JPH05293932A - Wall decorating sheet and wall decorating sheet composite panel - Google Patents

Abstract

PURPOSE:To obtain a wall decorating sheet based on inorg. matter having fireproof capacity and safety and a wall decorating sheet composite panel using said sheet. CONSTITUTION:An inorg. matter base wall decorating sheet 6 having a three- dimensional uneven decorative surface is composed of a sheet like molded article with a wt. basis of 500g/m2 or more obtained by coating the surface of a fire retardant or non-combustible sheet like substrate with an inorg. matter base paint based on an ethylene/vinyl acetate queous emulsion resin, a fire retardant agent and an aluminum hydroxide powder and drying the coated substrate to compound the paint with the substrate. The inorg. base wall decorating sheet 6 is bonded to and compounded with the entire surface of a panel or to the entire surface and cut end of the panel to obtain an inorg. matter base wall decorating sheet composite panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wall-mounting sheet mainly composed of an inorganic material, which has fireproof performance and safety, and a wall-mounting sheet composite panel using the same.

[0002]

Conventional wall wear sheets, polyvinyl chloride is in mainly mineral wallpaper amount normally basis is 500 g / m ² or less, most were 200 to 400 g / m ^2. Thick inorganic wall coverings are not sheet-shaped, but are mainly coated on-site, so-called plastering.
As a roll-shaped wallpaper, there is no thick, deeply carved three-dimensional pattern. In particular, when the amount of the inorganic material is large, it lacks flexibility, has no bending resistance, and cracks and cracks.
When trying to give fire protection as wallpaper, the above problems occur. Conventional flame-retardant wallpaper is as thin as possible
The fire resistance equivalent to that of the base material was given at about 150 to 350 g / m ² .

In the case of fireproof wall covering materials, as is the case with paper wallpaper and woven wallpaper, in case of wall covering materials having a high degree of fireproof performance, such as the first grade of fireproof wallpaper, the wallpaper weight (grammage) 500 g / m ²
It is prescribed as follows. As described above, when the organic paper or woven fabric is used, it becomes more difficult to secure the fireproof performance as the basis weight increases. There is no limit to the weight of the inorganic wallpaper, which is mainly composed of inorganic materials, but the weight of the inorganic wallpaper with a blending composition that uses a polymer resin as a binder is 50%.
0 g / m ² or more, especially in heavy like 700~1500g / m ^2, organic a bond agent, to the amount of the resin come increases, the can be realized a high fire performance as fire primary It will be very difficult.

On the other hand, if the amount of the resin component is decreased and the amount of the inorganic component (inorganic filler) is increased, the fireproofing performance is improved, but as the wallpaper, the wallpaper tends to be harder and the bending resistance is improved. There is a drawback that cracking and the like are likely to occur during processing, and that the strength of the surface layer of the wallpaper is reduced and the wall becomes brittle. As described above, it is necessary to use a certain amount of resin components in order to secure the folding resistance and surface strength of the wallpaper, but in this case, in order to secure high fire protection performance, the type of resin used And the amount of resin, the selection and usage of flame retardant, the type and usage of fireproof fillers and auxiliaries, etc. are the most important points in terms of formulation.

On the other hand, with regard to wallpaper, which is a wall-mounted product,
Recently, the following two types of market needs have been demanded. (1) Increasing demand for inorganic wallpaper Inorganic appearance and feel are more favored than vinyl resin-like appearance and feel. For this reason, it is essential to use an inorganic-based paint for the wallpaper surface coating.

