JPH05171596A - Production of nonflammable trim material - Google Patents

Abstract

PURPOSE:To provide the subject trim material improved in the filterability when coated with an adhesive, excellent in stability with time, having mechanical strength at least comparable to that of wood. CONSTITUTION:A solution prepared by incorporating (A) a water-dispersible polyesterurethane resin solution with (B) calcium silicate, glass fibers, titanium dioxide, a thickening agent and silane coupling agent is first put to papermaking process to be made into a glass fiber paper. Second, both surfaces of a plain- woven glass fiber fabric are laminated, through a high-viscosity resin solution containing the above-mentioned ingredients, with these glass fiber papers and the resulting laminate is pressed and heat treated. Then, another kind of glass fiber paper surface-colored by roll coating is applied on the surface of this laminate through hot contact bonding, thus obtaining the objective trim material excellent in designability. Reinforcement of this trim material with steel wires increases its mechanical strength, thus giving a second trim material usable as a structural material. The trim material of the present invention, which consists of a homogeneous material as a whole, is recyclable, having corrosion resistance, insect-proofness and craftwork nature as well as nonflammability, also contributing to protecting the natural environment.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a non-combustible interior material.

[0002]

2. Description of the Related Art Up to now, glass fiber has been widely known as a material having incombustibility, and cloths and felts made of glass fiber are commercially available. However, conventionally manufactured glass fiber paper is Since the glass fibers are adhered by the starch-based binder, the glass fiber as the base material does not burn, but the binder has ignitability and is not completely incombustible. Further, the conventional glass fiber paper has coarse eyes formed by entanglement of glass fibers, and even if an adhesive is applied to such a surface, the adhesive penetrates into the glass fiber paper and is filtered downward. Was
Since no adhesive remains on the surface, a sufficient adhesive force cannot be obtained, and it is very uneconomical to use a large amount of adhesive. Therefore, in order to solve such problems, it has been attempted to increase the thickness of the glass fiber paper, but it has not been possible to prevent the filterability. Further, there has been a problem that it is difficult to obtain a glass fiber paper having excellent decorative properties because it is difficult to color the surface of the glass fiber paper.

On the other hand, in recent buildings, in addition to appearance and functionality, disaster prevention is important, and in order to make everything from the interior space to the corridor incombustible and stop the fire,
It is necessary to make the interior materials non-combustible and to make non-combustible synthetic wood. However, for example, a plywood that has been widely used as a thin plate for interiors of buildings can be manufactured at low cost and is excellent in processability, but it does not have noncombustibility and is generally used for its surface treatment. Since a layer made of synthetic resin is provided, there is a big problem that a toxic gas is generated at the time of fire.

Therefore, in order to solve such a disaster prevention problem, the development of a new material having excellent incombustibility and the development of a processing method for imparting incombustibility to a general interior material have hitherto been made. Have been studied, and glass fibers, cloths and felts made of glass fibers, and the like have been commercially available as materials having excellent incombustibility. However, in the case of these materials, there is a problem in that commercially available non-combustible adhesives cannot firmly bond glass fiber materials to each other. Further, since it is difficult to apply a color to such a material made of glass fiber while maintaining excellent incombustibility, a material having excellent decorativeness cannot be obtained. Even if the colorant is dispersed in a resin that does not have it and applied to the surface of the glass fiber cloth, the base material itself does not burn, but there is a problem that the surface layer burns. Further, as a method for producing a non-combustible interior material, a method of making the surface of natural wood incombustible is also known. For example, in a red shell lattice using iron oxide, the appearance of wood as a natural material And can't hold the feel. Under such circumstances, an interior material having excellent nonflammability and decorativeness is desired today.

On the other hand, recently, deforestation for obtaining natural timber has become a problem that has an adverse effect on the environment. From the viewpoint of forest protection, development of a material replacing natural timber has attracted attention. Now, if it is possible to manufacture a non-combustible synthetic building material, it is possible to effectively protect wood resources. It is also desired to develop a recyclable synthetic building material from the viewpoint of environmental protection. However, up to now, few reports have been made on methods for producing synthetic building materials that replace natural wood at low prices.
In addition, cement, which has been widely used as a building material up to now, has a problem that it has low durability and is easily deteriorated with time, and development of a building material replacing cement is desired.

[0006]

DISCLOSURE OF THE INVENTION The present invention has improved the above-mentioned drawbacks and, while maintaining the excellent incombustibility of glass fibers, has a non-combustible interior material (glass fiber paper which prevents filterability). ) Is provided. Further, the present invention provides a method for producing a non-combustible interior material (synthetic building material) having excellent non-combustibility and stability over time, and having a strength equal to or higher than that of wood at a low cost. It is an issue. Furthermore, it is also an object of the present invention to provide a method for producing a non-combustible interior material whose surface is colored and a non-combustible interior material whose strength is improved while maintaining excellent non-combustibility of the base material. is there.

