JPH0858027A - Non-combustible decorative architectural material and production thereof - Google Patents

Abstract

PURPOSE: To obtain a non-combustible decorative architectural material excellent in fire resistance, having high strength and water resistance and causing no ply separation. CONSTITUTION: A slurry containing sepiolite and a resin binder as main materials is supplied to a papermaking process to form a non-combustible sheet 2. A plurality of the non-combustible sheets 2 are superposed on decorative paper 3 being an exterior material to be integrally bonded thereto by hot pressure molding. Since the non-combustible sheet 2 containing sepiolite as a main material is used as a core material, the obtained architectural material is substantidlly non-combustible and also excellent in fire resistance and causes no collapse even if it is exposed to a flame for a long time and an org. component is carbonized or burnt off. Since the non-combustible sheet to which the resin is internally added by a papermaking process is used, the whole is uniformly integrated by hot pressure molding and high strength and water resistance are obtained and no ply separation is generated. As the resin binder, a phenol resin is pref. used.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-combustible decorative building material used as a fireproof door or a panel material for partitions, an interior wall material for a building or a vehicle, a ceiling material, or a floor material.

[0002]

2. Description of the Related Art Conventionally, various types of decorative building materials have been known and used for interior and exterior constructions.

Among them, the most common one is a veneer plywood having a core material, and a decorative plywood obtained by overlaying a veneer plywood with a surface material such as a resin film or by printing or painting. Further, instead of the plywood, a hard fiber board or particle board is used as a core material, and a fiber decorative board which is subjected to the same surface decoration treatment as the decorative plywood is also common.

Further, as a decorative building material, a resin-impregnated laminated decorative board such as a melamine resin decorative board is also typical. In this resin-impregnated laminated decorative board, a plurality of core papers coated or impregnated with a resin binder such as melamine resin or phenol resin and a decorative paper as a covering material are superposed, heat-pressed and integrally joined. Pulp paper such as kraft pulp is generally used as the core material paper.

All of these decorative building materials use a wood material such as plywood or pulp paper as a core material, and are therefore flammable. In addition to these combustible building materials, various non-combustible building materials are known. Typical ones are gypsum board, calcium silicate board,
Rock wool boards and the like. In particular, gypsum board is most widely used because it is relatively inexpensive. Also,
In contrast to these relatively high specific gravity inorganic boards, a so-called silica board is also known, in which Shirasu balloon, which is an inorganic hollow body, is used as the main material of filler (aggregate), and it is hardened with a binder of a water glass composition. (For example, Japanese Patent Laid-Open No. 1-
131084, JP-A-1-317148). Incidentally, asbestos slate was one of the typical ones of the inorganic board before, but asbestos is not good for health, so it is not used much now.

[0006]

As described above, the decorative building material is generally a decorative plywood, a fiber decorative board, a resin-impregnated laminated decorative board, or the like. And, although they are relatively thin and lightweight, they have relatively high strength,
It also has sufficient water resistance. Furthermore, since they are also excellent in workability, they are versatile as decorative building materials.
However, these decorative building materials are easily burnable because they use wood or paper as the core material. Although the flame-retardant treatment can make the flame-retardant to some extent, the fire resistance is limited.

On the other hand, inorganic boards such as gypsum board and silica board are completely nonflammable. Therefore, a non-combustible decorative building material can be obtained by using these inorganic boards as a core material and applying a covering material or a coating to the core material. However, since these inorganic boards have high hardness but are very brittle, it is necessary that the thickness thereof be sufficiently thick to have a certain level of strength. As a result, the weight also becomes heavy, and even if the silica board is relatively light in weight, when it is formed as a panel material for a large door, for example, the whole weight tends to be heavy. Therefore, a decorative building material using such an inorganic board as a core material is not combustible, but is thick and heavy, so that it is not versatile and its use is naturally limited.

By the way, the applicant of the present invention has focused on fine fibrous hydrous magnesium silicate mineral sepiolite under the demand of a non-combustible sheet material to replace asbestos fiber paper, and uses this as a main material. As a result, a non-combustible sheet produced as a paper has been developed (for example, JP-A-5-280121 and JP-A-6-25995). This non-combustible sheet is not only non-combustible because it is mainly composed of inorganic sepiolite, but also because sepiolite has sinterability as well as solidification, the sheet is exposed to fire heat for a long time and organic matter is carbonized. Even if burned or burned out, it does not drop off or fall off, its shape is retained, and the flame is shut off.

