JPH10166498A - Production of decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To produce a decorative panel excellent in both of humidity absorbing/ discharging properties and waterproofness and enhanced in design effect. SOLUTION: A sealing material layer 2 having waterproofness and humidity absorbing/discharging properties is formed on the surface of a substrate 1 composed of a porous inorg. panel and the transfer layer 6 of a transfer sheet 7 is superposed on the surface of the sealing material layer 2 to be bonded to the sealing material layer 2 and, subsequently, a carrier sheet 5 is peeled to form a decorative layer on the sealing material layer 2. As a sealing material, paint wherein either one of a hull powder of grain, a powder of a shell and a powder of a hinoki leaf material is added to a resin binder is used. Or, a shaping sheet having embossed patterns on its surface is used and the embossed patterns of the shaping sheet are superposed on and pressed to the sealing material layer to form embossed patterns on the sealing material layer. Though a coating film is formed, high design effect is imparted without sacrificing the humidity absorbing/discharging properties and waterproofness possessed by the substrate 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board used for the interior or exterior of a house or the like and a method for producing the same.

[0002]

Heretofore, as this type of decorative board, a decorative sheet made of polyvinyl chloride adhered to a substrate such as a wood plywood or a metal plate has been generally used. However, this type of decorative panel is not air-permeable and does not absorb or release moisture. In addition, since recent homes have a high degree of sealing, the interior side surface of the decorative panel or the interior side of walls, ceilings, etc. There is a problem that condensation occurs on the surface (when the wall, ceiling, etc. is hollow). Such condensation causes the substrate to corrode or induce rust or mold when left unattended. Further, a decorative sheet made of polyvinyl chloride, such as vinyl cloth, generates hydrogen chloride gas at the time of incineration, and thus has a problem in disposal.

On the other hand, a porous inorganic panel has been developed as a substrate having a high moisture absorption / release capacity and a function of minimizing a change in humidity in a room (Japanese Patent Laid-Open No. 6-11557).
No. 1). This inorganic panel has excellent strength and is nonflammable, but has a drawback of poor design. Therefore,
If a decorative sheet made of polyvinyl chloride is attached to this substrate to give it a design, the function of the substrate itself is not utilized, so it is used without decoration on the surface, or Regardless of the decoration, a breathable cloth may be applied (cloth finish) or a decorative paper finish without a waterproof coat, or a sculpture or shaping of an uneven pattern such as a joint groove on the surface may be applied. Limited to applying paint finish that does not impair moisture release. Nevertheless, in the case of cloth or decorative paper finish, the adhesive is limited to a specific material that absorbs and releases moisture such as starch paste, and since this type of adhesive is water-soluble, the cloth or decorative paper becomes wet when wet. It may come off, or the decorative paper itself may swell and soften (because there is no waterproof coat on the surface). In the case of an uneven pattern, the problem of poor color design remains. In addition, in the case of a paint finish that does not impair moisture absorption / release properties, starch-based, polyvinyl alcohol-based, etc., are limited to specific materials having high moisture absorption / release properties, and the coating amount must be kept low. There is a problem that it is water-soluble and poor in water resistance.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method of manufacturing a decorative board which is excellent in both moisture absorption / release properties and waterproofness and has high design properties. Is to do.

[0005]

In order to achieve the above object, a first manufacturing method according to the present invention is to provide a sealing material having both waterproofness and moisture absorbing / releasing property on the surface of a substrate made of a porous inorganic panel. Applying a material to form a filling material layer, then preparing a transfer sheet having at least a decorative layer as a transfer layer on a carrier sheet, overlaying the transfer layer of the transfer sheet on the surface of the filling material layer, and pressing. Bonding the transfer layer and the filler material layer, and then peeling off the carrier sheet to form a decorative layer on the filler material layer, and as a filler material, powder of cereal shell in a resin binder. Body, shell powder,
It is characterized by using a paint containing any of the powder of cypress leaves.