[0007]

The method for producing a non-combustible interior material according to the present invention comprises a water-dispersible polyester urethane resin solution containing no organic solvent and no emulsifier, calcium silicate, glass fiber, titanium oxide and a thickener. And to prepare a glass fiber dispersion by adding a silane coupling agent,
Paper making is performed using the glass fiber dispersion.

First, in the present invention, a glass fiber dispersion liquid is prepared as a raw material (a material used for carrying out a papermaking process) for producing a non-combustible interior material. The dispersion liquid is an organic solvent and Calcium silicate, glass fiber, titanium oxide, a thickener and a silane coupling agent are added to a water-dispersible polyester urethane resin solution containing no emulsifier, and these are uniformly dispersed for production. In this case, calcium silicate and glass fibers having a fine particle diameter contained in the glass fiber dispersion are for preventing the ignitability of the resin and for adjusting the density, and the thickener is the glass fiber dispersion. Is added in order to improve the processability of and to integrate the solid component and the resin component. Further, titanium oxide is added to make the background color of the interior material white, and may not be added if the background color does not have to be white. Furthermore, this dispersion contains
A silane coupling agent is added to enhance the adhesive force between the resin and the glass fiber, and the addition amount of the silane coupling agent in the present invention is about 1% with respect to the resin solid content.

In the present invention, the ratio of the inorganic substance to the solid content of the water-dispersible polyester urethane resin can be adjusted appropriately according to the application. However, if the proportion of the resin solid content is small, the inorganic substance is surely contained in the glass fiber. It becomes impossible to fix, and conversely, if the proportion of resin solids is high, sufficient incombustibility cannot be obtained. In particular, calcium silicate has a large particle surface area and a large density, and functions to enhance the adhesive force between glass fibers. That is, when calcium silicate is not added to the glass fiber dispersion liquid, the adhesive force between the glass fibers becomes very weak, and it is not possible to obtain a practical paper-like interior material. In the present invention, the resin solid content in the glass fiber dispersion is preferably 30 to 70 parts by weight with respect to 100 parts by weight of the inorganic substance, and the ratio of glass fiber to 100 parts by weight of calcium silicate is 30 to 70 parts by weight. It is preferably 120 parts by weight.

Further, in the present invention, since the water-dispersible polyester urethane resin solution which is the binder is water containing no organic solvent or emulsifier, no harmful organic solvent vapor is generated and the glass fiber dispersion liquid The dispersed state of each component dispersed in is stabilized, and an interior material having uniform physical properties can be obtained. Incidentally, as such a resin solution, a commercially available product containing no organic solvent and no emulsifier can be used, but among them, a particularly suitable one is a transparent film which has good nonflammability and adhesiveness and has large strength and flexibility. Can be formed uniformly, such as IMPRANIL. DLH. DISP (manufactured by Bayer) or IMPRANI.
L. DLN. DISP (manufactured by Bayer) and the like are mentioned, and the former is particularly preferable. Further, examples of the glass fibers added to the above glass fiber dispersion include glass fiber chop strands and those obtained by cutting glass fiber yarns, and it is preferable to mix fibers having different fiber lengths to obtain a desired viscosity. As the thickening agent added for this purpose, polyacrylic acid resin dispersion is preferable.

In the present invention, the glass fiber dispersion is applied to a paper machine to make a roll paper, and an interior material is obtained. When performing the paper making step, a general paper machine such as a Fourdrinier type is used. A wide range of paper machines and twin wire paper machines can be used. The thickness of the interior material obtained by the present invention is not particularly limited, and can be adjusted to the thickness according to the purpose by changing the papermaking conditions. The general thickness of the interior material produced by the present invention is about 0.2 mm. Moreover, in this papermaking process, the method of making paper can be arbitrarily changed, and when an interior material is manufactured and then a fine pattern is drawn or printing is performed on the surface thereof, it can be closely packed. It is preferable to produce a strained product.

The interior material produced by the above-mentioned method exhibits excellent noncombustibility because the raw material used has noncombustibility, and the glass fibers are firmly adhered to each other by the noncombustible resin. To be a structured structure,
It has excellent strength and prevents breakage and scattering, which are defects of glass fiber. Further, since this interior material has the property of being able to hold a fixed amount of a commercially available adhesive for glass fiber cloth on the surface, it is possible to easily perform the adhesion, and moreover, it has excellent resistance to water. As a result, it is possible to wash with water.

