JPH1076598A - Incombustible decorative plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently obtain an incombustible decorative plate having satisfactory external appearance. SOLUTION: This decorative plate 4 is constituted by superposing sheet materials 2, 3 for a decorative layer on a front surface or front and rear surfaces of a sheet material 1 for a core material layer coated with compound obtained by mixing phenol resin with two or more types of aluminum hydroxides having different particle sizes, laminating integrally it on a porous sheet base material made of mineral fiber. In this case, in the aluminum hydroxide having two or more types of particle sizes, large particle size is 50 to 200μm of mean particle size, small particle size is 1 to 30μm of mean particle size, total amount of the both is 50wt.% or more of overall filler, a ratio of the mean particle sizes of the both is 6 times or more, and a mixing ratio is 4:6 to 6:4.

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 plate mainly used for various purposes as an interior material for a building.

[0002]

2. Description of the Related Art Many conventional nonflammable decorative materials are inorganic materials which have many problems in workability, impact resistance, safety to the human body due to the inclusion of asbestos, and the like. On the other hand, organic resin-based cosmetic materials generate remarkable heat and smoke during combustion, and are subjected to a combustion test (notified by the Ministry of Construction,
No. surface burning test and substrate burning test. It is difficult to maintain the shape after the test (hereinafter, referred to as a nonflammable test), and the reliability as a nonflammable material cannot be obtained. In the production of conventional organic resin-based incombustible decorative panels, the resin content of the compound is extremely small, so the wettability and elongation of the compound during blending and coating are poor.
In particular, the quality of semi-finished products is hindered in the process of applying the lamination molding method, so that inefficient production such as application of additives and low-speed coating has been performed.

[0003]

SUMMARY OF THE INVENTION The present invention has been completed by examining various types of organic resin non-combustible decorative boards excellent in non-combustibility in view of the above-mentioned situation. It eliminates various additives and achieves higher production efficiency.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a core obtained by coating a porous sheet substrate made of inorganic fibers with a composition comprising a phenol resin and two or more aluminum hydroxides having different particle sizes. A decorative sheet in which a decorative layer sheet material is superimposed on a surface or front and back surfaces of a material layer sheet material and laminated and integrated, wherein the two or more kinds of aluminum hydroxides having different particle sizes have a large particle size. Has an average particle size of 50 to 200 μm
And those having a small particle size have an average particle size of 1 to 30 μm,
The non-combustible makeup is characterized in that the total amount of both is not less than 50% by weight of the total filler, the ratio of the average particle diameter of both is not less than 6 times, and the mixing ratio is from 4: 6 to 6: 4. Board.

[0005] The inorganic fiber base material used as the sheet material for the core layer is made of a glass non-woven fabric, in particular, having a basis weight of 30 to 1.
A glass non-woven fabric of 00 g / m ² is suitable.

In the present invention, the inorganic fiber base material used in the sheet material for the reinforcing layer obtained by impregnating with a melamine resin is a glass nonwoven fabric having a basis weight of 30 to 100 g / m ² or a basis weight of 45 to 220 g / m 2. ^Two glass fabrics are preferably used.

The composition of the composition applied to the sheet material for the core layer usually comprises 5 to 60% by weight of a phenolic resin and 95 to 40% by weight of aluminum hydroxide. For example, it is possible to comply with the Ministry of Construction Notification No. 1828 “Designating Noncombustible Materials”. If the phenolic resin content is less than 5% by weight, the resin cannot exhibit the function as a binder, so that there is a problem in handling the core material layer sheet material and in the interlayer strength after molding, which is not preferable.

The blend is applied as it is, or after being diluted with a diluent such as water or alcohol, at a ratio of 9 to 30 times (weight ratio) the inorganic fiber substrate. If it is less than 9 times, the adhesion and surface finish tend to be insufficient, and if it is more than 30 times, it may be difficult to handle the core material sheet when it is handled.

As the phenol resin, a resol type phenol resin using ammonia or an amine-based catalyst, for example, triethylamine or the like is usually used, but is not limited thereto.

In the present invention, it is preferable that two or more kinds of aluminum hydroxide having a large particle diameter and a small particle diameter are mixed and used, and the aluminum hydroxide be packed in the closest packing. At this time, those having a large particle diameter have an average particle diameter of 50 to 200 μm, those having a small particle diameter have an average particle diameter of 1 to 30 μm, and the total amount of both of them is 50% by weight or more of the total filler, The particle diameter ratio of the two is 6 times or more, and the compounding ratio is 4: 6 to 6: 4. When the particle size ratio is smaller than 6 times (the difference in particle size becomes smaller), the gap (volume) between the particles increases, and the apparent wettability of the blend decreases. If the compounding ratio is outside the range of 4: 6 to 6: 4, the oil absorption increases due to the increase in the particle surface area, or the apparent wettability of the compound decreases due to the increase in the interparticle gap, which is not preferable in production.

It is not preferable to use a compound having a small particle size of less than 1 μm in average particle size, or to use a compound having a small particle size alone because the workability at the time of mixing the mixture 2 is reduced. When the large particle size exceeds 200 μm in average particle size or when the large particle size is used alone, it is difficult to handle the sheet material for the core material layer, and at the same time, the nonflammability decreases due to the decrease in the particle surface area. Can be seen. By closely packing with two or more kinds of aluminum hydroxides having different particle diameters as described above, the wettability of the composition is improved at the time of preparing the sheet material for the core material layer, and at the same time the workability at the time of mixing the composition, the sheet material The handleability, non-combustibility, etc. of the rubber are also improved.