(2) Demand for a decorative surface having a three-dimensional concavo-convex pattern It has been desired to embody a decorative surface having a three-dimensional concavo-convex pattern with a relatively deep carved appearance. For that purpose, the coating layer on the surface of the wallpaper needs to have a certain thickness, and as a result, the weight of the wallpaper needs to be increased. That is, for this, the basis weight is 500 to 1500 g
It is necessary to make a high-weight wallpaper of about / m ² . However, in order to secure high fireproof performance [fireproof performance (1st grade) stipulated by Fire Protection Wall Material No. 0005 (inorganic wallpaper) defined by the Association for Wall Materials] in such heavy wallpaper It is essential to use, as the inorganic-based paint used for the surface coating, a paint having a very high fireproofing composition. At the same time, increasing the weight of the wallpaper tends to increase the thickness of the wallpaper, and generally, the greater the thickness of the coating layer, the lower the bending resistance and the more severe the strength. Therefore, it is necessary and important to adopt an inorganic-based paint which has sufficiently good bending resistance for thick wallpaper.

[0007]

In view of these points, the present invention has an object to provide a wall-mounted sheet and a wall-mounted sheet composite panel which solve the following problems (1) to (3). (Reserved) embodied inorganic metallic wall wearing sheet having a full-scale fire performance and safety, the weight (basis weight) 500 g / m ² or more, more preferably a high weight, such as 700~1500g / m ² However, it has a high fireproof performance, that is, the fireproof performance specified by Wall Material No. 0005.
Realization of high safety wallpaper that has (first grade), low smoke generation, and does not generate special malignant gas such as chlorine gas, hydrochloric acid gas, hydrocyanic acid gas, etc. Embodying a wallpaper with a decorative surface with a conspicuous three-dimensional uneven pattern, embodying a wallpaper with an inorganic appearance and feel, embodying an inorganic main wall sheet with excellent bending resistance, and an inorganic main surface with excellent surface strength Realization of wall covering sheet, realization of inorganic-based wall covering sheet with minimal change over time, as seen in vinyl chloride resin wallpaper and paper wallpaper Realization of an inorganic-based wall covering sheet that has no fading or is extremely small, has high moisture permeability and humidity adsorbability because it is an inorganic-based paint, and has humidity breathability that can respond to changes in indoor humidity, One high basis weight embodying Shimebun stock in large wall covering sheet in order to be, that is, realization of superior wall covering sheet of moisture-permeable and moisture breathability is.

[0008]

[Means for Solving the Problems] The above problems have been solved by developing an inorganic-based wall-mounting sheet and an inorganic-based wall-mounting sheet composite panel having the following structure. That is, an ethylene vinyl acetate-based aqueous emulsion resin, a flame retardant, an aluminum hydroxide powder, and a zinc-borate powder-based inorganic-based paint were applied on the surface of a flame-retardant or non-flammable sheet-like substrate and dried and composited. Inorganic main body wall covering sheet consisting of a sheet-shaped molded product having a basis weight of 500 g / m ² or more, the inorganic main body wall covering sheet described in that the surface of the inorganic main body wall covering sheet is a three-dimensional uneven decorative surface, and the inorganic main wall described above A composite sheet for an inorganic main wall-wearing sheet, which is a composite sheet in which a wearing sheet is rotated over the entire surface of the panel or between the surface and the surface to a small surface or a part of the small surface, and is bonded and composited.

Here, the ethylene-vinyl acetate copolymer-based aqueous emulsion resin is a so-called copolymer obtained by emulsion polymerization of ethylene and vinyl acetate, and is a resin in an aqueous emulsion state, and usually 40 to 60.
Refers to the resin with a solid content concentration of%. The resin used in the present invention is a resin that is stretchable to some extent in order to exhibit excellent bending resistance, and has a glass transition point of −
Use a resin in the range of 20 ° C to + 10 ° C. The flame retardants are commonly used in the market, and specific examples include halogen compound type, organic phosphorus compound type, organic sulfur compound type, organic sulfur phosphorus compound type, organic sulfur halogen compound type, halogen polyvalent metal. A flame retardant such as an oxide type may be used. The inorganic-based paint refers to a paint in which the weight ratio of the inorganic powder filler is 65% or more in terms of the solid content of the paint.