Further, it is possible to impart a color to the surface of the interior material produced by the present invention. In the case of imparting a desired color, the above-mentioned water-dispersible polyester urethane resin solution is colored with a coloring dye or an oxidant. The coloring liquid obtained by adding titanium,
The surface of the interior material should be coated. Roll coating can also be performed in this coating. still,
The coloring dye used at this time is preferably a dye having excellent light fastness and not discolored by heat, and an indanthrene dye having physical properties with a weather resistance of grade 8 as a standard, for example, Resin color ( Matsui dye company) and the like are suitable. In this way, the interior material obtained by coloring the surface with wood grain or drawing various patterns is a product with extremely high designability, and surface design paper such as wallpaper and furniture, Or it can be used as a painting. In addition to this, on the surface of the non-combustible interior material obtained by the present invention, a fluororesin may be uniformly applied to form a fluororesin layer. When such a resin layer is formed, , Light resistance, nonflammability, antifouling property, aging resistance, abrasion resistance and chemical resistance can be imparted.

The present invention is also a method for producing a non-combustible interior material having a larger thickness than the above-mentioned non-combustible interior material processed into a roll paper. In this method, an organic solvent and an emulsifier are used. Not containing water-dispersible polyester urethane resin solution, calcium silicate, glass fiber,
Titanium oxide, a thickening agent and a silane coupling agent are added to prepare a glass fiber dispersion liquid, and the step A for producing a glass fiber paper by papermaking the glass fiber dispersion liquid does not contain an organic solvent and an emulsifier, To the water-dispersible polyester urethane resin solution, calcium silicate, glass fiber, a thickener and a silane coupling agent are added to prepare a non-combustible solution (I), and the above non-combustible solution (I) is mixed with the glass fiber yarn. Extruded on both sides of a plain weave cloth woven using the glass fiber paper obtained in step A above,
Step B for laminating both sides of the plain weave cloth, and Step B
And a step C of heat-treating the laminated body obtained in step 1 while applying pressure.

First, in step A of the present invention, a roll-paper-like non-combustible interior material (glass fiber paper) is obtained in the same manner as the above-mentioned method. The glass fiber paper obtained in step A is Incombustible solution in step B to be performed later
If (I) is sparsely strained so that it can be easily impregnated inside, and is densely strained, a non-combustible solution
It becomes difficult for (I) to impregnate the inside, and sufficient adhesive strength cannot be obtained. Further, in the present invention, by using such a glass fiber paper, it is possible to obtain a laminate having good flatness because moisture in the inside easily escapes to the outside when laminated in a later step.

Next, FIG. 1 shows an example of manufacturing an incombustible interior material (synthetic building material) according to the present invention, and steps B and C in the method of the present invention will be described with reference to the drawings. First, as shown in FIG. 1, in the step B, the glass fiber paper 1 obtained in the step A is sent out from two places, an upper side and a lower side of the plain weave glass fiber cloth 3, and the glass fiber paper 3 From the tip slit 9, apply the incombustible solution (I) to the glass fiber cloth 3
The glass fiber cloth 3 and the glass fiber paper 1 are laminated by extruding the glass fiber cloth 3 and the glass fiber paper 1 on both sides of the glass to produce a laminate 2. The incombustible solution (I) used at this time is It was prepared by adding calcium silicate, glass fiber, a thickener and a silane coupling agent to a water-dispersible polyester urethane resin solution containing no solvent and no emulsifier. Further, as the plain weave glass fiber cloth 3, one woven using glass fiber yarn is preferable. In the present invention, the glass fiber paper 1 obtained in the above step A is sent from two or more places, and the incombustible solution (I) is provided between the layers.
It is also possible to extrude.

In the present invention, the surface hardness and the strength and elasticity of the obtained noncombustible interior material can be appropriately adjusted by selecting the resin according to the purpose, but the binding force and stability of the inorganic component and the resin component are stable. Due to its nature, the viscosity of the non-flammable solution (I) needs to be in a certain range. Generally, the preferred viscosity of such a non-flammable solution (I) is from 60,000 to 80
It is about 000 cps (25 ° C.), and the extruded thickness of the incombustible solution (I) is not particularly limited, but it is generally extruded from the tip slit 9 with a thickness of about 5 to 10 mm. In the present invention, it is necessary to use, as the pressure-feeding device 4, one capable of uniformly mixing the incombustible solution (I), capable of being adjusted according to the extrusion thickness, and capable of stable supply. In the present invention, not only can the thickness of the nonflammable interior material be increased by adjusting the viscosity of the nonflammable solution (I), but the amount of glass fiber used can be reduced, which is advantageous in terms of manufacturing cost. It will be

In such a non-combustible solution (I), glass fibers are mixed in the same water-dispersible polyester urethane resin solution used in the step A so as to cross each other, Calcium silicate is added to adjust the density. Further, the above-mentioned thickener is added to increase the viscosity, and after pressure feeding to a required thickness, heat and pressure are applied to obtain a required density. In this case, the same indanthrene dye as described above is suitable for imparting a desired color.

