JPH09216308A - Heat resisting decorative laminated sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain excellent heat resistance, fire retardancy, antibacterium, and mildew proofing by a method wherein a base sheet material, a metallic foil, a decorative material, and an ultraviolet setting synthetic resin film successively form layers, and the ultraviolet setting synthetic resin layer is formed of an urethane acrylate oligomer of a specific thickness and at least a specific value in pencil lead hardness. SOLUTION: This decorative laminated sheet is formed by successively constituting layers with a metallic foil combined by using a base sheet material 1, an adhesive 2, and a copper foil 3 only or the copper foil 3 together with an aluminum foil 3, by using a non-aqueous organic adhesive 4, an adhesive, a decorative material 7, and an ultraviolet setting synthetic resin film 9. The ultraviolet setting synthetic resin film layer 9 is 7-20μ thick, and formed by using urethane acrylate oligomer of at least 7H in pencil lead hardness. When the ultraviolet setting synthetic resin film of over 20μ film thickness is formed, an inclination wherein heat resistance of heat resisting decorative sheet gradually decreases, is indicated. When used as an interior finishing building part, light stability is decreased. When used as an exterior finishing building part. weatherability is decreased.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal foil layer formed on the surface of a basic board material such as an essential board material, a synthetic resin board material, etc., and a natural wood decorative veneer or an artificial book cosmetic is formed on the surface of the metal foil layer. A heat-resistant decorative board with a decorative material layer such as a veneer, decorative wallpaper, decorative coating film, etc., and a specific UV-curable hard synthetic resin coating thin film layer formed on the surface of the decorative material layer. ,
It has excellent physical properties such as mildew resistance, flame retardancy, durability, light resistance, and weather resistance, as well as workability in the field. Not only exterior building materials and interior building materials,
The present invention relates to a heat-resistant decorative board that can be used in various fields such as furniture such as a closet, a table, a counter, and a kitchen board material.

[0002]

2. Description of the Related Art As a heat-resistant decorative board or flame-retardant decorative material, it is considerable that an intermediate layer of aluminum metal foil alone is formed on the surface of a wooden base board material and a natural wood decorative veneer is attached to the surface decorative material. Although it has been widely known for a long time, various improvements have been made to such decorative materials because the long-term adhesion function of the aluminum foil forming the intermediate layer to the basic plate material or the decorative material is not so good. To the aluminum foil, which is an intermediate layer, and each of the base plate material and the decorative material, a pulp of this material, a water-soluble adhesive, and a specific thermosetting resin are interposed (Japanese Patent Laid-Open No. 50-31012), the intermediate A method of interposing a chemical fiber paper between the layer and the decorative material (Hirakai Sho 18-1865) is known.

On the other hand, heat resistance is not sufficient only by forming an aluminum foil intermediate layer on the surface of a wood-based base plate and attaching a natural wood decorative veneer to the surface decorative material, in order to improve the heat resistance. It is known to form a UV-curable synthetic resin coating film. For example, a decorative board (flat coating) in which a layer of an intermediate coating resin coating film is provided on the surface of an aluminum foil intermediate layer, and then a thick coating film of UV-curable synthetic resin is formed (flat Kaisho 2-175240
Gazette) or a water-soluble adhesive mixed with a chemical fiber paper and inorganic powder between the intermediate layer and the decorative material, and then a decorative plate having an ultraviolet-curable synthetic resin coating film formed thereon (Hirakai Sho 8-
No. 1865) is known.

[0004]

However, although the heat-resistant decorative board obtained by the above-mentioned means has various advantages described in the above-mentioned publication, in reality, the heat-resistant and flame-retardant properties of the decorative board are the physical properties of the decorative board. Is not yet sufficient, especially in addition to the heat resistance and flame retardancy that are strongly required as a kitchen veneer,
Not only is the antibacterial property, mildew resistance, durability, etc. insufficient, but when such a plate material is used as an interior / exterior member for construction, it has insufficient light resistance and weather resistance, and, It has a drawback that it cannot prevent erosion of insects by body fluids and infestation of termites from under the floor. On the other hand, when such a decorative sheet is actually used as a kitchen decorative sheet or a building interior / exterior member, there is a drawback in that the basic sheet material is exposed due to scratches during the work of striking the tongue. However, there is a drawback in that the aesthetic appearance and quality are greatly impaired by actually applying a decorative board of excellent quality and quality.

