JPH0217867Y2 - - Google Patents

Description

[Detailed Description of the Invention] (Industrial Application Field) The present invention relates to the improvement of inorganic decorative boards used as surface materials for architectural interiors, exteriors, furniture surface boards, etc.

(Prior art) The present applicant filed Utility Application No. 51-66564 (May 1978).
No. 58-42118, filed on the 24th), the main aggregates are aluminum hydroxide, calcium carbonate, etc., and are bonded to the surface of an inorganic substrate using a thermosetting resin binder. Therefore, a surface resin layer is formed, and an organic material is sealed inside this surface resin layer or a patterned surface is provided on the substrate, and an organic material is sealed between the back surface of this substrate and the surface resin layer or patterned surface of the substrate. - An inorganic decorative board was provided in which a net made of inorganic fiber was arranged, backer paper was arranged on the back side, and these were bonded together.

This inorganic decorative board is manufactured by Japanese Patent Application No. 1973-93583 (filed on August 14, 1970, Japanese Patent Publication No. 54-3704) and Japanese Patent Application No. 20209 (Showa 50), which are also filed by the present applicant.
This was made in order to solve the problems of mechanical strength and curved surface of the inorganic decorative board provided in the patent application filed on February 17, 1983, Japanese Patent Application Laid-Open No. 51-93983), and this improvement made it possible to prevent impact and bending. This reinforced its mechanical strength and effectively prevented it from warping, further increasing its commercial value, and it came to be widely used as a highly practical decorative board in various fields.

(Problem that the invention aims to solve) In addition to having the above-mentioned excellent properties, this inorganic decorative board is noteworthy in that its layer structure is stable because the mesh blends well with the substrate and pattern surface. It is something that will be done. However, with the diversification of applications, in certain fields there may be a need for improved interlayer adhesion strength or even greater impact resistance in the mesh part.
Therefore, it is no exaggeration to say that in order to take advantage of the above-mentioned excellent characteristics and further increase demand, it is a major mission for manufacturers to make further improvements and further improve quality. It wasn't.

(Means for Solving the Problems) The present invention was made in view of the above, and it is possible to connect nets, filaments, paper-like bodies, and fiber chops made of organic/inorganic fibers to the above-mentioned inorganic fibers through a synthetic resin adhesive layer. By interposing the decorative board between the substrate and the backer paper or between the substrate and the pattern surface (or the surface resin layer if the pattern surface is integrally encapsulated with the surface resin layer), the above-mentioned interlayer The adhesive strength is intended to further increase impact resistance.

(Embodiment) An embodiment of the present invention will be described in detail with reference to the accompanying drawings, together with its operation. Fig. 1 is a perspective view of an embodiment of the invention, and Fig. 2 is a cross-sectional view taken along the line -- of Fig. 1. The partially enlarged view, FIG. 3, is a similar view of another embodiment.

(Example 1) Figures 1 and 2 show an inorganic decorative board P whose surface is embossed with a mosaic tile pattern. Inorganic material such as aluminum hydroxide or calcium carbon is bonded and solidified with a thermosetting synthetic resin binder. The inorganic substrate 1, the same adhesive layer 5' as above, the same net body 4' (however, after being crimped and integrated, it will be buried in the adhesive layer 5' as shown in the figure), the pattern surface 3 and the heat A surface resin layer 2 made of curable synthetic resin is integrally laminated. Such a decorative board P is made of solid powder of hydroxyaluminum or calcium carbonate, reinforcing material of glass fiber chops (5 mm length), and phenolic resin (resol type).
A thermosetting synthetic resin binder is mixed and preformed into a plate shape, and a semi-cured phenol or melamine resin sheet (thickness 0.05 to 0.5
mm) and place a glass fiber net (50g/mm) on top of it.
² m2 (equivalent to about 10 mesh), and
On top of this, a patterned surface member made of patterned paper impregnated with melamine resin and dried to reveal a desired pattern (for example, wood grain or marble pattern) is placed, and then a transparent overlay paper, that is, a surface resin impregnated with melamine resin and dried, is placed. At the same time as covering the member, a backer paper is placed at the bottom of the lower die of the mold, and a net similar to the above net is placed on top of it, and the above semi-cured thermosetting synthetic resin sheet is further placed. Then, the preformed plates on which the above-mentioned nets, patterned surface members, etc. were placed were stacked and filled into the mold at a temperature of 150℃ and a pressure of 100Kg/cm ²
It is obtained by hot pressing under the following molding conditions. Note that instead of the upper and lower semi-cured thermosetting synthetic resin sheets, it is also possible to form a film by flow-coating a melamine or phenol resin liquid onto a predetermined position using a flow coater method or the like, and then hot pressing in the same manner. Furthermore, the glass fibers constituting the nets 4, 4' may be freely replaced with organic fibers such as vinylon fibers.