In the inorganic-based paint of the present invention, as an inorganic powder filler for imparting fire resistance,
Aluminum hydroxide powder and zinc borate powder are used as the main component of the inorganic powder filler, which is an essential inorganic filler. In addition, calcium carbonate powder, clay powder, color pigment or as an inorganic powder-based auxiliary filler. Titanium oxide powder as a concealing property-imparting filler, inorganic color pigments of each color as a colorant, and the like are also used as necessary. Since it is a paint, defoaming agents, dispersants, thickeners and the like are used as auxiliary additives as minor additives, if necessary for the characteristics of the paint. The paint has a PVC (pigment volume concentration) of about 30 to 65 and a viscosity of several hundreds to 100,000 centipoise. In some cases, a paint containing a small amount of glass fibers (short fibers) added and mixed therein may be used as a reinforcing material of the present paint.

The flame-retardant or non-flammable sheet-like substrate is a flame-retardant paper: a pulp paper having a basis weight of 70 to 130 g / m ^{2 and} treated with a flame-retardant agent, which is generally called flame-retardant paper. Base paper, non-combustible paper: Pulp paper base paper, generally called aluminum hydroxide paper (non-combustible paper), made by adding a suitable amount of aluminum hydroxide powder, which is a fireproof filler, to pulp, and glass fiber base Base paper: Glass fiber paper consisting mainly of non-combustible glass fibers, or glass fiber-containing paper or non-woven base paper containing at least 20% or more of glass fibers and other pulp or synthetic fiber pulp. , And so on. The above-mentioned three types of paper-like sheets are used as a base, and are selectively used according to required flame retardancy and noncombustibility.

The fireproof performance of wall covering material No. 0005 is defined by the wall covering material No. 0005 (inorganic wallpaper) in the fire prevention wall covering material regulations approved by the Ministry of Construction (Wall covering materials association). It also means that it has a fireproof performance as a fireproof wall covering material, that is, a first-class fireproof performance. More specifically explaining the above fireproof performance, the inorganic wall covering sheet according to the present invention, in the case where the wall covering sheet is directly stretched using a legally incombustible material as a base for the body like a 10 mm-thick pearlite plate, It is a wall covering sheet that has the performance to pass the regulation as a non-combustible material in the combustion test (surface test) prescribed by Ministry of Construction Notification No. 1828 (matter that specifies non-combustible material), 9 mm thick In the case of directly laying a wall covering sheet using a legal quasi-incombustible material as a base for a vehicle such as Sano's gypsum board, Ministry of Construction Notification No. 1372 (matters such as specifying quasi-incombustible material and flame-retardant material) It means that the wall covering sheet has a performance that passes the regulation as a quasi-incombustible material in the combustion test (surface test) prescribed in 1., and has the above-mentioned fire prevention performance.

The three-dimensional decorative surface is the main component of the product according to the present invention, which is obtained by finishing an inorganic main wall-mounting sheet in which a relatively deeply carved three-dimensional concavo-convex pattern is formed on the sheet surface. As shown in FIG. 1, the formation of the three-dimensional decorative surface is achieved by applying the inorganic-based coating material 1 onto the surface of the flame-retardant or non-combustible sheet-like substrate 2 with a roll coater 3 or the like and having a relatively thick high basis weight. And the flat coating sheet 4 is applied so that the surface becomes flat, and when the inorganic-based coating material 1 is still in a wet state, the surface of the coating material is used as a concavo-convex patterning roll (special surface It is produced by contacting with a roll 5 having the same and causing a special surface irregularity pattern to appear on the surface of the wet paint coating surface when the roll is separated from the roll surface, and then sending it to a drying step and drying and fixing. On this occasion,
Appropriately adjust the viscous properties of the paint so that wet and uneven patterns are likely to appear. It should be noted that the surface uneven pattern can be produced in various patterns by variously changing the surface texture structure of the special surface roll.