The decorative layer sheet material to be superimposed on the front surface or the back surface of the core material layer sheet material has a basis weight of 40 to 40 made of pulp, linter, synthetic fiber, glass fiber or the like.
Melamine resin 60 on 120 g / m ² sheet or paper
~ 95% by weight, aluminum hydroxide or silica 40 ~ 5
Impregnated sheet (or paper) impregnated with a mixture consisting of wt%
Is used. The impregnation of this formulation is from 100 to 400% by weight, based on the sheet or paper. Melamine resin is
Those containing 0.1 to 20% by weight of a usual modifier can also be used, and an acidic curing agent can be appropriately compounded.

The decorative layer sheet material is laminated and integrated as a decorative layer on the front surface or the front and back surfaces of the core material sheet material. Is preferably 300 g / m ² or less. Those exceeding this range make it difficult to pass the nonflammability test. Also, it may be difficult to pass the nonflammability test for a molded product having a total thickness of less than 3 mm. A plurality of the core material layer sheet materials prepared in this way are stacked, and the decorative layer sheet material is stacked on the front surface or the front and back surfaces, and heated and pressed to form the nonflammable decorative plate of the present invention. At the time of molding, a mirror-finished plate, an embossed plate, an embossed film, or the like is overlaid, and the surface is finished to a mirror finish, an emboss finish, or the like.

[0014]

The present invention will be specifically described below with reference to examples and comparative examples.

EXAMPLE A glass fiber nonwoven fabric having a basis weight of 75 g / m ² , a specific gravity of 0.23 g / cm ³ and an organic binder amount of 11% by weight was coated with 92% by weight of aluminum hydroxide (46% having an average particle diameter of 160 μm).
Weight% and 46 weight% with an average particle size of 10 μm)
And a blend of 8% by weight of a resol-type phenolic resin, thereby obtaining a core material sheet material (1) having an impregnation ratio of 20 times.
Next, a melamine resin containing a curing agent is impregnated into a decorative base paper for a building material having a basis weight of 80 g / m ² to prepare a decorative layer sheet material (2) having an impregnation ratio of 100% by weight, and a basis weight of 60 g / m ^2.
Was impregnated with a melamine resin containing a curing agent to produce a decorative layer sheet material (3) having an impregnation rate of 115% by weight. 4 sheets of core material sheet material (1),
One sheet of decorative layer sheet material (2) on the front side and one sheet of decorative layer sheet material (3) on the back side, 140 ° C, 100k
g / cm ² under the condition of 20 minutes and thickness 3.5mm
Was obtained.

Comparative Example A glass fiber nonwoven fabric having a basis weight of 75 g / m ² , a specific gravity of 0.23 g / m ³ and an organic binder amount of 11% by weight was added with 92% by weight of aluminum hydroxide (10% by weight having an average particle diameter of 160 μm and 10% by weight). A mixture of 82% by weight having a particle size of 10 μm) and 5% by weight of a resol-modified phenol resin was applied to obtain a core material sheet material (5) having an impregnation ratio of 20 times. A sheet material for decorative layer (2) and a sheet material for decorative layer (3) similar to those in Example 1 are superimposed on four sheets of core material layer sheets (5) one by one, and the same conditions as in Example 1 are used. To obtain a non-combustible decorative plate (6) having a thickness of 3.6 mm. The incombustible decorative board (4) and its core material sheet material (1), the incombustible decorative board (6) of the comparative example and its core material sheet material (5)
Was evaluated for coating speed and appearance. The results are shown below.

[0017]

[Table 1]

[0018]

The non-combustible decorative plate of the present invention comprises a porous substrate such as a nonwoven fabric or cloth made of inorganic fibers such as glass fibers;
It consists of a mixture of a phenolic resin and aluminum hydroxide, and as the aluminum hydroxide, two or more kinds having different particle diameters are compounded. A large amount can be blended, and nonflammability can be realized without blending extra additives. Further, higher production efficiency can be obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a non-combustible decorative board (4) in which sheet materials (2) and (3) for a decorative layer are laminated and formed on the front and back surfaces of a sheet material (1) for a core material layer.

FIG. 2 is a cross-sectional view of a non-combustible decorative plate (6) in which decorative layer sheet materials (2) and (3) are laminated and formed on the front and back surfaces of a core material layer sheet material (5).

[Explanation of symbols]

 1 Sheet material for core layer 2 Sheet material for decorative layer 3 Sheet material for decorative layer 4 Non-combustible decorative board 5 Sheet material for core layer 6 Non-combustible decorative board

Claims (2)

[Claims] 1. A surface of a sheet material for a core material layer in which a composition comprising a phenolic resin and two or more kinds of aluminum hydroxides having different particle diameters is applied to a porous sheet substrate comprising inorganic fibers. A decorative sheet in which a sheet material for a decorative layer is laminated on the front and back surfaces and laminated and integrated, wherein the two or more types of aluminum hydroxide having different particle diameters have a large particle diameter with an average particle diameter of 50 to 200 μm. The average particle diameter is 1 to 30 μm, the total amount of both is 50% by weight or more of the total filler, and the ratio of the average particle diameter of both is 6 times or more; Is from 4: 6 to 6: 4. 2. A sheet material for a reinforcing layer in which a melamine resin is applied to a sheet substrate made of inorganic fibers and the content of which is 40 to 400% by weight is inserted between sheet materials for a core material layer. The nonflammable decorative board according to claim 1.