Therefore, in view of the current state of decorative building materials, the non-combustible sheet excellent in fire resistance is used as a core material,
Similar to the conventional resin-impregnated laminated decorative board, it was examined to manufacture a non-combustible decorative building material by applying and impregnating a resin binder and laminating a plurality of the sheets together with decorative paper. The decorative building material thus obtained had not only high strength and water resistance similar to those of the resin-impregnated laminated decorative board, but also substantially nonflammability and excellent fire resistance. However, since this non-combustible sheet has a relatively dense structure structure, when the resin binder is simply applied and impregnated into the non-combustible sheet, the resin binder is not uniformly impregnated into the whole, and therefore the obtained cosmetic When a building material was subjected to a boiling water immersion test or the like, there was often a tendency for delamination to occur.

Therefore, an object of the present invention is to provide a non-combustible decorative building material which has excellent fire resistance, high strength and water resistance, and is free from delamination, and a method for producing the same.

[0011]

A non-combustible decorative building material according to claim 1 comprises a plurality of non-combustible sheets formed by making a slurry containing sepiolite as a main material and a resin binder, and a decorative paper as a covering material. Are superposed, heat-pressed, and integrally joined.

Here, as the resin binder, one kind or two or more kinds of any thermoplastic resin or thermosetting resin can be used, and among them, a phenol resin which is a thermosetting resin is preferable. .

That is, the non-combustible decorative building material according to claim 2 is
Multiple non-combustible sheets made by making a slurry containing sepiolite and phenol resin as the main material, and decorative paper as the covering material are overlaid, and integrally molded by heating and pressing at the curing temperature of the phenol resin. It is made by joining.

Further, a method for producing a non-combustible decorative building material according to a third aspect of the present invention is a method for forming a slurry containing a main material such as sepiolite and a resin binder, and a papermaking process for forming the slurry formed in the slurry forming step. Step, pressing and dehydrating the paper layer formed in the paper making step, then drying step of drying, a plurality of non-combustible sheets obtained in the drying step, and the decorative paper as a surface covering material,
And a heat and pressure step of heat and pressure molding and joining them together.

Further, in the method for producing a non-combustible decorative building material according to claim 4, the resin binder in claim 3 is embodied in a phenol resin which is a thermosetting resin, and sepiolite and phenol resin as main materials are used. A slurry forming step of forming a slurry containing, a paper making step of making a slurry formed in the slurry forming step, a paper layer formed in the paper making step is squeezed and dehydrated, and then dried at a temperature at which the phenolic resin does not cure. A drying step, a plurality of non-combustible sheets obtained in the drying step, and a decorative paper as a covering material are superposed, and a heating and pressing step of joining them by heating and pressurizing at the curing temperature of the phenol resin. It is equipped with.

[0016]

The non-combustible decorative building material according to claim 1 has decorative properties because it is provided with a decorative paper as a surface material.
Since the core material is composed of multiple non-combustible sheets with sepiolite as the main material, it is substantially non-combustible and has excellent fire resistance, and the organic matter disappears or carbonizes when exposed to flame for a long time. Even so, since sepiolite has a caking property or a sinterability, the shape is maintained without chipping or falling. Further, since the resin binder is internally added to the non-combustible sheet by papermaking, the resin binder melted during the heat and pressure molding combines the components composed mainly of sepiolite forming the non-combustible sheet with a plurality of sheets. Non-combustible sheet and decorative paper are joined together,
The whole is uniformly integrated. Therefore, high strength and water resistance are obtained, and delamination does not occur even under wet conditions.

In the non-combustible decorative building material according to claim 2, phenol resin which is a thermosetting resin is used as the resin binder in claim 1, and the non-combustible sheet containing this is heated and pressed at the curing temperature of the phenol resin. Therefore, the phenol resin melts and hardens during this heat and pressure molding. Therefore, in addition to the above-mentioned effects, strength and water resistance are further enhanced, and heat resistance is also enhanced.

In the method for producing a non-combustible decorative building material according to a third aspect, a non-combustible sheet containing sepiolite as a main material and containing a resin binder uniformly is formed by a slurry forming step, a papermaking step, and a drying step, and heated. In the pressurizing step, a plurality of the non-combustible sheets and the decorative paper as the covering material are superposed, heat-pressed and integrally joined, so that the non-combustible decorative building material having the action of claim 1 is produced. Well obtained.

