JPH11222998A - Decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve performance by arranging a resin decorative layer on at least one surface of a decorative sheet base board mainly composed of gypsum by specifying the reinforcing fiber content and bulk density. SOLUTION: For example, a decorative sheet 1 is composed of a resin layer 2, pattern-printed pattern paper 3, an adhesive layer 4 and a decorative sheet base board 5 by covering both surfaces of a gypsum plate 6 containing reinforcing fiber such as glass fiber with base paper 7. Next, the reinforcing fiber is set to 0.3 to 5 % of gypsum weight, and bulk density of the base board 5 is set to at least 0.8 g/cm<3> . The resin layer 2 is formed of a urethane resin, an acrylic resin, an acrylic urethane resin and an expoxy resin. A reinforcing face material such as a thin steel plate, base paper and a glass mat is laminated on the opposite surface of the resin layer 2 or both surfaces, and an antibacterial agent is applied to the resin layer 2 and/or the inside/outside surfaces of the base board 5. Therefore, a warp can be prevented, water repellency, sound insulating performance, heat insulating performance, surface hardness, fireproof performance, mildewproof performance, workability and design can be improved, and a cost can be also reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative plate excellent in design without warpage, provided with a decorative layer made of resin on at least one surface of a gypsum board or a base paper-pasted gypsum board.

[0002]

2. Description of the Related Art A decorative plate provided with a resin decorative layer made of a urethane resin, an acrylic resin, an acrylic urethane resin, an epoxy resin, or the like generally has excellent design properties in addition to surface hardness and water repellency. It is widely used in architectural applications such as floors, ceilings, partitions, etc., in the field of furniture such as tables, counters and cupboards, and in the field of home appliances such as televisions, stereos and refrigerators.

[0003] In particular, urethane resin, acrylic resin, acrylic urethane resin or epoxy decorative board is obtained by coating the above resin on a substrate itself or a substrate having a pattern paper adhered thereto. It is a decorative board with a deep handle and good texture. On the other hand, plywood, various wood-based boards, various cement boards, calcium silicate boards, and the like have been generally used as the substrate.

[0004] However, none of the above-mentioned substrates satisfies all of the performances required for the substrate, such as being inexpensive, in addition to the performances such as sound insulation, heat insulation, workability, and fire protection. There is a strong demand for a decorative board using a decorative board substrate having all the performances.

As a substrate satisfying all of the above-mentioned required performances,
Gypsum, an admixture such as a setting modifier and water are kneaded to form a slurry, formed and hardened and dried, and a gypsum plate obtained by coating the front and back surfaces of the gypsum plate with base paper (for example, gypsum) Board), but the resin decorative plate obtained by coating the above resin on these substrates is difficult to handle because the resin decorative layer side is warped at the end thereof, and the seam between the decorative plates is not smooth. In addition, there were obstacles in construction (in use).

[0006]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to use a gypsum board or a gypsum plaster board as a decorative board substrate without warping, and furthermore, sound insulation, heat insulation, workability, fire protection and antibacterial properties. In addition to various properties such as mold resistance, inexpensive resin decorative board,
In particular, it is an object of the present invention to provide a urethane resin, an acrylic resin, an acrylic urethane resin or an epoxy resin decorative board.

[0007]

The above object is achieved by the present invention described below. That is, a decorative layer made of a urethane resin, an acrylic resin, an acrylic urethane resin or an epoxy resin is provided on at least one surface of a decorative board substrate mainly composed of gypsum containing reinforcing fibers. It is a board.

According to the present invention, a reinforcing fiber is contained in the core material of a gypsum board or a base paper-bonded gypsum board used as a decorative board substrate, and further, the interlayer strength of the base paper in the base paper-bonded gypsum board is increased, or By increasing the bulk density of the board, by increasing the strength of the gypsum board as a decorative board substrate or the gypsum board with base paper, urethane resin,
It is possible to extremely efficiently prevent the decorative board substrate from being warped when a decorative layer made of an acrylic resin, an acrylic urethane resin, or an epoxy resin is provided.

[0009]

Next, the present invention will be described in more detail with reference to preferred embodiments. The gypsum board used in the present invention is obtained by calcining gypsum alone or a mixture of natural gypsum, by-product gypsum, and flue gas desulfurization gypsum, kneading it with water, molding and curing. In addition, the base paper-bonded gypsum board used in the present invention is obtained by coating at least one surface of the gypsum board with the base paper at the time of production.

