which a metal layer 6 and a decorative layer 10 are laminated in this order on one surface of a base material 2, wherein a hole forming step and a hole forming step are performed. Includes a smoothing step, which is a subsequent step.
The hole forming step is a step of forming a plurality of holes 30S in the metal layer 6 by cutting the metal layer 6. The smoothing step is a step of smoothing the metal layer 6 by crushing the uneven portion 56 formed on the metal layer 6 in the hole forming step.
As a result, by smoothing the uneven portion 56 formed in the hole forming step, it is possible to improve the sticking state of the non-combustible decorative plate 1. In addition to this, it is possible to provide a method for manufacturing the non-combustible decorative board 1 capable of easily achieving the non-combustible performance specified in the Building Standard Law.

(Modification example)
(1) In the first embodiment, the plurality of hole portions 30S are arranged in a hexagonal lattice in a plan view, but the present invention is not limited to this, and the plurality of hole portions 30S are arranged in a square lattice (lattice shape) in a plan view. May be placed in.
In this case, as in the first embodiment, the spacing L1 along the first direction and the spacing L2 along the second direction orthogonal to the first direction may be arranged so as to have the same length. ..
That is, the plurality of holes 30S may be arranged in a dot shape.

(2) In the first embodiment, the plurality of holes 30S are arranged in a hexagonal lattice in a plan view, but the present invention is not limited to this. That is, as shown in FIGS. 9 and 10, for example, a group formed by a plurality of holes 30S in which a plurality of holes 30S are linearly arranged with their long sides oriented parallel to the first direction is formed. It may be arranged in a shape (perforated shape) arranged at equal intervals along two directions.
In the examples shown in FIGS. 9 and 10, the length La of the long side 30Sa is set to 2 [mm] along the first direction, the interval L1 is set to 1 [mm], and the interval L2 is set to 10 [. Set to [mm].
(3) In the first embodiment, the metal layer 6 is formed of aluminum foil, but the present invention is not limited to this. That is, for example, as shown in FIG. 11, the metal layer 6 is a double-sided thin paper-covered aluminum having two sheets of tissue paper 22, 24 and a metal foil 26 arranged between the two sheets of tissue paper 22, 24. It may be formed of foil.

(4) In the first embodiment, the second adhesive layer 8 is arranged between the metal layer 6 and the decorative layer 10, but the present invention is not limited to this. That is, for example, as shown in FIG. 11, a sealer layer 40 containing a sealer agent may be arranged between the metal layer 6 and the decorative layer 10 in addition to the second adhesive layer 8. In this case, the sealer layer 40 has a sealer agent content of 5 [g / m ² ] or less in terms of solid matter.
(5) In the first embodiment, the base material 2 is formed by using a volcanic vitreous multi-layer plate, but the present invention is not limited to this, and the base material 2 is other than the volcanic vitreous multi-layer plate. It may be formed by using a nonflammable / flame retardant material.

(6) In the first embodiment, the hole 30 is formed in a shape in which the opening area does not change, but the hole 30 is not limited to this. That is, for example, as shown in FIG. 12, the hole 30 is the opening area of the hole 30 when the metal layer 6 is viewed from the side of the first adhesive layer 4, and the metal layer 6 is on the side of the second adhesive layer 8. The opening area of the hole portion 30 as viewed from the front may be formed in a different shape. In the example shown in FIG. 12, the length Lb1 of the short side of the hole 30 on the side of the first adhesive layer 4 is short on the side of the hole 30 on the side of the second adhesive layer 8. It is formed in a shape larger than the side length Lb2.