In the method for producing a non-combustible decorative building material according to the fourth aspect, since the phenol resin which is a thermosetting resin is used as the resin binder, the non-combustible decorative building material having the action of the second aspect can be obtained with high productivity. .

[0020]

Embodiments of the present invention will be described below.

FIG. 1 is a perspective view showing an incombustible decorative building material according to an embodiment of the present invention.

As shown in FIG. 1, the non-combustible decorative building material of the present embodiment, which is designated by 1 in its entirety, is a board shape in which a plurality of non-combustible sheets 2 and decorative paper 3 as a covering material are integrally joined to each other. It is composed of a laminated body of. The decorative paper 3 is made of ordinary pulp paper such as colored paper and pattern paper, but the non-combustible sheet 2 is made by making a slurry containing sepiolite as a main material and a resin binder, and a resin binder to be added internally. Thus, the plurality of non-combustible sheets 2 and the decorative paper 3 are integrally joined.

FIG. 2 is an explanatory view showing the outline of the manufacturing process of the non-combustible decorative building material of one embodiment of the present invention.

As shown in FIG. 2, in the manufacturing process of the non-combustible decorative building material of this embodiment, a slurry forming step A for forming a slurry containing sepiolite as a main material and a resin binder, and a slurry for forming the slurry are made by a paper machine. Papermaking process B
And a step of producing a non-combustible sheet by compressing and dehydrating the wet paper layer formed in the paper-making step B, and then drying the same, and then producing a plurality of non-combustible sheets and as a cover material. And a heat-pressing step (laminating step) D in which the decorative paper of (1) is stacked, heated and pressed, and integrally joined. Each of these steps will be described in detail below.

<Slurry Forming Step> In order to manufacture a noncombustible sheet for a noncombustible decorative building material, first, a slurry forming step A is performed.
In, a slurry containing a resin binder containing sepiolite as a main material is formed.

Here, sepiolite used as the main material of the non-combustible sheet is commonly known as mountain leather,
Clay minerals called mountain cork and mountain wood, and sepiolite in Japan is one of these. Its appearance may be cork-like, leather-like, or a pure white soft lump, but it is generally a magnesium silicate lump having fibrous properties. The surface thereof has a highly reactive hydroxyl group and has basic properties such as adsorptivity, thixotropy, and caking property.

The hydrous magnesium silicate mineral, sepiolite, is not only excellent in caking properties due to its hydroxyl group, but also excellent in compatibility with water, and is easily dispersed by being charged with cations or nonions in water. To do. Therefore, a sheet can be easily formed by paper making, and the formed sheet has sufficient paper strength. Therefore, sepiolite can be used alone as a main material for forming a non-combustible sheet, but preferably, reinforcing fibers are used together in order to more sufficiently enhance the handling strength of the non-combustible sheet formed. .

As the reinforcing fibers, glass fibers, mineral fibers such as rock wool fibers, metal fibers such as stainless fibers, ceramic fibers such as potassium titanate fibers, or inorganic compound fibers such as whiskers and gypsum fibers are used. be able to. However, from the viewpoint of material cost, cohesive effect, etc., glass fiber is most suitable among them. And
Generally, these inorganic fibers can be added in an amount of 3 to 20% by weight based on the whole noncombustible sheet.

As the reinforcing fibers, not only inorganic fibers, but also organic fibers such as wood pulp, or phosphite pulp obtained by making it flame-retardant, aramid fibers, woven fibers such as vinylon fibers, and the like can be used. . However, the blending amount thereof is preferably 10% by weight or less based on the whole nonflammable sheet in order to ensure sufficient nonflammability, fire resistance and shape retention after thermal decomposition. It is more preferably not more than wt%.

Further, in addition to these reinforcing fibers, various inorganic fillers can be blended, if necessary.
Such inorganic fillers include aluminum hydroxide,
Inorganic powders having self-extinguishing properties such as hydrous calcium borate (apatite) and magnesium hydroxide (brucite) are particularly preferable. In addition, binding inorganic fillers such as colloidal silica, vermiculite, plate particles such as synthetic swelling mica or synthetic smectite are also preferable for imparting strength to the noncombustible sheet. However, these inorganic fillers are used in a relatively small proportion so as not to impair the characteristics of sepiolite as a main material.