The details of the sheet composite panel for inorganic main wall covering are as follows. The inorganic-based wall-mounting sheet according to the present invention is bonded and composited with various panels to form a composite panel. The adhesive compounding at this time is usually carried out using an adhesive, a pressure-sensitive adhesive, an adhesive rubber sheet or the like. As a panel material used in combination, wood board or panel material: plywood board (preferably waterproof and flame-retardant plywood) hardboards, particle board, etc. Steel plate: zinc-coated steel plate, aluminum plate, etc. , Inorganic board: Asbestos slate, Flexible asbestos slate board, Perlite board, Caycal board, Pulp cement board, Gypsum board, etc. Concrete panel: ALC board (autoclave curing lightweight foam concrete board), PC board (precast concrete board) ), GRC board (glass fiber reinforced concrete board), extruded cement board, etc. Hard foam boards: Polyvinyl chloride-based, polyurethane-based, phenol resin-based hard foamed foam boards, inorganic fillers and flame retardants Flame-retardant or quasi-incombustible rigid foams using are more desirable. Of these, flame-retardant plywood, asbestos slate board, flexible asbestos slate board, perlite board, gypsum board, calcareous board, ALC board, flame-retardant or semi-incombustible hard foam, and the like are preferable.

The basis weight of the inorganic-based wall covering sheet of the present invention is 500 g / m ² or more and 1500 g / m ² or less, more preferably 700 g / m ^2.
It is m ^{2 to} 1200 g / m ² . The reason why the weight of the inorganic-based wall-mounting sheet according to the present invention is larger than that of ordinary wallpaper is that the inorganic-based coating used in the present invention is a flame retardant and a fireproof filler powder such as aluminum hydroxide powder and borohydrate. It is a fairly full-scale fire-prevention performance paint that contains a sufficient amount of zinc oxide powder. Therefore, the purpose of the present invention is to improve the fireproof performance of the wallpaper surface and to improve the fireproof safety by forming the coating layer on the wallpaper surface relatively thickly. In particular, when the base precursor surface is a wood-based board such as plywood or polyurethane foam board, the surface fire prevention effect of the wallpaper according to the present invention becomes great. As described above, the appearance is relatively conspicuous and the carving is deep. This is because it is necessary to have a basis weight of at least 500 g / m ² or more in order to realize a three-dimensional uneven pattern on the surface of the wall covering sheet.

[0016]

According to the present invention having the above-mentioned structure, a thick and deeply carved three-dimensional uneven pattern can be obtained even as a sheet-shaped wallpaper. In particular, the ethylene-vinyl acetate copolymer-based water-based emulsion resin has excellent flexibility, bending resistance, and crack resistance despite the fact that the amount of inorganic substances is increased.
Exhibits (cracking) properties. It is possible to improve the fire protection performance of the wallpaper surface and improve the fire safety by covering the wallpaper surface with a relatively thick coating of an inorganic-based paint that contains a sufficient amount of aluminum hydroxide powder and zinc borate powder. Became. At the same time, by using an ethylene-vinyl acetate copolymer-based aqueous emulsion resin instead of the polyvinyl chloride-based resin or the like, it becomes possible to suppress the change over time due to ultraviolet rays, that is, yellowing or fading. Since it is an inorganic-based paint, it has high moisture permeability and moisture adsorption,
It has the ability to respond to changes in indoor humidity, and has the effect of increasing the amount of moisture stock because of its high basis weight.

[0017]

【Example】

Example 1 (1) Preparation of Sheet for Inorganic Main Body Wall Mount on Flat Surface An inorganic main paint having the composition shown in Table 1 (paint composition for flat) was prepared, and this paint was used by a roll coater facility to
80g / m ² basis weight flame-retardant paper-Coat on the surface of the substrate so that it is thick and smooth, and then continuously dry in a hot air drying facility to obtain a flat surface. A sheet for wall covering was obtained. The obtained sheet is a white sheet having an inorganic appearance, a basis weight of about 700 g / m ² , and a sheet thickness of 0.5 to 0.
It was a 6 m / m sheet, which was relatively flexible, and had good folding resistance and sheet surface strength. Table 1 Raw material name Usage amount kg Mixing ratio% Ethylene vinyl acetate copolymer water-based emulsion resin 30.000 28.34% (solid content concentration: about 50%) Defoamer 0.300 0.28% Halogen-phosphorus flame retardant 3.749 3.54% Dispersant 1.500 1.42% Water 4.500 4.25% Titanium oxide powder 5.500 5.19% Zinc borate powder 30.000 28.34% Aluminum hydroxide powder 30.000 28.34% Thickener 0.326 0.31% Total compounding amount 105.875 100.00%