(7) In the first embodiment, the structure of the non-combustible decorative board 1 is such that the first adhesive layer 4, the metal layer 6, the second adhesive layer 8 and the decorative layer 10 are laminated in this order on one surface of the base material 2. However, the configuration is not limited to this.
That is, for example, as shown in FIG. 13, the structure of the non-combustible decorative board 1 is such that the thin paper 22 is arranged on one surface of the metal layer 6 (in FIG. 13, the surface on the first adhesive layer 4 side). It may be configured as such.
In this case, for example, the thin paper 22 is attached to the metal layer 6 using a urethane-based resin emulsion adhesive (coating amount: 23 [g / m ^{2] or less in terms of solid content).}
With the non-combustible decorative board 1 having such a configuration, by arranging the thin paper 22 on one surface of the metal layer 6, it is possible to suppress the occurrence of wrinkles and slack during the processing of forming the holes 30. It becomes. In addition to this, when the metal layer 6 is laminated on the base material 2, the surface on the side on which the thin paper 22 is arranged is attached, so that a smooth structure can be obtained.

(Second Embodiment)
Hereinafter, the second embodiment of the present invention will be described with reference to the drawings.
(composition)
The configuration of the non-combustible decorative board 1 will be described with reference to FIGS. 1 to 13 with reference to FIGS. 14 and 15.
The non-combustible decorative plate 1 of the second embodiment has the same configuration as the non-combustible decorative plate 1 of the first embodiment described above, except for the metal layer 6.
In the non-combustible decorative board 1, as shown in FIG. 1, the first adhesive layer 4, the metal layer 6, the second adhesive layer 8, and the decorative layer 10 are laminated in this order on one surface of the base material 2, and the base material is formed. A reinforcing layer 20 is laminated on the other surface of 2.

(Structure other than metal layer 6)
The structure of the base material 2, the first adhesive layer 4, the second adhesive layer 8, the decorative layer 10, and the reinforcing layer 20 is the same as that of the first embodiment described above.
(Structure of metal layer 6)
The detailed configuration of the metal layer 6 will be described with reference to FIGS. 14 and 15.
The description of the same configuration as that of the first embodiment may be omitted.
A plurality of holes 30 are formed in the metal layer 6.
In the second embodiment, a case where the hole portion 30 is formed in a cross shape in which two straight lines 30Ca and 30Cb having a long side and a short side and having the same shape are orthogonal to each other will be described. In the following description and in FIGS. 14 and 15, the hole portion 30 formed in the metal layer 6 is represented by the reference numeral “30C”.

The length Lc of the long side is in the range of 5 [mm] or more and 20 [mm] or less.
In the first embodiment, a case where the length Lc is set to 5 [mm] will be described.
The length Ld of the short side is in the range of 0.01 [mm] or more and 0.05 [mm] or less.
The two holes 30C adjacent to each other along the preset first direction have a distance L3 between the centers of two straight lines 30Ca and 30Cb orthogonal to each other within a range of 10 [mm] or more and 30 [mm] or less. Is.

In the second embodiment, as in the first embodiment, a case where the first direction is set to the transport direction (flow direction) of the base material sheet (not shown) which is the original fabric of the base material 2 will be described.
In the second embodiment, the case where the interval L3 is set to 15 [mm] will be described.
In the two holes 30C adjacent to each other along the second direction orthogonal to the first direction, the distance L4 between the centers of the two straight lines 30Ca and 30Cb orthogonal to each other is 10 [mm] or more and 30 [mm] or less. Is within the range of.
In the first embodiment, the case where the interval L4 is set to 15 [mm] will be described.
Further, as shown in FIG. 14, the plurality of hole portions 30C are arranged in a square lattice in a plan view (plan view of the noncombustible decorative plate 1 and plan view of the metal layer 6).

(Manufacturing method of non-combustible decorative board 1)
A method for manufacturing the non-combustible decorative board 1 will be described with reference to FIGS. 14 and 15.
The method for producing the non-combustible decorative plate 1 is a method of forming the non-combustible decorative plate 1 in which the metal layer 6 and the decorative layer 10 are laminated in this order on one surface of the base material 2, and is a hole forming step. And a smoothing step which is a post-step of the hole forming step.
The hole forming step is a step of forming a plurality of holes 30S in the metal layer 6 by cutting the metal layer 6.

