JPS58516Y2 - FRP reinforced inorganic decorative board - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to an FRP-reinforced inorganic decorative board that has good strength, water resistance, etc. and is particularly useful as a sanitary construction member for bathrooms, washrooms, latrines, and the like.

As is well known, inorganic decorative laminates such as asbestos slate decorative laminates, calcium silicate decorative laminates, and pulp cement decorative laminates generally have poor impact resistance. When used as a building material, some kind of reinforcement is required, but it is generally not easy to reinforce such inorganic decorative boards by laminating FRP, and even if they are lined with FRP, the parts will quickly deteriorate. There were problems such as peeling, and therefore reinforcement in this field was generally done by laminating reinforcing plates such as plywood, steel plates, aluminum plates, etc. with adhesive to form a composite plate. .

However, such composite boards are difficult to use as sanitary building materials such as bathrooms, washrooms, and toilets because of their poor water resistance and workability, and also from the manufacturing process standpoint. From a cost perspective, it is difficult to say that it is advantageous because it requires complicated complex processes and expensive reinforcing plates, and it also has problems such as being difficult to transport and handle because the thickness and weight increase significantly. had.

This invention◆ was made in view of the circumstances mentioned above, and it satisfies the strength, water resistance, workability, durability, etc. required for sanitary building components, and is lightweight and easy to handle. The purpose is to provide a useful FRP-free inorganic decorative board that can be mass-produced with ease.

Hereinafter, the present invention will be described in detail with reference to the drawings.

That is, the inorganic decorative board of the present invention comprises an inorganic substrate 1, a resin decorative layer 2 provided on the upper surface of the substrate 1, and a reinforcing base material for FRP that is integrally bonded by thermocompression to the bottom of the substrate 10 via a resin layer 3. layer 4
and an FRP layer 5 impregnated and hardened on the lower surface of the reinforcing base material layer 4, and is a decorative board made of a flat plate-like wall as shown in Figures 1 and 2 or a decorative board as shown in Figure 3. The surface is embossed.

Here, as the inorganic substrate 1, conventionally known asbestos slate boards, calcium silicate boards, pulp cement boards, etc. are used. A lightweight, pressure-molded inorganic substrate with good strength, fire resistance, water resistance, and durability is used.

The resin decorative layer 2 on the upper surface of the base material 1 can be formed, for example, by placing a resin-impregnated decorative paper cloth on the substrate 1 and bonding it under heat by a force N or a thin resin decorative board (thickness 0.4 to 1.5 mm). The former method is more advantageous in terms of manufacturing method, especially when using the inorganic substrate 1 of the official seal. When thermocompression-bonding the resin decorative layer 2 thereon, it is desirable to prime the surface of the substrate 1 with a resin having high affinity in advance in order to increase the adhesion strength between the resin decorative layer 2 and the inorganic substrate 1. It will be done.

For resin-impregnated decorative paper cloth or resin decorative board, inorganic substrate 1
In order to take full advantage of the fire-resistance characteristics of the paper, it is made of decorative paper cloth impregnated and dried with a thermosetting resin such as melamene or diallyl phthalate, which has good heat resistance, or a similar thermosetting resin. A decorative board or the like is preferably used.

The resin layer 3 on the lower surface of the inorganic substrate 1 functions as a kind of adhesive for the reinforcing base material layer 4 for FRP, and also functions as a warping/clamping layer for the inorganic substrate 1.

That is, when forming the above-mentioned resin decorative layer 2, if a highly shrinkable material such as melamine resin-impregnated decorative paper cloth is used, the inorganic substrate 1 will warp due to its shrinkage, but this resin layer 3 The shrinkage force of the resin decorative layer 2 is alleviated or offset by the force, thereby serving to prevent the inorganic substrate 10 from warping.

Therefore, as a member for forming such a resin layer 3,
Paper cloth impregnated with approximately the same amount of the same resin as the resin-impregnated decorative paper cloth used for the resin decorative layer 2 is preferably used.

The biggest feature of the present invention is that through the resin layer 3 as described above,
The point is that the reinforcing base material layer 4 for FRP is integrally formed on the lower surface of the inorganic substrate 1 by thermocompression bonding.