In order to achieve the same object, a second manufacturing method according to the present invention comprises applying a sealing material having both waterproofness and moisture absorption / desorption properties to a surface of a substrate made of a porous inorganic panel. To form a filling material layer, then prepare a shaped sheet having an uneven pattern on the surface, apply the uneven pattern of the shaped sheet on the filling material layer and press it, and then peel off the shaped sheet The process consists of forming an irregular pattern on the filler material layer. As the filler material, a paint containing any of cereal shell powder, shell powder, and cypress leaf powder in a resin binder is used. It is characterized by having done.

[0007] In the decorative plate manufactured by the above method, since the moisture absorption / release properties and the waterproofness of the sealing material layer are both large, the moisture absorption / release properties of the substrate are not impaired. Moreover, cereal shells and shells are insoluble even when the surface is wet with water. Further, since the sealing material layer itself has a design such as an earth wall or a stucco tone, it can be suitably used for interiors of houses and the like. Furthermore, since both sides of the decorative board are made of a material having excellent moisture absorption / desorption properties and waterproofness, both indoor dew condensation and dew condensation inside the building structure such as walls and ceilings can be waterproofed.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 shows a procedure of a first method for manufacturing a decorative board according to the present invention. To explain this, first, as shown in FIG. 1A, a substrate 1 made of a porous inorganic panel is prepared, and as shown in FIG.
Is provided with a sealing material layer 2 having both waterproofness and moisture absorption. The filling material layer 2 is formed by applying a paint containing powder 4 of any of cereal shells, shells, and cypress materials in a resin binder 3 on the surface of the substrate 1. On the other hand, a transfer sheet 7 is prepared by laminating a transfer layer 6 composed of at least a decorative layer on a carrier sheet 5 in a releasable manner.
As shown in FIG. 3, the transfer layer 6 side of the transfer sheet 7 is overlapped with the sealing material layer 2 side and pressurized (heating and pressing as necessary), and the transfer layer 6 and the sealing material layer 2 are pressed. Then, only the carrier sheet 5 is peeled off to form the transfer layer 6 on the filler material layer 2 as shown in FIG.

FIG. 2 shows a procedure of a second method of manufacturing a decorative board according to the present invention. Also in this manufacturing method, FIG.
First, as shown in FIG. 2A, a substrate 1 made of a porous inorganic panel is prepared, and as shown in FIG. 2B, a sealing material layer 2 having both waterproofness and moisture absorption is provided on the surface of the substrate 1. Is provided. The filling material layer 2 is formed by applying the same paint as described above to the surface of the substrate 1. On the other hand, a shaping sheet 8 having an uneven pattern on its surface is prepared, and as shown in FIG. 2C, the uneven pattern of the shaping sheet 8 is overlaid on the filler material layer 2 and pressed (necessary). 2 (d), and then, as shown in FIG. 2 (d), the shaping sheet 8 is peeled off to form an uneven pattern 9 on the filler material layer 2.

The inorganic panel used for the substrate 1 includes:
Even if a cement board such as ALC (lightweight cellular concrete), GRC (glass fiber reinforced concrete), wood powder cement, a plaster board, a ceramic board, etc. which are usually used as a building material is used, the presence of the filling material layer 2 At least one having an effect of preventing dew condensation on the indoor side can be obtained. However,
In order to prevent condensation on the inner side surface and obtain a higher performance, it is necessary to use a porous inorganic panel having good moisture absorption / release properties for the substrate 1 itself.