As a specific example of the hole forming step, for example, as shown in FIG. 16, the stamp 60 is pressed against the metal foil sheet 6S which is the material of the metal layer 6, and the notch SS of the target size of the hole 30C is SS. It is possible to use a method of forming a plurality of the above at the same time.
The push die 60 includes a plurality of cutting blades 62.
The cutting blade 62 is formed in a cross shape capable of making a notch CS having a target size and shape of the hole 30C.
The smoothing step is a step of smoothing the metal layer 6 by crushing the uneven portion 56 formed on the metal layer 6 in the hole forming step. The smoothing step is the same as that of the first embodiment described above.

(Action)
The operation of the second embodiment is the same as that of the first embodiment described above.
The above-mentioned second embodiment is an example of the present invention, and the present invention is not limited to the above-mentioned second embodiment, and even if it is an embodiment other than this embodiment, it relates to the present invention. As long as it does not deviate from the technical idea, various changes can be made according to the design and the like.

(Effect of the second embodiment)
The non-combustible decorative board 1 of the second embodiment can achieve the effects described below.
(1) The hole portion 30C is formed in a cross shape in which two straight lines 30Ca and 30Cb having a long side and a short side and having the same shape are orthogonal to each other. In addition to this, the length Lc of the long side is within the range of 5 [mm] or more and 20 [mm] or less, and the interval L3 and the interval L4 are within the range of 10 [mm] or more and 30 [mm] or less. ..
As a result, it is possible to secure a sufficient area of the metal layer 6 in the two adjacent holes 30C, so that it is possible to suppress the exposure of the base material 2 and to reduce the radiant heat generated in the event of a fire. It is possible to efficiently exert the preventive effect.
(2) A plurality of holes 30C are arranged in a square grid in a plan view.
As a result, the amount of gas released from the inside of the base material 2 due to a fire or the like can be averaged over the entire metal layer 6, and the nonflammable effect can be efficiently exhibited.

The non-combustible decorative board 1 of Examples 1 to 5 and the non-combustible decorative board of Comparative Examples 1 to 3 will be described with reference to the first embodiment and the second embodiment according to the examples described below. ..
(Example 1)
The non-combustible decorative board 1 of Example 1 has the following configuration (see FIG. 1).
The base material 2 was formed by using a volcanic vitreous multi-layer plate having a thickness of 3 [mm].
The first adhesive layer 4 was formed using a vinyl copolymer resin emulsion (coating amount: 40 [g / m ² ] (dry) in terms of solid content).

The metal layer 6 was formed by using an aluminum foil having a thickness of 0.03 [mm]. In addition to this, in the metal layer 6, the linear holes 30S are arranged in a hexagonal lattice in a plan view, the interval L1 is set to 20 [mm], and the interval L2 is set to 15 [mm].
The second adhesive layer 8 was formed by using a vinyl copolymer resin emulsion (coating amount: 20 [g / m ² ] (dry) in terms of solid content).
The decorative layer 10 was formed into a plurality of layers using an olefin resin film having a thickness of 0.13 [mm].
The reinforcing layer 20 was formed by using double-sided thin paper-clad aluminum foil. Further, the reinforcing layer 20 was attached to the other surface of the base material 2 using a vinyl acetate resin adhesive.

(Example 2)
The non-combustible decorative board 1 of the second embodiment has the same structure as the non-combustible decorative board 1 of the first embodiment except for the structure of the metal layer 6.
In the metal layer 6 included in the non-combustible decorative plate 1 of Example 2, the cross-shaped holes 30C are arranged in a square lattice in a plan view, and the lengths of the intervals L3 and L4 are set to 15 [mm].
(Example 3)
The non-combustible decorative plate 1 of Example 3 has the same configuration as the non-combustible decorative plate 1 of Example 1 except for the configuration of the metal layer 6.
In the metal layer 6 included in the non-combustible decorative plate 1 of the third embodiment, the linear holes 30S are arranged in a perforated manner, and the length La of the long side 30Sa is set to 2 [mm] along the first direction. Then, the interval L1 was set to 1 [mm], and the interval L2 was set to 10 [mm] (see FIGS. 9 and 10).