The obtained sheet is pasted on a 10 mm-thick pearlite board (legal non-flammable material) using an adhesive of starch / ethylene vinyl acetate emulsion resin mixed system, which is the surface side of the wall-mounted sheet of the composite panel. About the Ministry of Construction Notification No.
As a result of conducting a combustion test according to No. 1828 (a surface test, the surface on which the sheet for wall covering is adhered) was confirmed to pass the regulation as a non-combustible composite panel.

(2) Preparation of inorganic-based wall-mounting sheet having a three-dimensional uneven pattern surface An inorganic-based paint having a composition as shown in Table 2 (uneven pattern coating composition) was prepared and rolled as shown in FIG. Using the coating composition 3 using the present coating material, it becomes thicker on the surface of the aluminum hydroxide paper (non-combustible paper) substrate 2 of 110 g / m ² basis weight,
Moreover, the paint was applied so that the surface became smooth. Then, as described above, the flat coating surface is brought into contact with the surface of the special surface roll (concavo-convex patterning roll) 5 and then removed, so that the surface of the coating layer is coated as shown in FIGS. 2 (A) and 2 (B). As shown, a relatively large vertical-striped three-dimensional uneven pattern was developed and continuously dried and fixed as it was in a hot air drying facility to produce a wall covering sheet.

The obtained inorganic-based wall-mounting sheet 6 has a basis weight of about 900 g / m ² and a sheet thickness of a relatively flexible inorganic material having concave portions of about 0.6 to 0.7 mm and convex portions of about 0.9 to 1.1 mm. It was a white sheet having an external appearance, and was a sheet having good sheet surface strength and folding resistance.

A combustion test (surface test) according to the Ministry of Construction Notification No. 1828 was similarly conducted on a panel in which this wall covering sheet was laminated on a pearlite board having a thickness of 10 mm with an ethylene vinyl acetate emulsion resin adhesive and composited. As a result of the implementation, it was proved that it passed the regulation as a noncombustible composite panel. Table 2 Raw material name Usage amount kg Mixing ratio% Ethylene vinyl acetate copolymer water-based emulsion resin 30.000 27.71% (solid content concentration: about 50%) Defoamer 0.300 0.28% Halogen-phosphorus flame retardant 3.749 3.46% Dispersant 1.500 1.39% Thickener 0.326 0.30% Water 4.500 4.16% Titanium oxide powder 5.500 5.08% Zinc borate powder 40.000 36.94% Aluminum hydroxide powder 22.400 20.69% Total amount of compound 108.275 100.00%

Further, using a glass fiber paper having a basis weight of about 90 g / m ² mainly composed of glass fibers as a substrate, a wall-mounting sheet similar to the above-mentioned example was manufactured. This sheet was laminated and bonded to a flame-retardant plywood, but since the application was around water, an aqueous acrylic emulsion resin adhesive filled with calcium carbonate powder was used as the bonding adhesive.

Example 2 As shown in Table 3 (compound coating for uneven pattern), in addition to aluminum hydroxide powder and zinc borate powder, which are essential main fireproof inorganic fillers as an inorganic powder filler, An inorganic-based paint was prepared, which was composed of kaolin clay powder and titanium oxide powder as auxiliary inorganic fillers. 100g / m with this paint by roll coater equipment
Coating is applied on the surface of a flame-retardant paper substrate of ² grammage so that the coating amount is thick and the surface is smooth, and then as described above, the special surface roll By contacting the flat coating surface with the surface of FIG. 3) and then removing it, a relatively large special three-dimensional concavo-convex pattern as shown in FIGS. 3 (A) and 3 (B) is developed on the surface of the coating material layer, As it was, it was continuously dried and fixed in a hot-air drying facility to manufacture an inorganic-based wall-mounting sheet. Table 3 Raw material name Usage amount kg Mixing ratio% Ethylene vinyl acetate copolymer water-based emulsion resin 30.000 27.81% (solid content concentration: about 50%) Defoamer 0.300 0.28% Halogen-phosphorus flame retardant 3.749 3.48% Dispersant 1.500 1.39% Thickener 0.326 0.30% Water 4.500 4.17% Titanium oxide powder 5.500 5.10% Zinc borate powder 37.000 34.30% Aluminum hydroxide powder 20.000 18.54% Kaolin clay powder 5.000 4.63% Total compounding amount 107.875 100.00%