[0010] Examples of the reinforcing fibers used for reinforcing the gypsum board include waste paper such as newspapers, virgin pulp, glass fibers which are inorganic fibers, rock wool, wallest night, sepiolite and the like. These reinforcing fibers can be contained alone or as a mixture in the gypsum board in an amount of 0.3 to 5%, preferably 0.5 to 1.5% of the weight of the gypsum constituting the gypsum board. .

In order to disperse these reinforcing fibers in a gypsum board in a good condition, the fibers are mixed with calcined gypsum before kneading the calcined gypsum with the fibers and water to form a slurry. Preferably, the fiber surface is coated with calcined gypsum or has a sizing property, and is subjected to a surface treatment with polyethylene oxide or the like which exhibits dispersibility in contact with water before use.

By coating the surface of the fiber with plaster of paris or a dispersant in this way, the fiber is easily and uniformly dispersed in the slurry of plaster of Paris and finally in a state of being uniformly dispersed in the gypsum plate. The fibers are mixed, and the fibers function as a link for the cured body. Therefore, a gypsum board with sufficiently improved strength can be obtained. In particular, it is preferable to use glass fiber as the inorganic fiber because the reinforcing effect is high when the glass fiber is formed into a gypsum plate.

The bulk density of a gypsum board containing reinforcing fibers or a gypsum board with at least one side of the gypsum board covered with base paper is at least 0.8 g / cm ³ , and the preferred range is 0.1 g / cm ³ . 9 to 1.3 g / cm ³ . When the bulk density is less than 0.8, it is difficult to sufficiently suppress the warpage of the decorative board after the resin layer is formed. On the other hand, when the bulk density exceeds 1.3 g / cm ³ , The resulting decorative board is difficult to handle due to its construction.

The resin for the decorative layer applied to the decorative board substrate as described above includes urethane resin, acrylic resin, acrylic urethane resin or epoxy resin. A preferred example of the urethane resin is a two-pack resin paint obtained by using a polyalkylene polyol, a polyester polyol, a polycarbonate polyol or the like as a base resin and combining a polyisocyanate compound as a crosslinking agent for these polyols. A typical example is a resin paint containing a homo- or copolymer of an acrylic monomer such as (meth) acrylic acid ester having a reactive group such as (meth) acrylic acid, (meth) acrylic acid ester, hydroxyl group or epoxy machine, A preferred example of the acrylic urethane resin is a two-pack resin paint using acrylic polyol as the polyol in the polyurethane resin, and a preferred example of the epoxy resin is an epoxy resin as a main component and a polyamine as a curing agent. Two-part curable resin combined with polycarboxylic acid A. Such resin coatings can be obtained from various commercial products and used in the present invention.

[0015] In addition, urethane resin, acrylic resin,
A reactive resin in which an acryloyl group or a vinyl group that is a polymerizable group is introduced into an acrylic urethane resin or an epoxy resin,
A UV-curable or electron-beam-curable urethane resin, acrylic resin, acrylic urethane resin, epoxy resin, or the like obtained by mixing a polyfunctional (meth) acrylate monomer with the resin can also be used. Such a photocurable resin paint can be obtained from various commercial products and used in the present invention.

The resin paint as described above may be a clear paint or a colored paint colored with a pigment. As a method for applying these resin paints, any conventionally known application methods such as a roll coater, a flow coater, and spraying may be used. When applying the paint to the decorative board substrate, the resin layer may be formed by directly applying to the decorative board substrate, or a decorative sheet may be attached to at least one surface of the decorative board substrate. Alternatively, the resin paint may be applied and cured on the surface of the decorative plate after an arbitrary pattern or the like is applied to the surface of the decorative plate substrate by a thermal transfer method, a hydraulic transfer method, a finger pressure transfer method, or the like. Further, the surface of the decorative board substrate to which the resin paint is applied may be one side, two sides, or a side surface, or may be the whole surface. The thickness of the resin layer formed by the resin coating is preferably 50 to 150 μm.

Further, in order to improve the strength of the gypsum board as a decorative board substrate, a thin steel sheet for reinforcement or base paper (for example, usually used for the production of gypsum board) is provided on the opposite or both sides of the gypsum board from the resin decorative layer. Gypsum board base paper), glass nets, glass mats, and other reinforcing surface materials. In particular, when laminating the base paper on the front side of the gypsum board, not only does the strength of the gypsum board be improved, but also the resin is applied to the base paper surface, so that the resin penetrates the base paper moderately and the resin for the gypsum board is removed. And the adhesion of the resin layer to the gypsum plate is also improved.