Further, in the subsequent step C, pressure and heat are applied from both sides to the laminated body 2 obtained in the above step B to remove water, and at the same time, the resin component in the incombustible solution (I) is removed. Is completely cured and the density is adjusted to obtain a plate-shaped noncombustible interior material. By this heat treatment step, the surface strength of the obtained non-combustible interior material can be improved, and the generation of toxic gas at the time of fire can be minimized. Generally, this heat treatment is preferably performed at a temperature of 150 to 160 ° C. As a method of applying pressure and heat from both sides to the laminate, a heat treatment drum 5 as shown in FIG. Is preferably adjusted to 150 to 160 ° C.

In the apparatus shown in FIG. 1, a plurality of pressure-bonding rolls 6 are in contact with the heat treatment drum 5, and the pressure-bonding rolls 6 apply pressure in the thickness direction. The first heat treatment drum is a synthetic rubber drum, and is provided with a water cleaning brush 7 and a rubber doctor 8 for cleaning the drum surface and is not heated. On the other hand, heat of 150 to 160 ° C. is applied to the surface of the heat treatment drums after the second heat treatment drum.
In order to make the non-combustible interior material obtained by the heat treatment into a flat surface, it is preferable that the diameter of the heat treatment drum 5 is 2000 mm or more so that the resin component contained in the non-combustible solution (I) is completely removed. To cure, the number of heat treatment drums 5 is 3
The above is preferable. The flat product after the heat treatment process is generally cut into a certain length by a cutting device.

The non-combustible interior material obtained by the above-mentioned steps A to C is, as shown in FIG. 2, the intermediate layer 10 formed by curing the non-combustible solution (I) on both surfaces of the glass fiber cloth 3. It has a cross-sectional structure in which the glass fiber paper 1 is laminated with the glass fiber paper 1 interposed therebetween, and has a large strength because the glass fiber cloth 3 is inserted and integrated in the central layer. When obtaining a thick building material, the laminated body shown in FIG.
It suffices if they are laminated and integrated with each other via the incombustible solution (I),
Since the non-combustible interior material obtained by the present invention is integrated by the non-combustible solution composed of the same components,
The interlayer strength is high, and the strength of the entire building material is also high.

Further, the interior material produced by the present invention exhibits excellent nonflammability because the raw material used has nonflammability, and the glass fibers are firmly bonded to each other by the nonflammable resin. It has a sufficient mechanical strength because it has an adhesively integrated structure. In particular, since the glass fibers cross each other after being bonded, the adhesive strength is high, and since a non-combustible resin containing calcium silicate is used, breakage and scattering, which are the defects of the glass fibers, are prevented. .. Further, unlike the natural wood, the non-combustible interior material obtained by the present invention hardly deteriorates with time and does not corrode. Moreover, since it has insect repellent properties and workability, it is a very excellent building material.

Further, in the present invention, the strength and specific gravity of the obtained non-combustible interior material change depending on the ratio of each component added, but the surface strength, the bending strength and the like are different from those of the resin and the inorganic material impregnated in the glass fiber. It can be sufficiently used in combination with a substance, and when the building material has a thickness of 15 mm or more, it can be used as a floor material of a gymnasium or the like. On the other hand, it is possible to obtain building materials of various weights by adjusting the addition ratio of calcium silicate. In addition, when using a thick building material,
The noncombustible interior materials obtained by the above steps may be further laminated together. Further, in order to impart properties such as light resistance strength, nonflammability, antifouling property, aging resistance, abrasion resistance and chemical resistance, the surface of the obtained nonflammable interior material is uniformly coated with a fluororesin. Just do it.

Further, in recent building materials, requirements other than strength and price are that they are visually excellent and have excellent tactile sensation. It is also a method for producing a non-combustible interior material having excellent decorative properties that satisfy such conditions. That is, in the production method of the present invention, the surface-colored glass fiber paper is applied to the surface of the synthetic building material obtained by the above-mentioned steps A to C via the non-combustible solution (II) which is a homogeneous paste. The surface-tinted glass fiber paper is obtained by adding calcium silicate, titanium oxide, a thickener and a coloring pigment to the water-dispersible polyester urethane resin solution. It is characterized by being manufactured by roll-coating the surface of the glass fiber paper obtained in the above step A with the non-combustible solution (III).