One such panel is a porous calcium silicate plate. Conventional calcium silicate plates have insufficient moisture absorption / release properties.
Preferred is a tobermorite-based calcium silicate plate as described in JP-A-15571. More particularly, tobermorite, a mix of C-S-H and quartz, comprises 2 to 12% by weight of pulp as a reinforcing material, more CaO / SiO ₂ molar ratio from 0.6 to 0.85, a bulk density of 0 0.4 to 0.6 g / cc
Is a calcium silicate plate. Among these components, tobermorite achieves excellent heat resistance, C-S-H having a large specific surface area and a large number of pores achieves excellent moisture absorption / release properties, and quartz achieves sufficient strength. . Further, pulp improves strength and processability.
If the pulp is less than 2% by weight, the strength processability is insufficient, and if it exceeds 12% by weight, the nonflammability is insufficient. As the pulp, pulp such as softwood, hardwood, hemp and straw is used. Ca
O / SiO ₂ molar ratio maintain neutralization and strength of PH plate by a 0.6 to 0.85. If the molar ratio is less than 0.6, it becomes acidic, and if it exceeds 0.85, it becomes alkaline. By maintaining the bulk density at 0.4 to 0.6 g / cc, appropriate processing (cutting, cutting, etc.) suitability is obtained. If necessary, 1 to 8% by weight of inorganic fibers such as glass may be added to the components. As this kind of calcium silicate plate, a material having a specific surface area of 80 m ² / g or more and a porosity of 70 to 90% is used from the viewpoint of moisture absorption and desorption properties. The specific surface area referred to here is "the amount of nitrogen gas that can be adsorbed in 1 g of material (BET method)". That is, the physical adsorption phenomenon in which water vapor is adsorbed or released on the surface of a material depends on the specific surface area of the material. The thickness is usually 5-30m
m. Specifically, "OSRITE (trademark)" (manufactured by Chichibu Onoda Co., Ltd.) is an example of such a tobermorite-based porous calcium silicate plate.

Another example of the inorganic panel used for the substrate 1 is a panel made of a volcanic glassy deposit and mineral fibers. Specifically, there is an inorganic board “Dailite (trademark)” (manufactured by Daiken Kogyo Co., Ltd.) in which both front and back surfaces of a shirasu balloon layer are sandwiched by rock wool layers.

If necessary, an undercoat layer serving as an easily-adhesive primer or a sealer may be provided on the surface of the porous inorganic panel as long as the moisture absorption and release properties of the panel itself are not impaired. . Examples of the paint used for these undercoat layers include acrylic resin-based water-dispersed emulsions.

The shape of the substrate 1 may be a flat plate as shown in FIGS. 1 and 2, a curved plate having a curved surface, a plate having an uneven surface, or the like. A mortise or a mortise may be formed at the end of the substrate for bonding with another adjacent substrate.

The coating material for forming the filler material layer 2 is prepared by using a powder of a grain shell, a shell, or a cypress as a main component and adding a resin binder thereto. Rice, wheat, buckwheat, millet, leeks, high sorghum, etc. are used as cereal husks. Among them, rice husk is particularly effective. In other words, rice hulls are rich in silicon as a component element, have good moisture absorption and desorption properties, good air permeability, and are insoluble in water. In addition, the color is similar to Kyoto wall, and furthermore flame retardancy, antibacterial property, antiseptic Has the properties of deodorant and deodorant. Scallop shells are effective as shells. That is, the shell of the scallop is porous, contains abundant calcium as a component element, has a white color, and is suitable for general white walls. The cypress leaf material is wood of a tree, also called the following cypress or asunaro, and its powder is used.

Both the above rice hulls and scallop husks are natural residues that are inevitably generated, and the hinoki leaf material is sufficient for processing and sawing of sawdust, plane shavings, etc. for the purpose of the present invention. There is no other effective use method, and there is an advantage that heat treatment, chemical treatment, and the like are not required for use. Grain husks, shells, or cypress leaf materials are used after being ground to appropriate dimensions. If the cypress leaf material is selected from sawdust having an appropriate particle size, the trouble of grinding can be omitted. Usually the average particle size is 1
The thing of about 100 micrometers is used. The shells of these cereals,
The amount of the shell or cypress powder added to the paint is about 10 to 90% by weight in the binder. These grain shells, shells or cypress powder may be used alone,
It is also possible to use a mixture of two or more of these.

As the resin binder of the paint, when the powder of cereal shell, shell or cypress is exposed on the surface of the filler material layer or when the amount of addition is large, it is waterproof (water-insoluble). It is not particularly limited as long as it is one. However, it is preferable to use a waterproof and moisture-absorbing resin. For example, a paint which forms a porous coating film made of a long oily alkyd containing an extender or a styrene acrylic copolymer resin of Akzo Nobel Co., Ltd. may be mentioned.

The coating amount of the coating material for forming the filler material layer 2 is 2
It is preferably about 0 to 200 g / m ² (at the time of drying). Then, in order to form the filling material layer, application is performed by a method such as spray coating, flow coating, comma coating, knife coating, brush printing, or the like. The filling material layer 2 smoothes (fills) fine irregularities on the surface of the base material 1 and
It becomes the transfer layer 6 and the receiving layer of the uneven pattern 9.