The base paper is generally composed of a plurality of layers. When the resin is coated on the base paper surface, the base paper is easily peeled between the layers due to the warping stress generated on the coating surface side. Is maintained at 2.5 kg / cm ² or more, or by applying a sealer such as an epoxy resin to the base paper surface, delamination can be prevented. still,
When a conductive thin plate made of aluminum or the like is used as the reinforcing surface material, it is used not only to reinforce a gypsum plate or a gypsum plaster board, but also to prevent various kinds of radio interference from the outside.

Further, an antibacterial agent is applied to the inner and outer surfaces of the resin decorative layer and / or the inner and outer surfaces of the decorative board in order to prevent the generation of mold on the walls, floors, ceilings and the like around the water in bathrooms and kitchens. can do. As the antibacterial agent, commercially available antibacterial agents can be used. For example, aniline derivatives, halogen compounds, sulfur compounds, 2- (4-thiazolyl)
Examples include imidazole / thiazole compounds such as benzimidazole, and inorganic antibacterial agents such as silver, copper, zinc and tin.

The amount of the above-mentioned antibacterial agent used is as follows:
Depending on the type of antibacterial agent and the place where the decorative board is used, etc., in consideration of economy and effect, in general, when the antibacterial agent is internally added to the resin decorative layer or the decorative board substrate, it is preferable to add at 0.1 to 3.0 percent relative to the weight, when applying the antimicrobial agent to the resin decorative layer or veneer substrate, a resin layer or a veneer board 1 m ² per 0.01
It is preferable to apply in a range of 4 g. The application of the antibacterial agent is not particularly limited, but is preferably applied to the surface (resin layer side) of the decorative board substrate or internally added to the resin decorative layer.

An example of the decorative board of the present invention will be described more specifically with reference to the drawings. As shown in FIG. 1, the decorative board 1 of the present invention includes an acrylic polyurethane resin layer 2, a pattern paper 3 on which various patterns are printed, an adhesive layer 4, and a decorative board substrate 5. Are coated with base paper 7 on both sides of the gypsum plate 6. However, in order to prevent the strength of the decorative board substrate 5 from being reduced due to moisture absorption or water absorption from the side and back sides of the gypsum board 6, not only the side and back faces but also the paraffin-based or silicon-based Alternatively, a water repellent treatment can be performed using another water repellent.

It is needless to say that the pattern paper 3 can be omitted when a plain decorative board is produced, but when the decorative design of the decorative board is particularly improved, the pattern paper 3 may be used instead. White titanium paper can be used. When the pattern paper 3 is not used, the adhesive layer 4 can be omitted.

The gypsum plate or the base paper-bonded gypsum plate used in the present invention is composed mainly of β-type calcined gypsum, which is widely used industrially, as the gypsum, reinforcing fibers, and if necessary, pearlite. , Lightweight aggregates such as vermiculite,
Various foaming agents, gypsum water reducing agent, gypsum setting accelerator, gypsum setting retarder and the like may be used in combination, and the gypsum plate or base paper-bonded gypsum plate may have a predetermined amount of calcined gypsum, reinforcing fiber , Water and various additives are mixed together to form a slurry, which is molded and cured and dried according to a conventional method.

When the gypsum base paper is used as a decorative board, the base paper gypsum board has the same core material as that of the gypsum board, obtains the same slurry as described above, and obtains the base paper gypsum according to a conventional method. It is obtained by coating and molding and curing and drying using a base paper for board.

[0025]

Next, the present invention will be described more specifically with reference to examples and comparative examples. Example 1 Base paper-laminated gypsum board containing 0.8% by weight of glass fiber (thickness: 9.
(5 mm, width 100 mm and length 600 mm) A two-component acrylic urethane resin paint is applied to all surfaces including side surfaces by spraying so that the thickness at the time of drying becomes 100 μm, dried and cured, and the decorative board of the present invention is obtained. I got

Example 2 The same two-pack type acrylic urethane resin paint as in Example 1 was applied to the entire surface including the side face of the gypsum board with the same base paper as in Example 1 by spraying so that the thickness when dried was 50 μm. After that, the printing film is hydraulically transferred to one side and side surfaces thereof, and the same acrylic urethane resin paint as above is applied to the transfer surface so that the thickness when dried becomes 50 μm.
After drying and curing, a decorative plate of the present invention was obtained.

Example 3 A decorative board of the present invention was obtained in the same manner as in Example 1 except that a two-pack type urethane resin paint was used instead of the resin paint in Example 1.

Example 4 A decorative plate of the present invention was obtained in the same manner as in Example 2 except that a two-pack type epoxy resin paint was used instead of the resin paint in Example 2.