The glass fiber paper used in this case is generally a roll paper having a thickness of about 0.2 mm, and the glass fiber paper is calcium silicate or titanium oxide. Or containing coloring pigments,
The non-combustible solution (III) of the same quality as the paste is roll-coated and is densely filtered so that design can be imparted. on the other hand,
The non-flammable solution (II) used for bonding is prepared by adding calcium silicate and a thickener to a water-dispersible polyester urethane resin solution containing no organic solvent and emulsifier, and generally, In the invention, the viscosity range of the non-flammable solution (II) is preferably 10,000 to 30,000 cps.
(25 ° C). Then, the glass fiber paper to which the design property is imparted by the incombustible solution (III) is
It is arranged so that the coated surface of (III) is on the surface side, and it is adhered to the surface of the interior material obtained by the above-mentioned steps A to C by thermocompression bonding through the incombustible solution (II). A non-combustible interior material having excellent decorativeness, which is integrated with the non-combustible resin, can be obtained. The glass fiber paper surface-treated in this way has the same luster and hue as natural wood, and is rich in design effects.

FIG. 3 shows a cross-sectional structure of an example of the noncombustible interior material obtained by this manufacturing method. In the case shown in FIG. 3, the above-mentioned incombustible solution is formed on the surface of one glass fiber paper 1 of the noncombustible interior material shown in FIG.
A glass fiber paper 1'having a surface layer 12 formed by applying (III) is integrally bonded. In the present invention, in order to further increase the hardness of the surface, in the polyester urethane resin liquid described above, a mixture of glass fiber powder for imparting an incombustibility effect, after being thinly coated with a synthetic rubber doctor, You may heat-process with a 140 degreeC heat processing drum. A fluororesin layer may be provided on the surface layer 12. Incidentally, in the present invention, the hue of the surface of the obtained synthetic building material can be freely adjusted by changing the type and blending ratio of the pigment used, and when producing a nonflammable interior material having a hue The above-mentioned indanthrene dye may be added to the incombustible solution (III). Furthermore, in order to obtain the texture of the wooden surface, it is sufficient to mix mica flakes (mica powder),
The conventional thermocompression bonding or vacuum pressure bonding method and the embossing method may be used together.

The non-combustible interior material obtained by using the method of the present invention as described above has a very high decorativeness. Particularly, as the non-combustible solution (III), both the above-mentioned inorganic substance and coloring pigment are used. In the case of using those containing, the non-flammable interior material excellent in gloss and hue is obtained. In the present invention, the surface of the glass fiber paper produced by the papermaking process using the glass fiber dispersion described above, it is possible to apply any color by using the above-mentioned non-combustible solution (III), designability There is an advantage that a rich non-combustible interior material can be produced, and glass fiber paper colored by such a non-combustible solution (III) may be attached to both front and back surfaces.

Further, the present invention is also a method for producing a non-combustible interior material having excellent non-combustibility and extremely high strength. In this case, the glass fiber material obtained in the above step A is used. Paste the paper on the inner wall surface of the mold having the desired shape, and arrange the steel wire inside the mold, then fill the inside of the mold with the above-mentioned incombustible solution (I), pressurize, It is characterized in that it is taken out from the mold after heat treatment to cure the resin component.

FIG. 4 shows a cross-sectional structure of a prismatic non-combustible interior material obtained by a method using such a molding die. Inside the glass fiber paper 1, five cross-sections are shown. A steel wire 11 is inserted, and the steel wire 11 has a structure in which the intermediate layer 10 formed of the incombustible solution (I) is filled around the steel wire 11. As the glass fiber paper 1, it is preferable to use the glass fiber paper obtained in the above step A. In addition, in the present invention, since the insertion amount of the steel wire 11 can be appropriately adjusted according to the mechanical strength required, a structural material corresponding to various uses can be manufactured. In order to obtain a structural material having a design property, the glass fiber paper obtained in step A may be used by being roll-coated with the above-mentioned incombustible solution (III).

In the present invention, as an application example thereof, a roof tile of Japanese architecture can be manufactured by the above method. After the roof tile is processed into the shape of the roof tile by the above method using a plaster mold, A structure with sufficient resistance against disasters can be obtained by adhering the overlapping parts with an adhesive or the like to integrate the entire roof, and this structure can be cracked even if impact force is applied. There is also no fall. Further, this structure has excellent resistance against heating, cooling, drying or humidification, and hardly deteriorates with time.

Further, in the case of producing a deformed molding material as a substitute for furniture wood by using the present invention,
Make a desired prototype with gypsum etc., put the above-mentioned glass fiber paper in this, inside it, the above water-dispersible polyester urethane resin solution, glass fiber chop strands, calcium silicate, thickener and silane The dispersion containing the coupling agent is filled, molded, and taken out from the original mold. At this time, in order to give a design to the surface, the resin having the dye dispersed therein may be applied and colored on the surface of the molded article by a crafting method.