[0005]

Means for Solving the Problems In order to improve the drawbacks of various heat-resistant decorative boards as described in the preceding paragraph, the present inventors provide a copper foil layer between the base board and the decorative board. By providing this, this problem is fundamentally solved (patent application dated January 9, 1996 by the present inventors), and in the process of pursuing light resistance, weather resistance and more cost-effectiveness, copper foil and aluminum foil are used. It has been found that it is suitable to solve the problems associated with the use of the above and the use of a specific ultraviolet curable hard synthetic resin coating thin film layer as the ultraviolet curable synthetic resin coating.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention is basically a decorative plate comprising a base plate material, a metal foil, a decorative material, and an ultraviolet-curable synthetic resin coating film in the order of layers. The present invention relates to a heat-resistant decorative board that is a UV-curable hard coating film of a urethane acrylate oligomer having a resin coating film thickness of 7 μm to 20 μm and a pencil hardness of 7H or more, and has light resistance, weather resistance,
In addition to heat resistance and flame retardancy, it has excellent basic physical properties such as antibacterial properties, mildew resistance, and durability. It also resists erosion by various body fluids such as termites and liquids such as table miso soup, soy sauce, and vinegar. On the other hand, when the decorative plate is actually used for each purpose or each member, the base plate material is less likely to be exposed,
It can be applied to a large area without impairing the appearance and quality of the decorative board itself. Hereinafter, embodiments of the present invention will be described in detail.

The basic board material of the present invention means a wood board material, a synthetic resin board material, an inorganic board material, and the like, and the essential board materials are natural book board, lauan plywood, structural plywood, natural book-made plywood, and printed plywood. , Overlay plywood, hardboard,
Particle board, insulation board, pulp cement board, bamboo, etc., synthetic resin board materials such as rigid urethane foam, urea / phenolic foam, phenolic foam, and other synthetic resin foam, acrylic board, vinyl chloride board, and other plastic boards, inorganic Examples of the system board material include calcium silicate board, various cement boards, decorative gypsum board, and the like. Among these, the inorganic board material originally having heat resistance and flame retardancy is generally fragile in mechanical strength. Therefore, the heat-resistant decorative board, which is the main object of the present invention, does not show significant improvement in performance except for thermal properties, and the preferable base board is a wood-based board in general and urea. It is a thermosetting synthetic resin foam board such as phenol foam or phenol foam.

As the metal foil, a copper foil or an aluminum foil can be used. However, when the aluminum foil alone is used, there are many drawbacks as the above-mentioned heat-resistant decorative board, and the copper foil alone or the combination of the copper foil and the aluminum foil is used. Use metal foil. The commercially available copper foil has a thickness of 30 μ to 150 μm.
Although it is μ, it is preferable that it is as light as possible in order to obtain a heat-resistant decorative board having a large area, and the effect of the present invention can be obtained even when the copper foil is as thin as about 30 μ. Use something of a degree. Aluminum foil with various thicknesses of 20 μ to 1000 μ is commercially available, but it is preferably about 20 μ to 50 μ in order to prevent a processing step and electrical corrosion with a copper foil.

As the metal foil, a copper foil alone or a combination of copper foil and aluminum foil can be used as described in the preceding paragraph. However, in the case where the copper foil and the aluminum foil are sequentially formed on the surface of the base plate material. preferable. This is because when an aluminum foil layer is first formed on the surface of the base plate material and then a copper foil is formed, a change in adhesion over time is likely to occur at the interface between the base plate material and the aluminum foil layer. It is well known that in order to achieve this, it is quite effective to use an adhesive having an excellent adhesive strength or an adhesive mixed with a specific filler at the interface between the base plate and the aluminum foil.

