JPS62215749A - Inorganic embossed decorative board - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to an inorganic embossed decorative board used for the interior and exterior of tiles, boards, wall boards, etc.

(Conventional technology) The present inventors filed Japanese Patent Publication No. 54-3704 (application).

(August 14, 1972), we proposed a nonflammable inorganic decorative board that was made nonflammable by simultaneously applying a surface resin layer (decorative layer) and embossing on an inorganic substrate.

This inorganic decorative board consists of a resin shielding layer, a surface resin layer on top of the resin shielding layer, a surface resin layer on top of the resin shielding layer, and a resin shielding layer that contains a thermosetting resin. The patterned surface provided on the above-mentioned shielding layer can be integrated with heat and pressure at the same time when molding the embossed concave grooves, and has gained popularity due to its nonflammability, good moldability, and excellent appearance due to deep embossing. Architectural interior,
It has become widely prized as a decorative board for exteriors and furniture.

(Problems to be solved by the invention) The present inventors have worked to further improve quality and increase production efficiency based on the conventional accumulated technology described above, but in the process, the following were discovered. We found a problem that needs to be solved. In other words, in conventional decorative laminates, the patterned surface responsible for the decorative properties is made of cellulose pulp paper or cloth impregnated with a thermosetting resin and then dried under the surface resin layer. Will a pattern surface member impregnated with resin and dried be placed?

A pattern is formed on the surface of the shielding layer by printing, or a metal foil or thin plate of aluminum, copper, iron, etc. is laminated on the shielding layer, or it is printed directly on the surface of the cellulose valve paper or cloth itself. However, during embossing molding, cracks occur in the pattern surface itself or in the surface resin layer or shielding layer that supports the pattern surface, which often causes the pattern to collapse and result in defective products. It is.

The present invention was made as a result of extensive research into the above-mentioned problem, and by using paper/cloth with strong stiffness and high shear resistance as the material constituting the pattern surface member, it is possible to prevent the pattern from collapsing and produce defective products. The object of the present invention is to provide a new inorganic decorative board that can significantly reduce the occurrence of.

(Means for Solving the Problems) The structure of the inorganic decorative board of the present invention for achieving the above object will be explained based on the attached embodiment drawings. FIG. 1 is a perspective view showing an embodiment of the decorative board of the present invention, and FIG.
FIG. 3, an enlarged longitudinal cross-sectional view, is similar to FIG. 2 of another embodiment. That is, the inorganic decorative board of the present invention has a content of 20 to 97% (
The main aggregate is aluminum hydroxide (weight ratio, same below).

An inorganic substrate 1 containing 3 to 12% flame retardant thermosetting resin binder and hardened into a plate shape, and a thermosetting composite paper/cloth made of cellulose pulp and synthetic fibers and/or inorganic fibers. A decorative layer 2 impregnated with a resin and integrally bonded by thermocompression on the substrate, and an embossed groove 3 recessed from the surface of the decorative layer 2 to the inside of the thickness of the substrate 1 along with the decorative layer 2.
The gist is that the molding hardening and layer adhesion of the substrate 1 and the decorative layer 2 are simultaneously performed by heat pressure during the embossing molding of the embossed grooves 3.

First, the materials constituting the substrate 1 and the decorative layer 2 will be described in detail.

[1] Inorganic substrate material ■Main aggregate: Aluminum hydroxide Afi20.・3H
, O solid powder is used.

■Auxiliary aggregate: Calcium carbonate, silica sand, calcite powder, calcium silicate, zeolite, kaolin, bentonite, acid clay, etc. are used.

■Reinforcing materials: Mineral fibers (asbestos, etc.), inorganic fibers (glass fibers, ceramic fibers), metal fibers (iron fibers, aluminum fibers, rice casing, etc.), natural fibers (cotton, connecting wires, etc.), synthetic chemical fibers (vinylon, etc.) , nylon, Tetron, etc.) are used.

(2) Binders: Used are phenol/formalin condensates and their derivatives, urea, melamine/formalin condensates and their derivatives, furan/formalin condensates and their derivatives, resins such as polydiphenyl oxide resins, and their derivatives.

The above aluminum hydroxide powder serves as a mechanical strength material for the substrate, and is blended in an amount of 20 to 97% (weight ratio, preferably 50 to 70%) of the total amount, and is molded at a molding temperature of 200%.
There is no thermal change below ℃, but when the ambient temperature is 300-500℃
℃, it releases crystal water to suppress combustion and at the same time becomes AQ and □ as a heat-resistant material, giving the substrate nonflammability. If the blending amount is less than 20%, it will be insufficient to obtain nonflammability, and if it exceeds 97%, the bonding strength will decrease, so the desirable range is 50 to 70%.