(Example 4)
The non-combustible decorative plate 1 of Example 4 is different from the non-combustible decorative plate 1 of Example 1 except that the configuration of the second adhesive layer 8 and the primer layer are arranged between the metal layer 6 and the second adhesive layer 8. It has a similar configuration.
The second adhesive layer 8 provided in the non-combustible decorative plate 1 of Example 4 was formed by using an acrylic pressure-sensitive adhesive and having a thickness of 0.04 [mm].
The primer layer provided in the non-combustible decorative board 1 of Example 4 was ^{formed by using a rubber-based primer (coating amount: 7 [g / m 2} ] (dry) in terms of solid content).

(Example 5)
The non-combustible decorative board 1 of Example 5 has the following configuration (see FIG. 11).
The base material 2 was formed by using a volcanic vitreous multi-layer plate having a thickness of 3 [mm].
The metal layer 6 was formed by using a double-sided thin paper-covered aluminum foil having a thickness of 0.012 [mm]. In addition to this, in the metal layer 6, the linear holes 30S are arranged in a hexagonal lattice in a plan view, the interval L1 is set to 20 [mm], and the interval L2 is set to 15 [mm].
The sealer layer 40 was formed by using a urethane resin (coating amount: 2.3 [g / m ^2]).
The second adhesive layer 8 was formed by using a vinyl copolymer resin emulsion (coating amount: 20 [g / m ² ] (dry) in terms of solid content).
The decorative layer 10 was formed into a plurality of layers using an olefin resin film having a thickness of 0.13 [mm].

(Comparative Example 1)
The non-combustible decorative board of Comparative Example 1 has the same structure as the non-combustible decorative board 1 of Example 1 except for the structure of the metal layer 6 and the second adhesive layer 8.
The metal layer 6 provided in the non-combustible decorative plate of Comparative Example 1 does not have a hole 30 formed therein.
The second adhesive layer 8 was formed by using a urethane-based resin-reactive hot melt (coating amount: 40 [g / m ^2]).
(Comparative Example 2)
The non-combustible decorative board of Comparative Example 2 has the same structure as the non-combustible decorative board 1 of Example 1 except for the structure of the metal layer 6.
In the metal layer 6 included in the non-combustible decorative plate of Comparative Example 2, a plurality of circular holes having a diameter of 0.3 [mm] are arranged in a square lattice in a plan view, and the intervals between adjacent holes are 2 It was set to [mm].

(Comparative Example 3)
The non-combustible decorative board of Comparative Example 3 has the same structure as the non-combustible decorative board 1 of Example 4 except for the structure of the metal layer 6.
The metal layer 6 provided in the non-combustible decorative plate of Comparative Example 3 does not have a hole 30 formed.
(Performance evaluation)
Performance evaluation (total calorific value, maximum heat generation rate, 200k excess duration, etc.) was performed on the non-combustible decorative boards 1 of Examples 1 to 5 and the non-combustible decorative boards of Comparative Examples 1 to 3 according to the following methods, respectively. Durability and nonflammability evaluation) were performed. The evaluation results of nonflammability are shown in Table 1.

(Incombustibility)
The non-combustibility was evaluated based on the following criteria by conducting a heat-generating test on the non-combustible decorative plate 1.
As a heat generation test, a cone calorimeter tester that complies with ISO5660-1 and conforms to the fireproof test method and performance evaluation standard based on Article 2-9 of the Building Standards Act and Article 108-2 of the Construction Ordinance of the Building Standards Act. A heat generation test by (manufactured by Toyo Seiki Seisakusho Co., Ltd.) was adopted.
Then, when the above-mentioned conditions (A) to (C) were satisfied, the comprehensive evaluation was evaluated as "○". Further, when at least one of the above-mentioned conditions (A) to (C) was not satisfied, the comprehensive evaluation was evaluated as "x".
(Performance evaluation)
As shown in Table 1, it was confirmed that the non-combustible decorative boards 1 of Examples 1 to 5 are more nonflammable than the non-combustible decorative boards of Comparative Examples 1 to 3.