As described above, when forming a composite layer of copper foil and aluminum foil as a metal foil, thinning the aluminum foil layer has been described above. For adhesion of the copper foil and aluminum foil, polyvinyl acetal, polyvinyl butyral, polyacetic acid are used. Vinyl, polyvinyl acetate copolymer, vinyl methyl ether / maleic anhydride copolymer, polyvinyl chloride, vinyl chloride / vinyl acetate copolymer, vinylidene chloride copolymer,
Multi-liquid type such as methyl polycyanoacrylate, chromanindene, polyamide, polyamide epoxy, epoxy resin, alkyd resin, unsaturated polyethresul, polyurethane, phenolic epoxy, phenolic polyamide, phenolic polyvinyl acetal, butadiene acrylonitrile rubber, polysulfide epoxy, solventless It is preferable to use a non-aqueous adhesive of a mold type or a solvent type, or a non-molded mixture of these components. By interposing a non-aqueous adhesive layer, durability and weather resistance are significantly improved.

When a copper foil is formed on the surface of a base plate material, a general adhesive is used in accordance with a usual method. Although a thermosetting synthetic resin such as an epoxy resin is superior in heat resistance, the copper foil is used. The general heat-dissipating property is excellent, and therefore, general thermoplastic synthetic resin can be used, and such an advantage was a technical problem that could not be known at all with aluminum foil. Moreover, when forming the copper foil layer on the base plate material, the layer forming workability that could not be achieved with the aluminum foil due to the weight of the copper foil, that is, the coating performance of the metal foil on the base plate material was significantly improved. It is something that the present inventors could not know that such performance is important without actually going through the experimental stage. What is more surprising is that the copper foil is similar in color to wood-based decorative materials and thermosetting synthetic resin foam board materials. Even if the mold synthetic resin coating or aluminum foil is scratched from the outside, it is less affected by scratches and abrasions, and the heat-resistant decorative board is constructed on-site and the butt joint is required during the butt joint work. For the first time, it was found that even if it was scratched, it did not cause any major problems in appearance.

As the decorative material of the present invention, a natural decorative veneer, a decorative veneer such as an artificial decorative veneer, various decorative wallpaper, a plastic sheet, a decorative film, a cosmetic coating, and other aesthetic layers are formed. The material can be used as the decorative material layer. In particular, for use as a decorative plate for kitchen or a decorative member for interior construction, the above-mentioned veneer veneer has many uses, and so-called veneer-like and veneer-like veneer can be illustrated as a preferable example. When forming it on the foil surface, a general adhesive is used, but thermosetting synthetic resins such as epoxy resin are superior in heat resistance, but the heat dissipation of the copper foil is very excellent. Therefore, a general thermoplastic synthetic resin can also be used, and the advantages thereof are the same as those described above. When forming a coating film decorative material layer using a general paint in forming such a decorative material layer, it is not necessary to use an adhesive, and the coating film layer can be shortened in that the heat-resistant decorative board manufacturing process can be shortened. Is effective.

The UV-curable hard coating film of a urethane acrylate oligomer having a thickness of 7 μm to 20 μm and a pencil hardness of 7 H or more in the present invention means an oligomer of isocyanate and an acrylic acid monomer having a polyfunctional group. The acrylic acid monomer can be partially replaced with a methacrylic acid monomer. Among these oligomers, those capable of forming a urethane acrylate hard coating film having a pencil hardness of 7H or more to a thickness of 7 to 20 μ are preferable in order to obtain a decorative board having more excellent heat resistance, which is the object of the present invention. When forming a UV-curable synthetic resin coating film having a layer thickness of more than 20μ, the heat resistance of the heat-resistant decorative board tends to gradually decrease, and when used as an interior building member, the light resistance is It has been found that the weather resistance is reduced when used as an exterior building member.
When the coating material is formed on the surface of the decorative material, a polymerization initiator is added, and a dye colorant is added if necessary to form a coating layer. As the coating material, 20 to 60 g / m ^{2 is used.}
It is preferable that the coating amount is

[0014]

EXAMPLES Examples are shown below to further clarify the features of the present invention.

The performance of each test piece in the following examples and comparative examples was determined by the method described below.