Auxiliary aggregate is used to improve the mechanical strength of molded products, reduce costs by increasing the amount, or as an auxiliary binder and to provide fluidity and increase the amount during molding.The amount used is the total amount. 77% or less, and if it exceeds 77%, nonflammability is impaired, and a desirable range is 15 to 45%.

Reinforcements are used to further improve the mechanical strength of the molding and are added up to 15%, preferably 2-10%.

The binder is a flame-retardant thermosetting resin that gives mutual molding fluidity to the above materials and can be cured by heat pressure, and the amount used is 3.
~12%. If the amount is less than 3%, the binding strength will be insufficient, and if it exceeds 12%, even if the amount of aluminum hydroxide is increased, it will not be a noncombustible material. It is preferably 6 to 10%.

[2] Decorative layer member ■ Composite paper/cloth: Paper/cloth (including non-woven fabric) made by mixing cellulose pulp fibers and synthetic fibers, paper/cloth made by mixing cellulose pulp fibers and inorganic fibers, composite with cellulose pulp fibers Paper and cloth made by mixing fibers and inorganic fibers, as well as
Paper, cloth, etc., which are made by laminating cellulose pulp paper and synthetic fiber paper/cloth or inorganic fiber paper/cloth with an adhesive or an impregnated resin described later, are used. Synthetic fibers include polyethylene terephthalate (hereinafter abbreviated as PET) resin fibers,
Those having a melting point of 150°C or higher, such as acetate resin fibers, nylon resin fibers, and polypropylene (pp) resin fibers, are preferably used, and as the inorganic fibers, glass fibers, carbon fibers, iron fibers, etc. are used.

When making cellulose pulp paper, titanium oxide (T i O,) is generally added at the same time, but the same is true for the above-mentioned composite paper. 1 When mixed with synthetic fibers, cellulose pulp fibers vs. synthetic fibers vs. oxidized The blending ratio of titanium is 20-80:10-50:10-40, preferably 35-50:25-35:20-30 in parts by weight.

■Impregnated resin: urea, melamine, diallyl phthalate,
The above composite paper is used by impregnating and drying a transparent or translucent thermosetting resin liquid such as acrylic acid, methacrylic acid ester, or derivative resin thereof.

The impregnating resin is impregnated by immersing the composite paper in a resin liquid, or it is simultaneously impregnated during papermaking of the composite paper, and the resin is carried between the fibers of the composite paper and dried. In addition, the decorative layer member is the main element responsible for the design of the decorative board, and is either printed with a desired pattern on the surface of the composite paper in advance, colored at the same time as the paper is made, or impregnated with resin and then colored. The design can be obtained by appropriately printing a patterned surface member or the like on the surface.

[3] Member used in combination with decorative layer member: The decorative layer member described above is mainly used alone and is formed as a decorative layer 2 on the substrate 1, and a transparent or translucent resin is coated on both the front and back surfaces of the decorative layer 2. It is also possible to use the surface layer 4 and the core layer 5 (see Fig. 3) stacked in a sandwich-like manner, or to use only the resin surface layer 4 similar to the above stacked on the decorative layer 2 shown in Fig. 2. It is.

■Expression resin layer member: Use cellulose bulk paper or cloth (including non-woven fabric) impregnated with the same resin liquid as the above-mentioned composite paper and dried.

(2) Tip layer member 8 Appropriate pulp paper or cloth is impregnated with a thermosetting resin similar to the above or a thermoplastic resin liquid such as acetic acid vinyl chloride or acrylic acid ester emulsion and dried.

When using the decorative layer member alone, approximately 50 to 150 g/
RRR composite paper impregnated with 100 to 250% resin liquid is used. However, when using the above-mentioned surface resin layer member and core layer member together, the decorative layer member has a 50 to 130
g/rd composite paper impregnated with 50 to 110% resin liquid and dried, the surface resin layer member is 10 to 30 g/rr.
r pulp paper or cloth impregnated with 100 to 300% resin liquid and dried, and the core layer member is 10 to 30%
150-300 g/rd pulp paper or cloth
% of the resin liquid is used, and as a result, the overall fiber density and impregnated resin concentration are approximately the same as when the decorative layer member is used alone. Further, since the surface resin layer has a low fiber density, it is transparent or semi-transparent, so that the decorative layer 2 directly below can be seen through.