For the purpose of increasing the surface hardness, a mixture of the above water-dispersible polyester urethane resin liquid and glass fiber powder is thinly applied with a doctor made of synthetic rubber, and then heat-treated again to give a surface treatment. It is also possible to obtain a non-combustible interior material having grain. In this way, according to the present invention, any deformed curved surface can be manufactured by the prototype, so that after manufacturing non-combustible parts, these are assembled to produce furniture having various complicated shapes, such as a desk or a chair. Etc. can also be manufactured. Further, in the present invention, it is possible to produce a raw wood such as Kitayama log, which is a natural material, by replicating it with a gypsum mold and then performing a surface processing step, such as hue and hardness of a black or purple platform. You can also reproduce the texture.

As described above, the interior material produced by using the present invention exhibits excellent nonflammability, has a variety of textures and colors, and is superior in strength to natural products. In addition, it can be widely used as a substitute for natural wood. Moreover, it is superior in cost to natural wood and contributes to the protection of forests and the environment. After use, the interior material is crushed and the interior material is manufactured again using this as a raw material. It is possible to recycle. Hereinafter, the present invention will be described more specifically with reference to Examples, but the present invention is not limited thereto.

[0034]

【Example】

Example 1: Method for producing non-combustible glass fiber paper First, a water-dispersible polyester urethane resin liquid IMPRANIL.
DLH. DISP (Bayer, solid resin content: approx. 40%) 10
0 parts by weight, 20 parts by weight of glass fiber (1 cm),
Calcium silicate (Tokuyama Soda Co., Ltd., trade name: Tokushiru)
50 parts by weight, 20 parts by weight of titanium oxide and 4 parts by weight of silane coupling agent were added and mixed uniformly, the resulting solution was diluted 5 times with water, and then a polyacrylic acid resin-based dispersant was used as a thickener. John (Chuo Dyeing Co., Ltd., thickener # 110) was gradually added to prepare a glass fiber dispersion. Then, using this glass fiber dispersion, papermaking was carried out by a Fourdrinier paper machine to produce glass fiber paper having a thickness of about 0.2 mm which was processed into roll printing paper.

Then, to 100 parts by weight of the above water-dispersible polyester urethane resin solution, 0.2 parts by weight of indanthrene dye, 40 parts by weight of titanium oxide and 4 parts by weight of calcium silicate are added as a non-flammable coloring dye, and uniformly added. The colored liquid obtained by stirring and thickening was designed on the surface of the glass fiber paper obtained above to obtain an interior material (wallpaper) having a wooden design on the surface.

The glass fiber paper obtained by this example is excellent in decorativeness due to the design on the surface, and its fireproof performance is shown in
As a result of examination by the test method prescribed in No. 1828, it was confirmed to have nonflammability that passes this test. The glass fiber paper was also excellent in stability over time. Furthermore, when an adhesive was applied to the surface of this glass fiber paper, the adhesive did not soak into the inside of the glass fiber paper, and it was possible to bond the glass fiber paper to each other with the minimum necessary amount of adhesive.

Example 2 Method for Producing Nonflammable Wall Sheet Material First, in step A, a filter paper-like glass fiber paper having a thickness of about 0.2 mm was prepared in the same manner as the method described in Example 1 above. Then, in step B, 100 parts by weight of the above water-dispersible polyester urethane resin liquid is added,
15 parts by weight of glass fiber chop strands, 40 parts by weight of calcium silicate, 20 parts by weight of titanium oxide, 4 parts by weight of silane coupling agent and 150 parts by weight of water were added and uniformly mixed, and used as a thickener in the above step A. The same polyacrylic acid resin-based dispersion as described above was gradually added to prepare a nonflammable solution (I) having a viscosity of about 70,000 cps (25 ° C.). Then, the incombustible solution (I) is put into a pressure-feeding device as shown in FIG.
(I) was applied to both sides of a plain weave glass fiber cloth (30 g / m ² ) woven in the same manner in the length and width directions using glass fiber yarns, each having a thickness of about 5 mm from the tip slit of the pressure feeding device, and between the glass fiber papers. The glass fiber paper obtained in the above step A was laminated while being extruded to form an intermediate layer.

Then, in the subsequent step C, using a dryer having eight heat treatment drums (diameter of about 2 m) to which a release agent for preventing adhesion is applied on the surface in advance, the step B is integrated. Heat was applied from both sides of the laminated body.
At this time, as shown in FIG. 1, each heat treatment drum is provided with a plurality of pressure bonding rolls so that pressure is applied in the thickness direction to obtain an interior material having a thickness of about 5 mm. It was The surface temperature of the heat treatment drum was set to 150 ° C. for the second heat treatment drum and 160 ° C. for the third to eighth heat treatment drums without heating the first heat treatment drum. In this way, the interior material having the sectional structure shown in FIG. 2 was obtained.