Then, a resin binder is further added to the above-mentioned slurry containing sepiolite as a main material. This resin binder is internally added to a non-combustible sheet by papermaking, and in the subsequent heating and pressing step D, the non-combustible sheet containing sepiolite as a main material is solidified, and the non-combustible sheets are mutually and also with the non-combustible sheet. Glue and bond to the decorative paper. Such resin binders include acrylic resin, polyethylene resin, polypropylene resin, vinyl chloride resin, polystyrene resin, ABS
Resin, AS resin, saturated polyester resin, polyamide resin, thermoplastic resin such as polyether resin, urea resin, amino resin such as melamine resin, epoxy resin, phenol resin, alkyd resin, unsaturated polyester resin, diallyl phthalate Thermosetting resins such as resins can be mentioned. And these can be used individually by 1 type or in combination of 2 or more types. However, among these, a thermosetting resin is preferable in that a particularly strong bond is obtained. Further, among the thermosetting resins, the phenol resin, which is a polycondensation product of phenols and aldehydes, has high adhesiveness, has an appropriate curing rate, and has a wide range of curing temperature and time. Can be used particularly preferably.

The resin binder can be dispersed in the slurry as a powder or as a dispersion or emulsion. Although it may be added as an aqueous solution, addition of a large amount thereof undesirably increases the viscosity of the slurry excessively and the yield during papermaking is poor. Most preferred is the powder form. Regarding the blending ratio of the resin binder to the whole non-combustible sheet, if it is too small, sufficient bondability between layers cannot be obtained, and if it is too large, sufficient non-combustibility, shape retention after carbonization, etc. cannot be obtained. Generally, it is preferably about 3 to 15% by weight for practical use. More preferred is 5 to 10% by weight.

The slurry for forming the non-combustible sheet has the same composition as in the case of ordinary pulp papermaking.
A cationic, anionic, or nonionic polymer compound mainly for aggregation can be added. Such a polymer compound can also serve as a part of the above-mentioned resin binder as a binder that enhances the paper strength of the non-combustible sheet, and an acrylic polymer or copolymer such as polyamide or polyacrylamide. , Polyethylene oxide and the like can be used. In addition to these, it is also possible to use natural polymer compounds such as guar gum and starch or modified products thereof, polyvinyl alcohol, CMC and the like. Since these polymer compounds form the dispersion medium of the slurry, the amount contained in the formed noncombustible sheet is smaller than that of the resin binder described above.

In the noncombustible sheet formed from such a slurry, the sepiolite as a main material is preferably contained in a proportion of at least 60% by weight, and more preferably 70% by weight or more. . As a result, it is possible to obtain sufficient non-combustibility of the finally obtained decorative building material and sufficient shape retention after carbonization or burning of organic components such as resin binder.

Here, an example of the composition of the slurry for forming the non-combustible sheet will be shown.

[0036]

[Table 1]

This slurry contains 78 parts by weight of sepiolite which has been defibrated in advance, 10 parts by weight of glass fiber having a length of about 6 mm,
Then, 5 parts by weight of pulp that was previously beaten in a beater was put in a mixing tank together with 3500 parts by weight of water, and mixed sufficiently until a uniform dispersion was obtained, and then 7 parts by weight of a phenol resin (resole type) was added thereto. In addition, it is formed by further dispersing and mixing. Also in this slurry,
50 parts by weight of a 0.2% aqueous solution of a cationic dimethylaminoethyl methacrylate (DMAEM) and 50 parts by weight of a 0.2% aqueous solution of an anionic acrylamide acrylic acid copolymer (AA) were formed into paper to form aggregated flocs. Previously added sequentially.

<Papermaking Step> Next, in the papermaking step B,
A paper machine is used to make a slurry containing a resin binder with the main material of sepiolite formed in the slurry forming step A.

This papermaking process B is the same as in the case of papermaking of ordinary pulp paper, and as a papermaking machine, fourdrinier type, cylinder type,
Alternatively, any type such as a combination type of these can be used. The size of the mesh is
Although it can be appropriately selected depending on the size of the component particles in the slurry, generally 60 to 80 mesh is suitable. Then, in the case of the slurry of the formulation example of Table 1 above,
It is possible to use 80-mesh paper making machine, for example, to make paper by a combination type paper machine. As a result, the flocculated flocs and water in the slurry can be rapidly separated on the paper making machine to form a wet paper layer containing sepiolite as a main material and a phenol resin as a resin binder uniformly contained therein.

<Drying Step> Next, in the drying step C,
The wet paper layer obtained in the papermaking process B is squeezed with a press roll to be dehydrated and then dried.