[4] In addition, the decorative layer 2 has a larger thermal shrinkage than the substrate 1, so when the substrate 1 is thin, it may warp after molding. It is also possible to use a reinforcing layer 6 (equivalent to the core layer 5) or a glass fiber cloth net or the like alone or in combination (see Figure 3), laminated on the back side of the substrate and molded as a whole. Ru.

In order to manufacture the decorative board of the present invention using the above-mentioned materials, etc., the substrate materials are well mixed using a co-kneader, Henshil mixer, etc., and the decorative layer member is placed on the embossing mold, and a surface resin layer and a core layer are used together. In this case, the surface resin layer member, the decorative layer member, and the core layer member are stacked in this order), and the above substrate material is filled thereon.

If necessary, place a backing paper etc. on top of this and heat to 20℃.
It is integrally embossed by hot pressing for several minutes at a temperature of 0° C. or lower and a pressure of 100 kg/aJ to 150 kg/d. When filling the substrate material, in order to improve the homogeneity of the molded plate, a preforming process is introduced between mixing and hot pressing. It is desirable to melt the mixture on a belt, level it, and mix it thoroughly, then remove the pressure on the belt and continuously fill the plate-shaped pieces into the mold for the final molding. In pre-forming, when fiber reinforcing material is mixed into the mixture, if the amount of binder is small, the fluidity of the molded product will be low and it will be difficult to obtain a board in which the reinforcing material is evenly dispersed, resulting in uneven density and partial strength loss. However, preforming has the advantage of avoiding this fear. As the pressing means, a conventionally known direct pressure press equipped with an embossing press mold can be used.

(Function) In the inorganic decorative board of the present invention having the above-mentioned structure, the decorative layer 2, which is responsible for the design of the decorative board, is a composite paper or cloth containing synthetic fibers or inorganic fibers that are strong and have high shear resistance. Since it is made of a material impregnated with a curable resin, cracks do not occur in the decorative layer 2 even if deep embossing 3 is applied during embossing molding, and the design of the embossing 3 and the decorative layer 2 is matched. It is possible to express a wide variety of patterns. Additionally, the incidence of defective products is significantly reduced, ensuring efficient production and inexpensive supply. Moreover, the decorative board of the present invention maintains almost the same performance as the inorganic decorative board of the prior art even if only the decorative layer 2 is deposited on the surface of the substrate 1, and the production efficiency can be reduced. It is considered possible. On the other hand, when the surface resin layer 4, core layer 5, backing paper 6, etc. are used in combination, the gloss and luster of the surface are improved, the appearance is improved, and the mechanical strength of the decorative board itself is further improved.

(Example) Next, examples will be described.

(Example-1) (i) Preparation of inorganic substrate material; PET resin fiber: pulp fiber: TiO, :=30:40
: 25 (parts by weight), 100 g/bo, 0.
A mixed paper with a thickness of 1 m+ was prepared, a pattern was printed on the surface, and the paper was immersed in a melamine resin solution and dried to obtain a decorative layer member impregnated and supported with 150% melamine resin.

(Blood) Hot pressure molding: The substrate materials of (i) are mixed in a co-kneader and extruded into a sheet to be preformed, while the decorative layer member of (n) is placed on the embossing mold of a direct pressure press with the surface facing down. The sheet was placed on top of the sheet and hot pressed at 150 kg/cJ and 150° C. for 5 minutes to obtain a decorative board as shown in FIGS. 1 and 2.

(Example-2) (i) Preparation of substrate material; same as Example 1 (...) Preparation of decorative layer member; PP resin fiber: pulp fiber: Ti02 = 30:40:2
5 (parts by weight) and 60 g/bo.

After printing a pattern on the surface of mixed paper with a thickness of 0.06 mm, it was immersed in a melamine resin solution and dried.
A decorative layer member impregnated and supported with 0% melamine resin was obtained.

(iii) Preparation of surface resin layer member: Pulp paper of 24 g/% and thickness of 0.03 W+ was immersed in a melamine resin solution and dried to obtain a surface resin layer member impregnated and supported with 250% melamine resin.

(tv) Preparation of core layer member: A 23 g/% pulp paper with a thickness of 0.02 m was immersed in a phenolic resin solution and dried to obtain a core layer member impregnated and supported with 200% phenol resin.