The fireproofing performance of the interior material obtained in this Example 2 was examined by the test method prescribed in Ministry of Construction Notification No. 1828 in 1965, and it was confirmed that the fireproofness passed the test. It was In addition, this interior material has a large strength because it has a structure in which glass fibers intersect with each other, and is excellent in terms of temporal stability.

Example 3: Method for producing non-combustible plate material having a design on the surface 100 parts by weight of the same water-dispersible polyester urethane resin solution as in Example 1, 20 parts by weight of glass fiber (1 cm), 50 parts by weight of calcium silicate Parts, 20 parts by weight of titanium oxide and 4 parts by weight of silane coupling agent were added and mixed uniformly, and the resulting solution was diluted with water 3 times, and then a thickener similar to that in Example 1 was gradually added. In addition, a glass fiber dispersion was prepared. Then, using this glass fiber dispersion, a papermaking process was carried out by a papermaking machine to produce a glass fiber paper having a thickness of about 0.2 mm which was processed into roll printing paper.

Next, in 100 parts by weight of the water-dispersible polyester urethane resin liquid similar to that in Example 1, 0.2 parts by weight of indanthrene-based dye as a non-flammable coloring dye and 4 parts of titanium oxide.
0 parts by weight and 4 parts by weight of calcium silicate were added, and the mixture was uniformly stirred and thickened to give the non-combustible solution (III) designed on the surface of the glass fiber paper obtained above, A glass fiber paper having a wood design was manufactured.
On the other hand, as a non-combustible solution (II) for laminating this glass fiber paper, 20 parts by weight of calcium silicate and water were added to 100 parts by weight of the same water-dispersible polyester urethane resin solution used in the above step A. Then, the mixture was uniformly mixed, and the same polyacrylic acid resin dispersion as that used in the above step A was gradually added as a thickener to prepare a viscosity of about 16000 cps (25 ° C.).

Then, the above glass fiber paper is
The surface coated with the non-combustible solution (III) is placed on the outer side, and the non-combustible interior material obtained in Example 2 is pasted through the non-combustible solution (II) and thermocompression bonded. Integrated. The interior material obtained in this Example 3 has a design property on the surface and, as a result of investigating its fireproof performance in the same manner as in Example 1, it is a noncombustible interior material that passes this test. confirmed.

Example 4: Method for producing non-combustible structural material in which steel wire is arranged Inside of the glass fiber paper having a colored surface is produced in the same manner as in Example 3, while using a molding die. A plaster mold having a prismatic cavity having a square cross-sectional shape with a side length of 30 cm was produced. Then, the above glass fiber paper was attached to the inner wall surface of the plaster mold, and further, inside the molding mold, as shown in FIG. Four high-tensile steel wires having a diameter of about 10 mm were arranged around the wire. Then, the incombustible solution having the same composition as in Example 2 above.
Pour (I) into the mold and apply pressure 1
A heat treatment was performed at 60 ° C. to cure the resin component, and after cooling to room temperature, the molded product was taken out. The square bar thus obtained is excellent in strength because it has a structure in which a high-strength steel wire is inserted, and it has the same excellent non-combustibility as in the case of Example 1. Showed sex.

Example 5: Method for manufacturing non-combustible shoji screen A non-combustible interior material obtained in Example 2 is further laminated to prepare a shoji cross, while the shoji paper is used as above. A glass fiber paper was produced in the same manner as in Example 1. Then, the above-mentioned shoji paper was attached to the shoji of the above-mentioned shoji screen to produce a shoji screen that was entirely processed to be incombustible. The shoji produced in this way exhibits excellent non-combustibility as a whole, and because the shoji paper has high strength and excellent resistance to water, it can be washed completely with water and always kept clean. It was something that could be kept.

[0045]

As described above, by using the present invention, an interior material having excellent nonflammability and stability over time can be manufactured by a relatively simple process. In particular, in the present invention, when a non-combustible interior material is manufactured, a water-dispersible polyester urethane resin solution containing an inorganic substance such as calcium silicate is used, and since it is integrated by a resin solution of the same quality,
The adhesion between the glass fibers becomes strong, and the glass fibers have excellent strength. In particular, in the glass fiber paper produced according to the present invention, since the filterability of the adhesive is improved, it is possible to perform the bonding using a small amount of the adhesive, and the glass fiber paper The surface of is suitable for use as a surface design paper such as wallpaper or furniture because it can be given a design and a high-class feel by applying various colors with a similar non-combustible resin solution in which a colorant is dispersed. ing.