In the heat resistance test, 10 seconds after igniting a commercially available cigarette, the test piece was placed horizontally on the surface of each test piece and left as it was, and the surface condition was observed after 15 minutes.

In the light resistance test, each test piece was exposed in a fade meter for 500 hours to observe the color change of the surface condition.

The weather resistance test was carried out by observing the color change of the surface condition after exposure for 500 hours in the sunshine type accelerated weather resistance test.

The antifungal test is ASTM (G21-70).
After making each test piece into a disk shape having a diameter of 30 mm, the test was conducted in a sterile petri dish having a major axis of 90 mm.
The mold used in the test was Aspergillus niger (ASPE
RGIILLUS NIGER, Penicillium FUNICULOS
UM), Chaetomium globosum (CHAETOM)
IUMGLOBOSOM), GLIOCLADIUM VIRENS, and AUREOBASI
5 types of DIUM PULLULANS), the medium is potato dextrose agar, and the culture conditions are 2 in an incubator.
The temperature was 7 ° C ± 2 ° C, and the growth state of hyphae produced on each petri dish was observed visually for 21 days.

In the soy sauce erosion test, a diameter of 10 mm and a height of 100 m were first applied to the surface of each test piece on the side of the ultraviolet-curable synthetic resin coating film.
After putting a commercially available concentrated soy sauce with a height of 80 mm on a glass tube of m to prevent it from spilling around and leaving it for 30 days,
The dark soy sauce was removed and the surface condition was observed.

In the cut and butt test, first, each test piece was cut in half with a saw, the cut surfaces were butted, and the discomfort of the joint was visually observed.

The layer structure of each test piece was as follows, and the color tone of the decorative material was yellowish green, which is about the color of Japanese zelkova or oak.

The test piece is a hard board (300 mm × 300 mm) with a thickness of 10 mm as a base plate, a copper foil of 50 μ standard as a metal foil, a natural wood decorative veneer of 300 μ as a decorative material, and a pencil hardness as an ultraviolet-curable synthetic resin coating film. 7H
The urethane acrylate hard coating of 15 μm thick is used, the epoxy resin adhesive layer 15 μ is between the hard board and the copper foil, and the epoxy resin adhesive layer 15 is between the copper foil and the natural wood decorative veneer.
μ was interposed.

The test pieces are bamboo (300 mm × 300 mm) with a thickness of 10 mm as a base plate material and copper foil 30 as a metal foil.
μ standard copper foil and 30μ aluminum foil, 300μ natural bamboo decorative veneer as a decorative material, UV-curable synthetic resin coating, pencil hardness 8H urethane acrylate hard coating 1
The thickness is 5μ, and the ethylene acetate building resin adhesive layer is 15μ between the bamboo base plate and the copper foil, and the epoxy resin adhesive layer is 15μ between the copper foil, the aluminum foil and the natural bamboo decorative veneer.
Intervened.

A test piece as a comparative example is a 10 mm thick hard board (300 mm × 300 m) as a base plate material.
m), copper foil of 70μ standard as metal foil, 3 as decorative material
00μ natural veneer veneer, UV-curable synthetic resin coating with a pencil hardness of 4H polyester acrylate hard coating 20μ thick, epoxy resin adhesive layer 15μ between the base plate and copper foil, copper foil and natural wood A phenolic epoxy resin adhesive layer 20 μ was interposed between the decorative veneers.

A test piece as a comparative example is a 10 mm thick hard board (300 mm × 300 m) as a base plate material.
m), a metal foil of 50μ standard aluminum foil, a decorative material of 300μ natural wood decorative veneer, a UV-curable synthetic resin coating film of pencil hardness 7H urethane acrylate hard coating film 15μ thick, hard board and aluminum foil 15μ between the epoxy resin adhesive layer and 15μ between the aluminum foil and the natural wood decorative veneer
Intervened.