This drying step C is the same as in the case of ordinary pulp paper, and a hot air dryer, roll type, nozzle type, box type rotary dryer or the like can be used for drying. However, the drying temperature may be equal to or higher than the melting temperature when the resin binder is a thermoplastic resin, but may be equal to or lower than the curing temperature when a thermosetting resin is used as the resin binder. is necessary. In the case of a phenol resin, since the curing temperature is relatively high and the curing speed is relatively slow, it is possible to dry at a temperature up to about 100 ° C. For example, heating at 100 ° C. for 8 minutes can dry the resin. it can. Then, the water content of the non-combustible sheet is preferably adjusted to 10% or less by this drying, which can prevent the rapid evaporation of the water during the subsequent heating and pressurizing.

In this way, it is possible to obtain a nonflammable sheet containing sepiolite as a main material and a resin binder, which is used for manufacturing a nonflammable decorative building material. For example,
From the slurry having the composition shown in Table 1 above, water was removed to substantially consist of 78% by weight of sepiolite, 10% by weight of glass fiber, 5% by weight of kraft pulp, and 7% by weight of phenolic resin. A non-combustible sheet containing aminoethyl methacrylate (DMAEM) and acrylamide acrylic acid copolymer (AA) is obtained. This non-combustible sheet can be used immediately for manufacturing a non-combustible decorative building material, but can also be rolled into a roll and temporarily stored as a stock. The nonflammable sheet is generally formed to have a thickness of about 0.3 to 0.6 mm.

<Heating / pressurizing step> And the heating / pressurizing step D
In the above, a plurality of the above-mentioned non-combustible sheets containing sepiolite as a main material and containing a resin binder and a decorative paper as a covering material are overlaid, and heat-pressed to bond them together to form a non-combustible laminate. Forming makeup building materials.

Here, the number of non-combustible sheets can be appropriately determined according to the thickness, strength, etc. required of the non-combustible decorative building material to be formed, and any number of non-combustible sheets can be used as long as it is two or more. it can. Further, when the non-combustible sheet has a sufficient thickness, it may be one sheet. On the other hand, as the decorative paper, any decorative paper such as a pattern paper formed of ordinary pulp paper with a wood grain pattern, an abstract pattern, a concrete pattern, or a plain colored paper can be used as long as a decorative effect can be obtained. can do. Further, a paper material such as a decorative base paper for pattern printing, which can be decorated later, can also be used as the decorative paper. This decorative paper as a cover material can be provided on the surface of at least one side of the plurality of noncombustible sheets forming the core material.

In the heating and pressurizing step D, a general-purpose hot press for lamination can be used for heating and pressurizing a plurality of superposed noncombustible sheets and decorative paper. The sheet and the decorative paper are sandwiched between stainless steel plates, which are heated and pressed between a pair of hot plates. The heating temperature is a temperature at which the resin binder contained in the noncombustible sheet melts or cures, and when a phenol resin is used as the resin binder, it is generally heated to 120 ° C to 170 ° C. Further, the pressurization, the plurality of non-combustible sheets and decorative paper are sufficiently joined to each other,
Also, to ensure that the structure of the non-combustible sheet is sufficiently densified,
Generally, it can be carried out at a pressure of ²⁰ to 90 kg / cm ² . However, this pressure is not limited, and may be a lower pressure or a higher pressure in relation to the heating and pressurizing time and the like.

By heat-pressing as described above, the resin binder internally added to the nonflammable sheet is melted or further hardened, and the sepiolite-based component forming the nonflammable sheet serves as a main component. The plurality of non-combustible sheets are joined together, and the non-combustible sheet and the decorative paper are also joined together. If the non-combustible sheet contains a relatively small amount of resin binder, either the adhesive or a resin of the same type as the resin binder should be applied in advance on the joint surface side of the decorative paper, or the entire decorative paper should be impregnated. Preferably. This makes it possible to bond the non-combustible sheet and the decorative paper more reliably.

Thus, as shown in FIG. 1, a non-combustible decorative building material 1 having a laminated structure composed of a core layer composed of a plurality of non-combustible sheets 2 and a surface material layer composed of decorative paper 3 is formed. A resin film or a transparent surface protection paper can be further overlaid on the surface material layer made of the decorative paper 3, and depending on the type of the decorative paper 3, the nonflammable sheet 2
It is also possible to interpose an underlayer shielding paper between and. Further, this non-combustible decorative building material can be further subjected to surface treatment such as water repellent treatment. The non-combustible decorative building material 1 can be formed to have an arbitrary thickness from about 1 mm to about 10 mm or about 30 mm by appropriately adjusting the number of non-combustible sheets 2.