In the present invention, the surface of the filler material layer 2 is further decorated to improve the design. As means for applying the decoration, transfer printing using a transfer sheet as described with reference to FIG. 1 or formation of a concavo-convex pattern using a shaping sheet as described with reference to FIG. 2 is employed. Filler layer 2 if necessary
You may color itself.

When coloring the filler layer 2, a pigment or a dye is mixed with the paint. Known pigments such as carbon black, titanium white, red iron oxide, graphite, titanium yellow, cadmium red, cobalt blue, ultramarine, aniline black, quinacridone red, isoindolinone, and phthalocyanine blue can be used. In addition, various additives can be added to the paint, if necessary, as long as the inherent moisture absorption / release properties and waterproofness of the paint are not impaired. Examples of these additives include antibacterial agents such as silver zeolite (silver ions supported ion exchangeably in zeolite), 10,
Examples include fungicides such as 10'-oxybisphenoxyarsine, formaldehyde scavengers composed of organic amino compounds, ultraviolet absorbers such as benzotriazole, light stabilizers composed of hindered amine radical scavengers, and antistatic agents.

As the carrier sheet 5 constituting the transfer sheet 7 used for transfer printing, polyethylene terephthalate,
Thermoplastic saturated polyesters such as polybutylene terephthalate, polyolefins such as polyethylene and polypropylene, polyvinyl chloride, and polyolefin coated paper are used. The thickness of the carrier sheet 5 is usually about 20 to 100 μm. If necessary, a release layer made of a silicon resin or the like is formed on the transfer layer 6 side of the carrier sheet 5. Peeling during transfer occurs at the interface between the release layer and the transfer layer 6, and the release layer is removed together with the carrier. The transfer layer 6 is formed at least from a decorative layer. A specific example of the decoration layer is a picture printing layer. When printing a pattern, the pattern is printed on the carrier sheet 5 by a known printing method and material such as gravure printing, silk screen printing, and offset printing. At this time, when the binder of the ink used does not have moisture absorption / release properties, FIG.
As shown in (c), the pattern is partially formed, but if the same moisture-absorbing / desorbing and waterproof resin as the filler material layer 2 is used as the binder, the entire surface can be solid. Examples of the pattern include a wood grain pattern, a stone grain pattern, a grain grain pattern, a cloth grain pattern, a geometric figure, a character, and a solid solid (when the binder has moisture absorbing and releasing properties). If necessary, a release layer may be formed on the transfer sheet 6 side of the carrier sheet 5, or an adhesive layer may be formed on the surface of the transfer layer 6. When transferring the transfer layer 6 of the transfer sheet 7 to the filling material layer 2, the transfer sheet 7 is transferred from the transfer layer 6 to the filling material layer 2.
And press the carrier sheet 5 side to bond them together. As a pressing method, for example, a rubber roller R as shown in FIG. 1C, a metal roll, a metal flat plate, or the like is used. When the transfer layer 6 or the sealing material layer 2 has thermal adhesiveness, heating is performed in addition to pressure. The heating is performed by heating a pressurized body such as a rubber roller or separately heating a transfer sheet or a filler material layer. Specific examples of the heating method include means such as infrared radiation, induction heating, dielectric heating, and supply of hot water, heated steam, or the like into the pressurized body.