A test piece as a comparative example is a 10 mm thick hard board (300 mm × 300 m) as a base plate material.
m), a metal foil of 70μ standard aluminum foil, a decorative material of 300μ natural wood decorative veneer, an ultraviolet curable synthetic resin coating film of pencil hardness 5H unsaturated polyester hard coating film of 15μ thickness, hard board and aluminum foil 15μ between the epoxy resin adhesive layer and 15μ between the aluminum foil and the natural wood decorative veneer
Intervened.

A performance test was conducted on each test piece, and the results shown in the table were obtained.

[0029]

According to the present invention, basically, a heat-resistant decorative board obtained by sequentially forming a base plate material, a metal foil, a decorative material, and an ultraviolet-curable hard synthetic resin coating thin film is generally used. Similar to a decorative sheet using metal foil, it has excellent heat resistance and flame retardancy, but due to the combined effect of copper foil and an ultraviolet curable synthetic resin coating film with a specific type and specific layer thickness, the heat resistance and flame retardancy Is significantly improved.

Further, what was unexpected was that the basic physical properties such as antibacterial properties, antifungal properties, durability, etc., and the light resistance and weather resistance required for interior and exterior materials were excellent, and various body fluids of insects such as termites were used. Resistance to liquids such as erosion, table miso soup, soy sauce, and vinegar is also large, and the effect is that copper foil is used as the intermediate layer between the base plate and the decorative material, or the copper plate and the decorative material side are on the basic plate side. It is presumed that this is due to the adoption of a dissimilar metal foil of aluminum foil. When the lid is provided with a copper foil layer, electrochemical reactivity such as alumite surface / internal aluminum that occurs when the aluminum foil is used alone is unlikely to occur, and fungi, fungi, and termites that are the inherent performance of copper metal are used. This is because the resistance to insect body fluids containing is not deteriorated, but the resistance is further increased by the combined use with a hard ultraviolet-curable synthetic resin coating thin film layer. Of course, the copper foil layer itself seems to be difficult to produce a vivid color tone when compared to the whiteness of the aluminum foil and the decorative material layer, but on the contrary, this heat resistance that stably integrates the decorative material layer It was made clear by the present inventors that it can be held on a sex decorative board.

Furthermore, when the decorative board of the present invention is actually used for each application or each member, the base plate material of the cut portion is hardly exposed, and the appearance and quality of the decorative board alone are not impaired. Although it can be installed, the effect is related to the previous paragraph. As described above, it is considered that this is due to the stable adhesiveness of the copper foil to the base plate material and the properties specific to the copper color tone.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a heat-resistant decorative board obtained by sequentially forming a base plate material, copper foil and aluminum foil as metal foil, natural wood decorative veneer decorative material, and ultraviolet curable hard synthetic resin coating film thin film. .

FIG. 2 is a cross-sectional view of a heat-resistant decorative board obtained by sequentially forming layers of a base plate material, a copper foil, a multicolor paint coating film decorative material, and an ultraviolet curable hard synthetic resin coating film thin film.

[Explanation of symbols]

 1 ... Basic plate material 2,4,6 ... Adhesive 3 ... Copper foil 5 ... Aluminum foil 7 ... Natural wood decorative veneer material 8 ... Multicolor paint coating cosmetic material 9 ... Ultraviolet curing type hard synthetic resin coating film thin film

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location B32B 33/00 B32B 33/00 E04F 13/08 8913-2E E04F 13/08 A

Claims (4)

[Claims] 1. A decorative plate comprising a base plate material, a metal foil, a decorative material, and a UV-curable synthetic resin coating film, which are successively formed, and a UV-curable synthetic resin coating film layer having a thickness of 7 μm to 20 μm. A heat-resistant decorative board that is a UV-curable hard coating film of urethane acrylate oligomer having a hardness of 7H or more. 2. The heat-resistant decorative sheet according to claim 1, wherein the metal foil is a copper foil alone or a combination of copper foil and aluminum foil. 3. The heat-resistant decorative board according to claim 2, wherein layers of copper foil and aluminum foil are sequentially formed on the surface of the base plate material. 4. The heat-resistant decorative board according to claim 2, wherein the foil interlayer adhesive of the copper foil and the aluminum foil is a non-aqueous organic adhesive layer.