That is, this reinforcing base material layer 4 for FRP is made of, for example, glass cloth, glass mat, romping cloth, chopped strand mat, non-woven fabric which is not impregnated with any resin.
A reinforcing base material for RP is placed on the bottom surface of the inorganic substrate 1 via the resin layer 3 and bonded by thermocompression.During the hot press, some of the resin eluted from the resin layer 3 impregnates and hardens to firmly form the inorganic substrate. 1, and before forming the 181 layer 5, this reinforcing base material layer 4 is bonded to the resin layer 3 on the opposite side (lower surface side part).
'ZF'RP by leaving a large amount of voids not impregnated with resin.
Equipped with resin impregnation ability.

Therefore, the 181st layer 5, which is the F-most layer, is made by pour-coating and impregnating the FRP reinforcing base material 4 with an FRP resin such as unsaturated polyester resin or epoxy resin using the usual hand-laying method or the like. Defoaming and crimping using rollers, etc. 6
It can be easily formed by curing in an i-cure, and is integrated with the FRP reinforcing base material layer 4 to form a strong FRP tub strong backing layer 6.

In order to make the FRP reinforcing backing layer 6 even stronger, as shown in FIG.
, it is desirable to embed the reinforcing base material 41 for RP.

It is preferable to embed the reinforcing base material 41 by applying the FRP resin, placing the reinforcing base material 41 on the coated surface, and degassing and pressing the resin with a roller or the like at the same time.

In the production of the decorative board of the present invention as described above, when conventionally known asbestos slate boards, calcium silicate boards, pulp cement boards, etc. are used as the inorganic substrate 1, (a) reinforcing base material for FRP;
The resin layer member, the inorganic substrate (preferably with primer treatment on both the front and back sides), and the resin decorative layer member are laminated one after another and integrated by thermocompression using a flat type or a hot press machine engraved with an enhos pattern. , or (b) The force of laminating the reinforcing base material for FRP, the resin layer member, and the inorganic substrate and bonding them together by thermocompression in the same way, and then bonding the resin decorative layer member to the top surface of the inorganic substrate with an adhesive. 181 by that method
When a decorative board without layer 5 is made and the inorganic substrate 1 is made of a substrate material as shown in Table 1,
(c) A reinforcing base material for FRP, a resin layer member, an inorganic substrate material, and a resin decorative layer member are sequentially loaded into the mold of a hot press machine equipped with a mold for molding, and the inorganic substrate 1 is heated and pressed. At the same time as the molding, the reinforcing base material for FRP and the resin decorative layer member are thermocompression bonded, or (→The inorganic substrate material is pre-formed into a plate shape by pressure, and this plate-like temporary molded product is used to perform the above-mentioned process. A decorative laminate with no FRP layer 5 formed thereon is made by either method () or force \ performed in the same manner as in (b), and the reinforcing base material layer 4 for FRP of the decorative laminate with no FRp layer 5 thus obtained is obtained. FRP is applied to the surface of the
After pouring the resin, defoaming and pressing with a roll etc.
This is easily accomplished by forming the RP layer 5.

If a conventionally known material such as asbestos slate is used as the inorganic substrate 1, the embossing will only be applied to the resin decorative layer 2, making it difficult to obtain a deeply embossed decorative board.Table 1 When using an inorganic substrate material such as, a deeply embossed decorative board reaching the inside of the inorganic substrate 1 as shown in FIG. 3 can be obtained.

If it is necessary to provide mounting brackets or other connecting parts on the inorganic decorative board of the present invention, attach the parts to the bottom surface of the FRP reinforcing base layer 4 with adhesive or the like before pouring the FRP resin. It is preferable to temporarily fix the parts and then completely attach them at the same time by forming the FRP layer 5, and there is no risk that the joined parts firmly attached in this way will fall off.

Next, the inorganic decorative board of the present invention will be explained with reference to Examples.

(Example 1) Aluminum hydroxide 70% (weight is the same below) Calcium carbonate 15%, Zeolite 5%, Glass fiber 2.5%
An inorganic substrate material consisting of 7.5 tons of polyphenolic and novolac type phenolic resins is kneaded, and the kneaded product is heated at a pressure of 20 kg/-.
Temporarily formed into a plate shape.

A layer of melamine resin-impregnated dry decorative paper is placed on the top surface of this temporary molded body, and 800 g of melamine resin-impregnated dry paper is placed on the bottom surface.
/po roving cloths are stacked on top of each other and pressed using a direct pressure hot press machine at a pressure of 100 kg/clt and a temperature of 1.
The plate was heated and pressed at 50° C. for 15 minutes to obtain a plate on which no FRP layer was formed.

Next, 400 g of Handler Tive unsaturated polyester resin was applied to the surface of the roving cloth of this board.
It was flow coated at a ratio of rrt, defoamed and crimped with a roll to obtain an FRP reinforced inorganic decorative board with a total thickness of about 5771771 mm.