The shaping sheet 8 used to apply the concavo-convex pattern 9 to the filling material layer 2 may be a thin flexible sheet (or film) having the same shape as the desired concavo-convex pattern. Alternatively, a material which is formed by forming a concavo-convex shape of reverse concavo-convex on the surface and which has a releasability from the filling material layer 2 is used. As the material of the shaping sheet 8, for example, a material such as thermoplastic saturated polyester such as polyethylene terephthalate and polybutylene terephthalate, polyolefin such as polypropylene, polyethylene and polymethylpentene, silicon resin, fluorine resin and polyvinyl chloride is used. If necessary, paper, nonwoven fabric, another synthetic resin sheet or the like may be laminated on the opposite side of the uneven pattern as a backing. The total thickness of the shaping sheet 8 is usually about 20 to 300 μm.
The pressing by the shaping sheet 8 is performed by a method in which the shaping sheet 8 is contact-pressed when the filling material layer 2 is in a liquid state and the filling material layer 2 is solidified and then released, or the filling material layer 2 is solidified. After that, any method may be used in which the shaped sheet 8 is contact-pressed in a state of being softened by heating, and the sealing material layer 2 is cooled and solidified and then released. As the uneven pattern 9, a conduit groove of a wood grain board,
Surface unevenness of the slab, squeezing, cloth texture, sand grain, tile joints, etc. are applied. The method of pressing and heating the shaping sheet 8 is the same as that of the transfer sheet.

The formation of the decorative layer on the transfer sheet and the formation of the concavo-convex pattern on the filler material layer on the shaping sheet may be performed either alone or in combination. There are the following three methods for applying both the decorative layer and the uneven pattern. (1) A method in which a decorative layer (transfer layer) is first formed on a transfer sheet, and then an uneven pattern is formed on a shaped sheet. (2) A method in which a concavo-convex pattern is first formed on a shaped sheet, and then a decorative layer is formed on a transfer sheet. (3) Prepare a transfer sheet having a transfer layer including a decorative layer formed on the uneven pattern surface of the shaped sheet, and superimpose the transfer layer and the uneven pattern surface on the filling material layer and pressurize the sheet. A method of forming an uneven pattern.

The decorative panel obtained by the production method of the present invention is preferably used for interior materials such as walls, partitions, ceilings and the like inside buildings.

[0025]

【Example】

Example 1 A 1040 × 3130 mm rectangular plate having a thickness of 15 mm made of a mixed system of tobermorite, C—S—H, and quartz, and a porous calcium silicate plate containing pulp as a reinforcing material “OS Light (trademark) "(made by Chichibu Onoda Co., Ltd.) was used for the substrate. The specific surface area of this substrate is 88 m ² / g, and the porosity is 78%. A coating material having the following composition A was applied to the surface of the substrate and dried to form a filler material layer. The coating amount was 100 g / m ² (at the time of drying).

<Composition A> Grain husk: Rice husk (average particle size: 10 μm) 90% by weight Pigment: Benzi Yellow 2% by weight Binder: Long-oiled alkyd resin containing extender 8% by weight (“Cetol TGL ™”) Akzo Nobel (Ran)

On the other hand, as a transfer sheet, a mixed resin of a silicon resin and an acrylic resin is gravure-coated on one side of a carrier sheet made of a biaxially stretched polyethylene terephthalate film having a thickness of 38 μm and thermally cured to release a layer (1 μm thick).
A decorative layer in which a grain pattern is scattered (partially) gravure-printed with an ink obtained by adding a petiole pattern as a pigment to a binder of an extender alkyd resin containing an extender pigment on the release layer. A transfer layer formed of was prepared. And, in the transfer layer and the filling material layer both in a semi-cured state,
The transfer layer and the filling material layer are overlapped, and the surface temperature is 150 ° C.
After pressing the carrier sheet side with the silicone rubber roller,
After cooling to room temperature and allowing the transfer layer and the filler material layer to be completely cured, only the carrier sheet was peeled off and the grain pattern was transferred onto the filler material layer.

The decorative plate thus obtained was excellent in moisture absorption / release properties and waterproofness, despite the formation of the filler material layer. The surface resembled the Kyoto wall, and it was excellent in design as a wall panel for a Japanese-style room.

(Example 2) An inorganic board "Dailite (trademark)" (manufactured by Daiken Kogyo Co., Ltd.) having a total thickness of 6 mm and having a three-layer structure of "iwate / shirasu balloon / iwawa" was used as a substrate. Used for A coating material having the following composition B was applied to the surface of the substrate and dried to form a filler material layer. The coating amount was 150 g / m ² (when dried).