[Production Example of Nonflammable Decorative Building Material] Here, a nonflammable sheet (water content: about 6%) having a thickness of about 0.4 mm obtained by making a slurry of the formulation example of Table 1 above and drying it is used. An example of manufacturing a non-combustible decorative building material will be shown.

Five sheets of this non-combustible sheet were piled up, and decorative papers made of high titanium dioxide content paper (plain white paper) were piled up on both sides of the sheet and set on a laminating hot press. A phenol resin adhesive was previously applied to the back surface of the decorative paper. And a temperature of 150 ° C., 7
Heat and pressure molding was performed for 60 minutes under a pressure of 0 kg / cm ² .

As a result, the plate thickness of 2.0 shown in FIG.
It was possible to obtain a non-combustible decorative building material having a mm and a specific gravity of 0.97. When a fire resistance test was performed on this non-combustible decorative building material at 1000 ° C., its surface was carbonized black or burned down, but even after 1 hour, its shape was maintained in its original shape and impervious to flame (gas burner). Showed sex. During the fire resistance test, the thermal decomposition odor peculiar to the phenol resin was hardly generated. This is considered to be due to the deodorizing action of sepiolite because it has adsorptivity. Further, in the boiling water immersion test of immersing in hot water of 100 ° C., no tendency of delamination was observed even after 30 minutes.

As described above, the noncombustible decorative building material 1 of this embodiment
Is composed of a plurality of non-combustible sheets 2 formed by paper-making a slurry containing sepiolite as a main material and a resin binder, and a decorative paper 3 as a covering material, which are heat-pressed and integrally joined. It is a thing.

Therefore, the non-combustible decorative building material 1 has decorative properties by providing the decorative paper 3 on the surface thereof, and also has a plurality of non-combustible sheets 2 mainly composed of sepiolite.
Since it is made of a core material, it is practically nonflammable, and has excellent fire resistance due to the solidification and sinterability of sepiolite, and the organic matter was burned or carbonized when exposed to heat. In that case, the shape is retained and the flame can be blocked. In addition, since the resin binder is internally added to the non-combustible sheet 2 by papermaking, the resin binder uniformly binds the component composed mainly of sepiolite forming the non-combustible sheet 2, and a plurality of sheets of the non-combustible sheet 2 are combined. The non-combustible sheet 2 and the decorative paper 3 are evenly bonded to each other. Therefore, the non-combustible decorative building material 1 has strength, water resistance, good inter-layer bondability, and does not delaminate even under wet conditions.

Further, since the non-combustible decorative building material 1 uses the non-combustible sheet 2 and the decorative paper 3 as base materials, it is free from brittleness as in the conventional resin-impregnated laminated decorative board, decorative plywood, or fiber decorative board. Even when formed in a large panel shape, it is difficult to break, and cracks do not occur even if nails are struck. Also,
Similarly, it has excellent workability.

Therefore, the non-combustible decorative building material 1 of this embodiment is
As a wall material for buildings or vehicles, ceiling materials, floor materials, and other interior / exterior materials, or surface materials for furniture, sports equipment, etc., it can be used for all purposes similar to conventional general decorative building materials. it can. In particular, since it has excellent fire resistance, it can be suitably used as a panel material for fire doors, partitions, and the like.

Further, the non-combustible decorative building material 1 of one embodiment of this embodiment
Is a plurality of non-combustible sheets 2 made by making a slurry containing sepiolite as a main material and phenol resin as a main material using a phenol resin which is a thermosetting resin as a resin binder, and a decorative paper 3 as a cover material. Are superposed on each other, heat-pressed at the curing temperature of the phenol resin, and integrally joined.

Therefore, according to this, the hardened phenolic resin more firmly binds the component composed mainly of sepiolite forming the nonflammable sheet 2, and the plurality of nonflammable sheets 2 and the decorative paper 3 Are more firmly bonded to each other. Therefore, not only heat resistance is enhanced, but also strength and water resistance are further enhanced, and delamination resistance is further enhanced.