Test piece of this decorative board (200x 100x5m
) was prepared and various physical properties were measured, and the results are shown in Table 2 below.

(Example 2) Pinch running for the roving cross of Example J, 130g/rr
FRP was made in the same manner as in Example 1 except that the nonwoven fabric of t was used.
A plate without layers was obtained.

On the surface of the nonwoven fabric of this plate, 600 g/y4 of the same unsaturated polyester resin as in Example 1 was flow-coated, and furthermore, a chopped strand mat of 450 g/rrt was placed on top of the unsaturated polyester resin, and then defoamed and degassed with a roll. The mat was buried at the same time as the crimping, and the FRP with the structure as shown in Fig. 2 was made with a total thickness of about 5 m.
A reinforced inorganic decorative board was obtained.

Test piece of this decorative board (200 x 100 x 5rrg
The physical property measurement results of n) are also shown in Table 2 below.As can be understood from the above explanation and examples, the present invention FR
In the P-reinforced inorganic decorative board, the FRP reinforcing base material layer 4 is integrally bonded by thermocompression to the inorganic substrate via the resin layer 3.
Its adhesive strength is high, and therefore, FRP is laminated on the lower surface of this reinforcing base material layer 4 by the Handley Atsushi method.
The layer 5 has an extremely high peeling resistance, and together with the reinforcing base material layer 4, a strong FRP reinforcing hammer 6 is formed, which is fully satisfactory as a building material as shown in Table 2 (-5≦).
It can exhibit bending strength and impact resistance.

In particular, when the F'RP reinforcing base material 41 is further embedded in the 184 layer 5, even higher strength is exhibited.

In addition, the 184 layer 5 is non-water permeable, and the inorganic decorative board of the present invention that enables backing reinforcement with such a 184 layer 5 has a low water absorption rate and is water resistant as shown in Table 2. It is especially suitable for bathrooms, washrooms, etc. where water resistance is required.
It can be suitably used as a sanitary construction member such as a toilet.

In addition, when FRP reinforcement is applied as in the inorganic decorative board of the present invention, the weight per 1rIl of the decorative board increases to u[ as shown in Table 2.
It weighs around 8 kg, compared to the conventional product reinforced with iron plates and plywood.
-The weight per unit is about 15 to 10 times, but it is much lighter than that, and it is extremely easy to handle and transport.

In addition, in the decorative board of the present invention, when the inorganic substrate 1 is formed of an inorganic substrate material as exemplified in Table 1 above, the fire resistance, durability, workability, etc. of the decorative board are greatly improved. Since the moldability of the inorganic substrate material is good, for example, a curved decorative board with a large curvature or a deeply embossed decorative board that reaches the inside of the inorganic substrate 1 can be easily obtained.

Furthermore, in terms of manufacturing method, the FRP reinforcing base material layer 4 is thermocompression bonded to the inorganic substrate 1 via the resin layer 3.
It is very advantageous because the formation of the 84 layer 5 can be carried out by a simple method such as .
Since the shrinkage balance on the front and back surfaces of the inorganic substrate 1 is maintained by the resin layer 3, there is no possibility that a curved decorative board with a constant curvature will result in a curved decorative board with a large curvature error.

The FRP reinforced inorganic decorative board of the present invention has many practical benefits as described above, and is extremely useful as a building material, especially as a sanitary building material.

[Brief explanation of the drawing]

FIG. 1, FIG. 2, and FIG. 3 are all schematic partial sectional views showing one embodiment of the present invention. Brief explanation of the drawings, 1...Inorganic substrate, 2...
...Resin makeup layer, 3...Resin layer, 4...
... Reinforcement base material layer for FRP, 41 ... Reinforcement base material for FRP, 5 ... FRP layer, 6 ... F
RP reinforced backing layer.

Claims (1)

[Scope of utility model registration request] 1. An inorganic substrate 1, a resin decorative layer 2 provided on the upper surface of this substrate 1, a reinforcing base material layer 4 for FRP integrally bonded by thermocompression to the lower surface of this substrate 1 via a resin layer 3, and this reinforcing base material layer. 4
An FRP reinforced inorganic decorative board consisting of an impregnated and hardened FRP layer 5 on the lower surface of the board. 2. Inside the FRP layer 5, a reinforcing base material 4 for FRP is further added.
The inorganic decorative board according to claim 1 of the utility model registration claim in which 1 is embedded.