The non-combustible decorative board of the present invention can be used for interior and exterior building materials such as ceilings and walls of buildings, doors, furniture and the like. In particular, by utilizing the non-combustibility of non-combustible decorative boards, it is suitably used for building materials used around kitchens such as sinks, gas stoves, and hoods, and other parts of buildings that are required to be non-combustible under the Building Standards Act. It is possible.

1 ... non-combustible decorative board, 2 ... base material, 4 ... first adhesive layer, 6 ... metal layer, 6S ... metal foil sheet, 8 ... second adhesive layer, 10 ... decorative layer, 20 ... reinforcing layer, 22 ... thin leaf paper, 24 ... Thin leaf paper, 26 ... Metal foil, 30 ... Hole, 30S ... Straight hole, 30Sa ... Long side of hole 30S, 30Sb ... Short side of hole 30S, 30C ... Cross hole, 40 ... Sealer layer, 50 ... slitter machine, 52 ... disk-shaped notch blade, 54 ... backup roller, 56 ... uneven part, 58 ... roller member, 60 ... push die, 62 ... notch blade, La ... long side 30Sa length, Lb ... The length of the short side 30Sb, Lb1 ... The length of the short side of the hole 30 on the side of the first adhesive layer 4, Lb2 ... The length of the short side of the hole 30 on the side of the second adhesive layer 8. Lc: the length of the long side, Ld: the length of the short side, L1: the distance between the two holes 30S adjacent to each other along the first direction, L2: the distance between the two holes 30S adjacent to each other along the second direction. Spacing, L3 ... Spacing between the centers of two orthogonal straight lines 30Ca, 30Cb of two adjacent holes 30C along the first direction, L4 ... Two holes adjacent along the second direction Distance between the centers of two straight lines 30Ca and 30Cb orthogonal to each other in 30C, SS ... Notch of target dimension of hole 30S, CS ... Notch of target dimension of hole 30C

Claims (15)