Further, in the method for manufacturing the non-combustible decorative building material 1 of this embodiment, a slurry forming step A for forming a slurry containing sepiolite as a main material and a resin binder, and a paper sheet for the slurry formed in the slurry forming step. Papermaking process B
And a drying step C in which the paper layer formed in the papermaking step is squeezed to be dehydrated and then dried, a plurality of non-combustible sheets 2 obtained in the drying step, and a decorative paper 3 as a covering material are overlaid. And a heating / pressurizing (laminating) step D in which heating, pressing, and joining are performed together.

Therefore, by the slurry forming step A, the papermaking step B, and the drying step C, the noncombustible sheet 2 containing sepiolite as the main material and containing the resin binder is formed, and a plurality of the noncombustible sheets 2 and the covering material are used. Since it is superposed on the decorative paper 3 and is heat-pressed and integrally bonded, it has decorativeness and incombustibility, and also has excellent fire resistance, high strength and water resistance, and delamination. The non-combustible decorative building material 1 that does not need to be produced can be obtained with high productivity from these simple steps. In addition, since the resin binder is internally added to the non-combustible sheet 2 by paper making, there is no need for a treatment operation of applying and drying the resin binder and equipment therefor, so that the non-combustible decorative building material can be manufactured at a lower cost. be able to.

Further, one embodiment of the method for producing the non-combustible decorative building material 1 of the present embodiment uses a phenol resin which is a thermosetting resin as a resin binder, and a slurry containing sepiolite and a phenol resin as main materials. Forming step A for forming a sheet, a sheet forming step B for forming a slurry formed in the slurry forming step, and a paper layer formed in the sheet forming step are squeezed and dehydrated, and then dried at a temperature at which the phenol resin does not harden. Drying step C, a plurality of non-combustible sheets 2 obtained in the drying step, and decorative paper 3 as a surface covering material are superposed, heated and pressed at the curing temperature of the phenol resin, and heat-bonded to join them together. And a pressure (lamination) step D.

Therefore, since the thermosetting resin, phenol resin, is used, the non-combustible decorative building material 1 has high heat resistance and further improved strength, water resistance, and delamination resistance.
Can be obtained. Further, since the phenol resin has a relatively high curing temperature and a relatively slow curing rate as compared with other thermosetting resins, drying in the drying step C can be performed at a relatively high temperature within a short time. Therefore, the nonflammable sheet 2 containing the phenol resin can be manufactured with high productivity, and can be stored with high stability.

By the way, in the above embodiment, the non-combustible decorative building material is formed into a plate shape, but in the case of carrying out the present invention, the non-combustible decorative building material is not limited to such a plate shape, and is appropriately heated and pressed. Any shape that can be molded can be formed into a curved or bent shape. Further, it may be formed into a tubular shape or the like, if necessary. Also in this case, the thickness of the non-combustible decorative building material can be appropriately set depending on the number of non-combustible sheets used.

Further, in the method for producing the non-combustible decorative building material of the above embodiment, the wet paper layer obtained in the papermaking step B is squeezed to be dehydrated, and then dried in the drying step C. Drying can be omitted. The same non-combustible decorative building material can be manufactured also by this. However, in this case, it is necessary to appropriately perform the pressurizing operation such as opening the mold many times so that the water can be sufficiently vaporized during the heating and pressurizing step. Therefore, as in the above example, it is preferable that the non-combustible sheet after papermaking is sufficiently dried, thereby facilitating heat and pressure molding, and also facilitating handling, storage, etc. of the non-combustible sheet. it can. Further, by forming such a dried non-combustible sheet, it can be used for other purposes other than the production of non-combustible decorative building materials.

[0063]

As described above, the non-combustible decorative building material according to claim 1 comprises a plurality of non-combustible sheets formed by making a slurry containing sepiolite as a main material and a resin binder, and a decorative material as a covering material. It is made by stacking paper and heat, pressurizing, and joining them together.

Therefore, since the decorative paper is provided as the surface material, the decorative material has the same decorativeness as general decorative building materials such as decorative plywood, while the core material is formed from a plurality of non-combustible sheets containing sepiolite as a main material. Since it has a substantial nonflammability, it also has excellent fire resistance due to the solidification and sinterability of sepiolite, and even if it is exposed to a flame for a long time and the organic matter is carbonized or burned out, it may be missing. The shape is retained without breaking and the flame can be blocked. Further, since the resin binder is internally added to the non-combustible sheet by papermaking, the resin binder is melted at the time of heat and pressure molding, and the component mainly composed of sepiolite forming the non-combustible sheet is combined with a plurality of sheets. The non-combustible sheet and the decorative paper are also joined together, and the whole is uniformly integrated.
Therefore, high strength and water resistance are obtained, and delamination does not occur even under wet conditions.