The obtained sheet has a basis weight of about 1100 g / m ² and a sheet thickness of a concave portion of about 0.7 to 0.8 mm and a convex portion of about 1.0 to 1.3 mm, which is a white with a relatively flexible inorganic appearance. The sheet had good surface strength and bending resistance.

[0025] Regarding a panel obtained by laminating and compositeting this inorganic-based wall-mounting sheet on a pearlite board (legal non-combustible material) having a thickness of 10 mm with an ethylene vinyl acetate emulsion resin adhesive, the Ministry of Construction No. 1828 stipulates in the same manner. As a result of carrying out a combustion test (surface test) according to the above, a result was obtained that the composite panel passed the regulations of noncombustible material.

Separately, a glass fiber-containing sheet-like substrate (basis weight: 70 g / gram), which is a non-woven fabric in the form of a paper, which is a ternary mixed paper made of 30% glass fiber and other pulp and polyester synthetic fibers (short fibers). The above-mentioned inorganic-based paint was applied to m ² ) to obtain a wall covering sheet that was substantially the same as that described in this example. A surface burning test was conducted in the same manner, and the result that the composite panel passed the regulation as a non-combustible material was obtained.

[0027]

EFFECTS OF THE INVENTION The wall covering sheet and the wall covering sheet composite panel of the present invention have not the vinyl resin-like appearance and feel as described above, but the inorganic appearance and feel that meet the user's needs. It has a high product value due to the feature that it has a decorative surface with a three-dimensional uneven pattern with deep carving, which is relatively noticeable in appearance. In addition, it has excellent flexibility, bending resistance, and crack resistance, as well as improved fire protection performance and fire safety. Furthermore, it has become possible to provide products that do not yellow or fade even after long-term use.
In addition, since it is an inorganic-based paint, it has high moisture permeability and moisture adsorption, has humidity breathability that can respond to changes in indoor humidity, and has a high basis weight, so it has a large moisture stock wall. It became a decorative sheet.

[Brief description of drawings]

FIG. 1 is a schematic view of an apparatus for manufacturing an inorganic-based sheet for wall covering.

FIG. 2A is a plan view and FIG. 2B is an end view of the inorganic-based wall-mounting sheet having a three-dimensional decorative surface of the present invention.

FIG. 3A is a plan view and FIG. 3B is an end view of the inorganic-based wall-mounting sheet having a three-dimensional decorative surface of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Inorganic-based coating material 2 Sheet-like base material 3 Roll coater 4 Flat coating sheet-like material 5 Concavo-convex patterning roll 6 Inorganic-based wall coating sheet

Claims (3)

[Claims] 1. An inorganic-based paint mainly comprising an ethylene vinyl acetate-based aqueous emulsion resin, a flame retardant, an aluminum hydroxide powder, and a zinc borate powder is applied on the surface of a flame-retardant or non-flammable sheet-like substrate. Dry composite basis weight 500g
An inorganic-based wall-mounting sheet composed of a sheet-shaped molded product of / m ² or more. 2. The inorganic main body wall-mounting sheet according to claim 1, wherein the surface of the inorganic main body wall-mounting sheet is a three-dimensional textured decorative surface. 3. A composite sheet for an inorganic main wall-mounting sheet according to claim 1, wherein the inorganic main-body wall-mounting sheet according to claim 1 is formed by adhering the entire surface of the panel or the surface and the surface to a small surface or a part of the small surface to bond the composite.