<Composition B> Shell: scallop shell (average particle size: 10 μm) 80% by weight Cypress material powder (average particle size: 100 μm) 7% by weight Pigment: titanium white 3% by weight Binder: acrylic water-dispersed emulsion 10 weight%

On the other hand, a 210 μm-thick polymethyltin layer is formed on a high-quality paper of 70 g / m ² by extrusion coating, and a 200 μm-deep and 5 mm-wide tile is formed on the polymethyldin layer by embossing. A shaped sheet in which reverse irregularities of the joint groove were formed was prepared. The portion corresponding to the bottom of the joint groove was formed with fine grained matte roughness and the tile portion was mirror-finished. Then, the unevenness of the shaped sheet was superimposed on the uncured filler material layer, pressed with a rubber roller, and the shaped sheet was peeled off after the filler material layer was cured to form an uneven pattern.

The decorative board thus obtained has a white surface similar to stucco, and has joint grooves formed in a lattice on the surface, and is excellent in design as a Japanese-style wall panel. Was. In addition, it was excellent in moisture absorption / release properties and waterproofness.

The humidity control data of the decorative plates A and B obtained in Examples 1 and 2, the decorative plate C having a 12.5 mm thick gypsum plate and a decorative plate C and a plaster board D each having a polyvinyl chloride cloth adhered to the surface thereof are shown. I took it. The test method is as follows. A sealed tank was prepared which was capable of raising and lowering the temperature repeatedly according to a program. When there is no sample in the bath, the temperature in the bath is raised and lowered alternately at 10 ° C. for 10 hours and at 45 ° C. for 10 hours, and the relative temperature in the bath is 20% RH when the temperature is raised and 9% when the temperature is lowered.
It was adjusted to be 0% RH. Then, various samples were inserted into the bath, the temperature was alternately raised and lowered at 10 ° C. for 10 hours and at 45 ° C. for 10 hours, and the relative temperatures in the bath were measured and compared. The results are as shown in the graph of FIG.

As can be seen from this graph, the decorative board C to which the polyvinyl chloride cloth was attached had little difference in humidity change from the case where there was no sample in the tank, and the stucco board D did not suppress the humidity change much. In the case of decorative boards A and B, the change in humidity in the tank was suppressed to a small value.

[0035]

As described above, according to the present invention,
A filler layer containing any of cereal shell powder, shell powder, and cypress powder is formed on the surface of a substrate made of a porous inorganic panel, and the filler is received. Since the decorative layer is transferred or the uneven pattern is formed as a layer, the moisture absorption / desorption properties of the substrate and the waterproofness of the substrate can be sacrificed despite the formation of the sealing material layer. It is possible to obtain a decorative plate having no design and high designability.

[Brief description of the drawings]

FIG. 1 is a process chart showing a procedure of a first method for manufacturing a decorative board according to the present invention.

FIG. 2 is a process chart showing a procedure of a second method for manufacturing a decorative board according to the present invention.

FIG. 3 is a graph of humidity control data measured on the decorative board of the present invention and other decorative boards.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Substrate 2 Filler material layer 3 Resin binder 4 Powder 5 Carrier sheet 6 Transfer layer 7 Transfer sheet 8 Shaped sheet 9 Uneven pattern

Claims (2)

[Claims] 1. A sealing material layer having a waterproof property and a moisture absorbing / releasing property is applied to a surface of a substrate made of a porous inorganic panel to form a sealing material layer. Then, at least a decoration as a transfer layer is formed on a carrier sheet. A transfer sheet having a layer is prepared, the transfer layer of the transfer sheet is superimposed on the surface of the filling material layer, and the transfer layer and the filling material layer are bonded to each other by pressing, and then the carrier sheet is peeled off to form the filling material The process consists of forming a decorative layer on the layer, and as a filler, a paint containing any of cereal shell powder, shell powder, and cypress powder in a resin binder A method for producing a decorative board, characterized by the following. 2. A sealing sheet having both waterproofness and moisture absorption / desorption properties is applied to the surface of a substrate made of a porous inorganic panel to form a sealing material layer, and then a shaped sheet having an uneven pattern on the surface. Prepare the irregular pattern of the shaped sheet on the filling material layer, press it, and then peel off the shaped sheet to form the concave and convex pattern on the filling material layer, as the filling material A method for producing a decorative board, comprising using a paint containing any of cereal shell powder, shell powder, and cypress powder in a resin binder.