Comparative Example 1 A decorative plate of a comparative example was obtained in the same manner as in Example 1 except that a gypsum plate in Example 1 was replaced with a calcite plate. Comparative Example 2 A decorative plate of a comparative example was obtained in the same manner as in Example 1 except that a similar gypsum plate containing no glass fiber was used instead of the gypsum plate in Example 1. The properties of the warpage of the boards of the above Examples and Comparative Examples are shown in Table 1 below, and other properties are shown in Table 2. In Table 2, Comparative Example 2 does not show other properties because it has a large warp and is not practical.

Table 1 Warpage: Measured by applying a ruler to the resin layer surface of the decorative board. Table 2 ：: good ○: normal ×: problematic JIS A 5414 “Pulp cement board (irradiated for 200 hours)” JIS K 5400 “General paint test method”

Example 5 A base paper was added to a gypsum core containing 0.3% by weight of "Coatside 110 granules" manufactured by Takeda Pharmaceutical Company Limited as an antibacterial agent and 0.8% by weight of glass fiber. The coated base paper-plastered plaster board and the base paper-plastered gypsum board containing 0.8% by weight of glass fiber without containing an antibacterial agent were respectively manufactured by an ordinary method, and an acrylic urethane resin layer was provided in the same manner as in Example 1. Each decorative board was prepared. Next, each decorative board was cut into a size of 10 × 10 cm, the side face was covered with aluminum foil, put in a desiccator filled with water, left in a room at 30 ° C., and observed for mold generation. The temperature inside the desiccator is 30 ° C.
The relative humidity was 100%. Table 3 shows the results.

Table 2 ：: No mold was found at all. ×: Mold was found.

As described above, the decorative board of the present invention has a fireproof, workable and economical property of the decorative board substrate constituting the decorative board.
Excellent in all compared to conventional decorative board base material,
Moreover, there is almost no warpage of the surface after coating with urethane resin, acrylic resin, acrylic urethane resin or epoxy resin, and the decorative board has excellent water repellency and surface hardness inherent in the resin, and has a deep handle and good design. Met.

[0034]

According to the present invention, a reinforcing fiber is mixed in a gypsum board as a decorative board substrate or a core material of a gypsum board with base paper, and in the case of a gypsum board with base paper, the interlayer strength of the base paper is increased, or Since the bulk density of gypsum board and base paper-plastered gypsum board is increased, even if a resin layer is formed on the surface, the resulting decorative board does not warp, and the water repellency and surface hardness inherent to the resin used. When a resin layer is formed using a urethane resin, an acrylic resin, an acrylic urethane resin, or an epoxy resin, a decorative board having a deep handle with good texture and excellent design can be obtained. In addition, since a gypsum board or a base paper-plastered gypsum board is used as a decorative board, in addition to sound insulation properties, heat insulation properties, workability, fire resistance, etc., an inexpensive decorative board provided with a resin decorative layer is provided. You. Further, by providing an antibacterial agent to the inner and outer surfaces of the decorative board substrate and / or the inner and outer surfaces of the resin decorative layer, a decorative board having excellent antibacterial and antifungal properties is provided.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a decorative board according to the present invention.

[Explanation of symbols]

 1: resin decorative board 2: resin layer 3: pattern paper 4: adhesive layer 5: base paper-bonded gypsum board 6: gypsum board 7: base paper

Claims (9)

[Claims] 1. A decorative board made of urethane resin, acrylic resin, acrylic urethane resin or epoxy resin is provided on at least one surface of a decorative board substrate mainly composed of gypsum containing reinforcing fibers. And decorative board. 2. The reinforcing fiber is 0.3 to 5% by weight of the gypsum.
The decorative board according to claim 1, which is contained at a ratio of: 3. The fiber according to claim 1, wherein the reinforcing fibers are glass fibers.
Or the decorative plate according to 2. 4. The decorative board substrate has a bulk density of at least 0.8.
veneer according to any one of claims 1 to 3 is g / cm ^3. 5. The decorative board according to claim 1, wherein a reinforcing face material is laminated on at least one surface of the decorative board substrate. 6. The decorative board according to claim 1, wherein an antibacterial agent is provided on the resin decorative layer and / or the decorative board substrate. 7. The decorative board according to claim 1, wherein an antibacterial agent is provided on the surface of the decorative board substrate. 8. The gypsum board according to claim 1, wherein the decorative board substrate is a gypsum board having at least one surface covered with base paper.
The decorative plate according to any one of items 7 to 7. 9. The decorative board according to claim 1, wherein the decorative board substrate and / or the base paper are waterproofed.