The thus obtained inorganic decorative board P is reinforced by the nets 4 and 4' present on the front and back surfaces, and has excellent bending strength, impact strength, etc.
In addition to preventing as much as possible the bending phenomenon caused by the difference in expansion properties due to temperature and humidity between the front surface and the back surface, the thermosetting synthetic resin adhesive layers 5, 5'
By interposing the adhesive layer 5, 5', the adhesive layer 5, 5' is bonded to the backer paper 6 and the substrate 1 so as to include the mesh bodies 4, 4'. and between the substrate 1 and the pattern surface 3 or the surface resin layer 2, so that it blends in with the thermosetting synthetic resin bonding material in the substrate 1 during pressure bonding.
Furthermore, it blends well with the pattern surface 3 and the surface resin layer 2, which are made of thermosetting synthetic resin, and also penetrates between the fibers of the backer paper 6, thereby firmly adhering each layer, even under the harsh conditions described above. Even if used for a long time under the surface, problems of delamination will not occur.

(Example 2) The inorganic decorative board _P1 shown in Fig. 3 is made into a paper-like material by paper-making inorganic/organic fibers such as glass fiber and vinylon fiber, and the paper-like material is heated with phenol resin, melamine resin, etc. A material impregnated with a curable synthetic resin liquid and dried (semi-cured) is integrally crimped in place of the semi-cured thermosetting synthetic resin sheet and net body in the above embodiment. In the decorative board _P1 ,
The paper-like bodies 41, 41' are the net bodies 4, 41, 41' of the above embodiment.
In addition to functioning as a reinforcing body similarly to 4', the thermosetting synthetic resin impregnated and supported on the paper-like bodies 41, 41' acts as adhesive layers 51, 51', ensuring strong adhesion between each layer. . Furthermore, when manufacturing the decorative laminate P of the first embodiment, it is necessary to pay close attention to avoid distortion when laminating the nets, but in this embodiment, such troubles are avoided. In addition, the net body becomes bulky at the intersections of the warp and weft yarns, and fine convex portions appear on the surface after hot pressing, which may impair the appearance, but this example has the advantage that there is no such concern. is also added.

In addition to the above examples, inorganic/organic fibers such as glass fibers and vinylon fibers are spun into filaments, which are arranged in a vertical and horizontal cross pattern through the adhesive layer and bonded together in the same way. An inorganic decorative board (not shown), or one obtained by kneading the above-mentioned fiber chips into a thermosetting synthetic resin liquid and molding it into a semi-hardened state, or one in which the above-mentioned fiber network is impregnated inside an adhesive layer of thermosetting synthetic resin. An inorganic decorative board (not shown) or the like which is used in place of the resin-impregnated paper-like material in the second embodiment and crimped together in the same manner has the same effect as the above, and does not deviate from the present invention. . In addition, in the above embodiment, reinforcing bodies such as net bodies 4, 4' and paper-like bodies 41, 41' and adhesive layers 5, 5', 51, 51' are arranged on the front and back surfaces of the substrate 1. From the viewpoint of preventing bending, it is essential to place it on at least the back side, and depending on the required strength, it can also be placed on the front side as appropriate, as shown in the figure.

(Effects of the invention) As described above, the inorganic decorative board of the present invention is such that the fiber net as a reinforcing body in conventional inorganic decorative boards of this kind is crimped and integrated through an adhesive layer of thermosetting synthetic resin. As a result, the mechanical strength such as excellent bending resistance and impact resistance, as well as the ability to prevent bending are maintained, and the impact resistance is further improved by imparting elasticity to the adhesive layer. The product is firmly attached to the product, making it more suitable for use in areas with high humidity and rapid temperature changes, and other harsh conditions, further increasing its commercial value. Furthermore, by using a paper-like material made of the above-mentioned fibers impregnated with a hard synthetic resin, in addition to the above-mentioned advantages, it is possible to reduce the complexity of manufacturing, and to suppress the occurrence of defects in product appearance. The value of the inorganic decorative board of the present invention having such numerous advantages is extremely high.

[Brief explanation of the drawing]

Fig. 1 is a perspective view of an embodiment of the present invention, Fig. 2 is a sectional view taken along the line - - of Fig. 1 and its partially enlarged view, and Fig. 3 is a perspective view of an embodiment of the present invention.
The figures are similar views of other embodiments. Explanation of symbols, 1...Inorganic substrate, 2...Surface resin layer, 3...Pattern surface, 4, 4'...Network, 4
1, 41'... paper-like material, 5, 5', 51, 51'...
...Hard synthetic resin adhesive layer.

Claims (1)

[Scope of utility model registration request] An inorganic substrate formed by heat-pressing an inorganic aggregate containing a thermosetting resin binder; a surface resin layer integrally formed on the surface of the substrate by the heat-pressing during molding of the substrate; In an inorganic decorative board consisting of a patterned surface sealed inside the surface resin layer itself or provided on an inorganic substrate, the back surface of the inorganic substrate and the substrate and the surface resin layer or patterned surface are At least on the back side of the substrate between them, a net made of inorganic fibers such as glass fibers or organic fibers such as vinylon fibers, filaments spun from these fibers, and paper-like materials made from these fibers. and an inorganic decorative board characterized in that these fiber chips are arranged via a thermosetting synthetic resin adhesive layer, and a backer paper is further arranged on the back side of the substrate, and these are integrally bonded together.