(v) Hot pressure molding: Arrange the surface resin layer member (m), the decorative layer member (ii), and the core layer member (tv) in this order on the embossing mold of a direct pressure press, and then In the same manner as in Example 1, sheet-like substrate materials were superimposed, and a glass net and a core layer member (TV) were further placed on top of the sheet material, and these were combined into 15
0kg/a#, hot press at 150℃ for 5 minutes, and
A decorative board as shown in the figure was obtained.

(Comparative example) (i) Preparation of substrate material; Same as Example 1 (ii) Preparation of decorative layer member; Pulp fiber: T i 01 = 75:25
Paper is made at a ratio of (parts by weight): 60g/I, 0.06mm
It was made into thick white paper, and then dipped in a melamine resin liquid and dried to obtain a decorative layer member impregnated and supported with 100% melamine resin.

(City) Preparation of surface resin layer member: Same as Example 2 (iv)
Preparation of core layer member: Same as Example 2 (v) Hot pressure molding:
On the embossing mold of the direct press, (in) the surface resin layer member and (ii) the decorative layer member.

Place the core layer member of (God), the sheet-like substrate material of (i), the glass net, and the core layer member of (iv), and hot press them all at once at 150 kg/a# at 150°C for 5 minutes. A decorative board having the same structure as in Example 2 was obtained.

Example 1. The decorative boards obtained in Example 2 and Comparative Example were tested for performance and examined for the occurrence of cracks during molding. The results are shown in Table 1.

However, (J) in Table 1 is based on JISA-1321, and (A) is based on the Japanese Agricultural Standard for Special Plywood, Ministry of Agriculture, Forestry and Forestry Notification No. 1.
373.

From Table 1, it can be seen that the decorative boards of Examples 1 and 2 are both completely nonflammable and more than fully provide the various performances required of plywood. Also, Example 1
．． Both samples had better bending strength than Comparative Examples, and in particular, Example 1 had about a 20% improvement in bending strength despite having only one decorative layer member, making it possible to obtain a decorative board that was difficult to break. Furthermore,
It can be seen that Examples 1 and 2 do not cause cracks in the decorative layer during molding, and there is almost no risk of producing defective products even if they are adopted in an actual production line. On the other hand, in Example 1, only two are required: the substrate and the decorative layer member, and the number of sheets to be assembled during production is small, making it possible to simplify the process and reduce costs. The decorative board thus obtained had a good design between the deep embossing and the decorative layer, and was extremely suitable as a decorative board for architectural interiors, exteriors, and furniture.

It goes without saying that the present invention is not limited to the above-mentioned embodiments, and that other changes can be made without departing from the scope of the present invention.

(Effects of the Invention) As described above, the inorganic decorative board of the present invention uses a composite paper/cloth containing pulp fibers and synthetic fibers or inorganic fibers that are strong and have high shear resistance as a decorative layer responsible for the design. This is because the decorative layer and an inorganic substrate containing aluminum hydroxide as the main aggregate and a thermosetting resin as a binder are integrally formed under heat and pressure at the same time as embossing molding. , almost no cracks occur in the decorative layer when embossing is applied. Moreover, it maintains its strong and lightweight characteristics, making it extremely useful as decorative laminates for architectural interiors, exteriors, and furniture.

[Brief explanation of drawings]

Fig. 1 is a perspective view showing one embodiment of the decorative board of the present invention;
The figure is an enlarged longitudinal sectional view taken along the line nn of FIG. 1, and FIG. 3 is a diagram similar to FIG. 2 of another embodiment. (Explanation of symbols) 1... Inorganic substrate, 2... Decorative layer, 3...
・Emboss. Figure 1 Figure 2 Figure 3

Claims (1)

[Claims] 1. An inorganic material whose main aggregate is 20-97% (by weight, the same applies hereafter) of aluminum hydroxide, which is molded and hardened into a plate shape, containing 3-12% of a flame-retardant thermosetting resin binder. a substrate, a decorative layer made by impregnating and carrying a thermosetting resin on a composite paper/cloth of cellulose pulp and synthetic fibers and/or inorganic fibers and integrally bonded by thermocompression on the substrate; Accordingly, it is made up of embossed grooves that are recessed into the thickness of the substrate, and that the molding hardening and layer adhesion of these substrates and decorative layers are simultaneously performed by heat pressure during embossing molding of the embossed grooves. Features an inorganic embossed decorative board.