The non-combustible interior material obtained by the present invention does not generate toxic gas at the time of fire,
Moreover, since silica stone, which exists in large quantities on the earth, is used as the main raw material, it is possible to respond to the current wood price due to mass production effects.
There is also an advantage that it is excellent in terms of price and practicality. Moreover, since this non-combustible interior material can be used in place of natural wood, it is the most useful means for forest and environmental protection. Furthermore, the non-combustible interior material manufactured according to the present invention can be completely recycled by pulverization because it is entirely made of the same material. In addition, as an excellent advantage of the non-combustible interior material obtained by the present invention, unlike natural wood, hardly deteriorates with time,
Since it does not corrode and has insect repellent properties and workability, it is extremely excellent as a building material. In the present invention, the non-combustible solutions (I) to (III) used in producing the synthetic building material are water containing no organic solvent or emulsifier, and therefore vapors of harmful organic solvents are generated. Moreover, there is also an advantage at the time of processing that the dispersion state of each component dispersed in the incombustible solution is stable.

Further, in the present invention, a building material having excellent strength can be manufactured by inserting a steel wire inside the structural material, and since molding is performed using a mold, the shape is complicated. Even if there is, it can be manufactured. At this time, by applying various colors to the surface of the glass fiber paper, it is possible to obtain a structural material having a design and high quality.

[Brief description of drawings]

FIG. 1 is a diagram showing an example of manufacturing a non-combustible interior material according to the present invention.

FIG. 2 is a view showing a cross-sectional structure of a noncombustible interior material obtained by the manufacturing method shown in FIG.

3 is a diagram showing a cross-sectional structure when a glass fiber paper 1 ′ provided with a surface layer 12 is attached to the surface of the noncombustible interior material shown in FIG.

FIG. 4 is a view showing a cross-sectional structure of a non-combustible structural material having a structure in which an outer peripheral portion is covered with a glass fiber paper 1 and a steel wire 11 is inserted inside.

[Explanation of symbols]

 (I) Incombustible solution 1, 1'Glass fiber paper 2 Laminated body 3 Plain weave glass fiber cloth 4 Pressure feeding device 5 Heat treatment drum 6 Crimping roll 7 Water cleaning brush 8 Rubber doctor 9 Tip slit 10 Intermediate layer 11 Steel wire 12 Surface layer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Internal reference number FI Technical display location D21H 19/44 17/53 17/63 17/67 7199-3B D21H 3/60 7199-3B 3 / 66 7199-3B 3/78

Claims (4)

[Claims] 1. A water-dispersible polyester urethane resin solution containing neither organic solvent nor emulsifier, calcium silicate,
Glass fiber, titanium oxide, a thickening agent and a silane coupling agent are added to prepare a glass fiber dispersion, and papermaking is performed using the glass fiber dispersion, a method for producing a non-combustible interior material .. 2. A water-dispersible polyester urethane resin solution containing neither organic solvent nor emulsifier, calcium silicate,
Step A in which glass fiber, titanium oxide, a thickener and a silane coupling agent are added to prepare a glass fiber dispersion, and the glass fiber dispersion is paper-made to produce glass fiber paper, an organic solvent and an emulsifier are added. To the water-dispersible polyester urethane resin solution, which does not contain calcium silicate, glass fiber, thickener and silane coupling agent, prepare a non-combustible solution (I), and add the non-combustible solution (I) to plain weave. Step B, in which the glass fiber paper obtained in the above step A is laminated on both sides of the plain weave cloth by extruding onto both sides of the glass fiber cloth, and heat treatment is applied to the laminate obtained in the above step B under pressure. The method for producing a non-combustible interior material, comprising: 3. A non-flammable solution (II) obtained by adding calcium silicate and a thickener to a water-dispersible polyester urethane resin solution containing no organic solvent and no emulsifier, and obtained by the above steps A to C. On the surface of the obtained synthetic building material, a surface-colored glass fiber paper is attached by thermocompression bonding, wherein the surface-colored glass fiber paper is the water-dispersible polyester urethane resin solution,
It is manufactured by roll-coating the surface of the glass fiber paper obtained in the above step A with the incombustible solution (III) obtained by adding calcium silicate, titanium oxide, a thickener and a coloring pigment. The method for producing a noncombustible interior material according to claim 2, characterized in that 4. A water-dispersible polyester urethane resin solution containing neither organic solvent nor emulsifier, calcium silicate,
After the step A in which glass fiber, titanium oxide, a thickener and a silane coupling agent are added to prepare a glass fiber dispersion, and the glass fiber dispersion is paper-made to produce a glass fiber paper, the above step A is performed. The glass fiber paper obtained in step (1) was attached to the inner wall surface of the mold, and after the steel wire was placed inside the mold, the water-dispersible polyester urethane resin solution containing no organic solvent and emulsifier was treated with silicic acid. The incombustible solution (I) obtained by adding calcium, glass fiber, a thickener and a silane coupling agent is filled in the inside of the above-mentioned molding die, pressurized, heat-treated, and then taken out from the die. A method for producing a non-combustible interior material.