A non-combustible decorative board in which a metal layer and a decorative layer are laminated in this order on one surface of a base material.
A plurality of holes penetrating the metal layer in the thickness direction are formed in the metal layer.
The hole is formed in a straight line having a long side and a short side.
The length of the short side is in the range of 0.01 mm or more and 0.05 mm or less.
The length of the long side is within a range of 2 mm or more and 20 mm or less along the first direction preset for the metal layer.
The distance between the two adjacent holes along the first direction is within a range of 1 mm or more and 30 mm or less.
The spacing of the two said holes adjacent to each other along a second direction perpendicular to the first direction, non-combustible decorative board, characterized in der Rukoto the range of 10mm or 30mm or less. A non-combustible decorative board in which a metal layer and a decorative layer are laminated in this order on one surface of a base material.
A plurality of holes penetrating the metal layer in the thickness direction are formed in the metal layer.
The hole has a long side and a short side, and is formed in a cross shape in which two straight lines having the same shape are orthogonal to each other.
The length of the short side is in the range of 0.01 mm or more and 0.05 mm or less.
The length of the long side is within the range of 5 mm or more and 20 mm or less.
The two holes adjacent to each other along the preset first direction have a distance between the centers of the two orthogonal straight lines of 10 mm or more and 30 mm or less.
The two holes adjacent to each other along the second direction orthogonal to the first direction are characterized in that the distance between the centers of the two orthogonal straight lines is within a range of 10 mm or more and 30 mm or less. Non-combustible decorative board. The non-combustible decorative plate according to claim 1 or 2 , wherein the thickness of the metal layer is within the range of 0.01 mm or more and 0.05 mm or less. The non-combustible decorative board according to any one of claims 1 to 3 , wherein the thin paper is arranged on one surface of the metal layer. The non-combustible decorative plate according to any one of claims 1 to 4 , wherein the plurality of holes are arranged in a hexagonal lattice in a plan view. The non-combustible decorative plate according to any one of claims 1 to 4 , wherein the plurality of holes are arranged in a square lattice in a plan view. The decorative layer contains a synthetic resin and is formed of a single layer or multiple layers.
The non-combustible decorative board according to any one of claims 1 to 6, wherein the thickness of the decorative layer is within the range of 0.06 mm or more and 0.18 mm or less. A first adhesive layer arranged between the base material and the metal layer,
A second adhesive layer disposed between the metal layer and the decorative layer is further provided.
The first adhesive layer is formed using an aqueous emulsion adhesive.
Any one of claims 1 to 7 , wherein the second adhesive layer is formed by using any one of an aqueous emulsion adhesive, a reactive hot melt adhesive, and a pressure-sensitive adhesive. The non-combustible decorative board described in item 1. The non-combustible decorative plate according to any one of claims 1 to 8 , wherein the base material is formed by using a volcanic vitreous multilayer plate. Further provided with a reinforcing layer laminated on the other surface of the substrate,
Claims 1 to 9 are characterized in that the reinforcing layer is formed of a double-sided thin paper-covered aluminum foil having two sheets of tissue paper and a metal foil arranged between the two sheets of tissue paper. The non-combustible decorative board according to any one of the above. Claims 1 to 10 are characterized in that the metal layer is formed of a double-sided thin paper-covered aluminum foil having two sheets of tissue paper and a metal foil arranged between the two sheets of tissue paper. The non-combustible decorative board according to any one of the above. The non-combustible decorative board according to claim 10 or 11 , wherein the thin paper is impregnated with a sealer agent. A sealer layer disposed between the metal layer and the decorative layer and containing a sealer agent is further provided.
The non-combustible decorative board according to any one of claims 1 to 12 , wherein the sealer layer has a content of the sealer agent of 5 g / m ^{2 or less in terms of a solid substance.} A method for producing a non-combustible decorative board in which a metal layer and a decorative layer are laminated in this order on one surface of a base material.
A hole forming step of forming a plurality of holes penetrating the metal layer in the thickness direction in the metal layer, and a smoothing step of smoothing the metal layer, which is a subsequent step of the hole forming step. And, including
In the hole forming step, the plurality of holes by cutting the metal layer is formed in a straight line shape having long sides and short sides, further, the length of the short sides than 0.01 mm 0. The length of the long side shall be within the range of 05 mm or less, the length of the long side shall be within the range of 2 mm or more and 20 mm or less along the first direction preset in the metal layer, and the two holes adjacent to each other along the first direction. The distance between the two holes adjacent to each other along the second direction orthogonal to the first direction shall be within the range of 10 mm or more and 30 mm or less.
The smoothing step is a method for producing a non-combustible decorative plate, which comprises smoothing the metal layer by crushing the uneven portion formed on the metal layer in the hole forming step. A method for producing a non-combustible decorative board in which a metal layer and a decorative layer are laminated in this order on one surface of a base material.
A hole forming step of forming a plurality of holes penetrating the metal layer in the thickness direction in the metal layer, and a smoothing step of smoothing the metal layer, which is a subsequent step of the hole forming step. And, including
In the hole forming step, the metal layer is cut to form the plurality of holes into a cross shape having a long side and a short side and two straight lines having the same shape are orthogonal to each other. The length of the short side is within the range of 0.01 mm or more and 0.05 mm or less, the length of the long side is within the range of 5 mm or more and 20 mm or less, and the two adjacent parts are adjacent to each other along a preset first direction. The holes are formed so that the distance between the centers of the two orthogonal straight lines is within a range of 10 mm or more and 30 mm or less, and the two holes adjacent to each other along the second direction orthogonal to the first direction are formed. The distance between the centers of the two orthogonal straight lines is 10 mm or more and 30 mm or less.
The smoothing step is a method for producing a non-combustible decorative plate, which comprises smoothing the metal layer by crushing the uneven portion formed on the metal layer in the hole forming step.

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