A non-combustible decorative building material according to claim 2 is a plurality of sheets obtained by using a phenol resin which is a thermosetting resin as the resin binder in claim 1, and making a slurry containing sepiolite as a main material and a phenol resin. The non-combustible sheet and the decorative paper as the surface covering material are superposed, heated and pressed at the curing temperature of the phenol resin, and integrally joined.

Therefore, since the phenol resin is cured by being heated and pressed at its curing temperature,
The heat resistance is enhanced and the bondability is enhanced. Therefore, higher strength and water resistance are obtained, and the delamination resistance is further improved.

Further, a method for producing a non-combustible decorative building material according to a third aspect of the present invention comprises a slurry forming step for forming a slurry containing sepiolite as a main material and a resin binder, and a papermaking for forming the slurry formed in the slurry forming step. Step, pressing and dehydrating the paper layer formed in the paper making step, then drying step of drying, a plurality of non-combustible sheets obtained in the drying step, and the decorative paper as a surface covering material,
And a heat and pressure step of heat and pressure molding and joining them together.

Accordingly, a non-combustible sheet containing sepiolite as a main material and a resin binder is formed by a slurry forming step, a papermaking step, and a drying step, and in the heating and pressing step, a plurality of the non-combustible sheets and a covering material are used. Since it is superposed on the decorative paper, heat-pressed, and integrally joined, there is no need for the step of applying or impregnating the non-combustible sheet with the resin binder and then drying, and the non-combustible cosmetic having the effect of the above claim 1. The building material can be manufactured with high productivity by these simple steps.

A method for producing a non-combustible decorative building material according to a fourth aspect is that a phenol resin is used as the resin binder in the third aspect, and a slurry forming step of forming a slurry containing sepiolite as a main material and the phenol resin is included. , A papermaking step of making a slurry formed in the slurry forming step, a drying step of squeezing and dehydrating the paper layer formed in the papermaking step, and then drying at a temperature at which the phenol resin does not cure, and a drying step A heat and pressure step of superposing a plurality of the non-combustible sheets and a decorative paper as a cover material, heat and pressure molding at the curing temperature of the phenol resin, and joining them together is provided.

Therefore, as in the case of claim 3, the non-combustible decorative building material having the effect of claim 2 can be manufactured with high productivity by these simple steps. Further, since the phenol resin has a relatively high curing temperature and a slow curing rate, the drying in the drying step can be performed at a relatively high temperature, and therefore the noncombustible sheet itself can be formed with high productivity.

[Brief description of drawings]

FIG. 1 is a perspective view showing a nonflammable decorative building material according to an embodiment of the present invention.

FIG. 2 is an explanatory view showing the outline of the manufacturing process of the non-combustible decorative building material of one embodiment of the present invention.

[Explanation of symbols]

 1 Non-combustible makeup building material 2 Non-combustible sheet 3 Decorative paper

Claims (4)

[Claims] 1. A plurality of non-combustible sheets made by making a slurry containing a sepiolite as a main material and a resin binder, and a decorative paper as a covering material are superposed, heat-pressed and integrally joined. Non-combustible makeup building material characterized by 2. A plurality of non-combustible sheets prepared by making a slurry containing sepiolite as a main material and a phenol resin, and a decorative paper as a covering material are superposed and heated at a curing temperature of the phenol resin. Non-combustible decorative building material characterized by being pressure molded and integrally joined. 3. A slurry forming step of forming a slurry containing sepiolite as a main material and a resin binder, a paper making step of making the slurry formed in the slurry forming step, and a paper layer formed in the paper making step. Is pressed, dehydrated, and then dried, and a plurality of non-combustible sheets obtained in the drying step and a decorative paper as a covering material are superposed, heat-pressed and integrally joined. A method for producing a non-combustible decorative building material, comprising: a heating and pressurizing step. 4. A slurry forming step of forming a slurry containing sepiolite as a main material and a phenol resin, a paper making step of making the slurry formed in the slurry forming step, and a paper layer formed in the paper making step. Is dehydrated by pressing, and then dried at a temperature at which the phenolic resin does not harden, a plurality of nonflammable sheets obtained in the drying step, and a decorative paper as a covering material are superposed, and the phenol A heating and pressurizing step of heating and pressurizing at a resin curing temperature to integrally bond the resin, and a method for producing a non-combustible decorative building material.