RU2814634C1 - Structure of fastening unit and method of applying decorative laminates - Google Patents

Abstract

FIELD: fasteners.

SUBSTANCE: invention relates to variants of the structure of the fastening unit and to a method for applying decorative laminates to a base material to obtain such a structure of the fastening unit for decorative laminates. The technical result is achieved in that the structure of the attachment unit for decorative laminates includes at least two paired decorative laminates attached to the base material, in which at least two paired decorative laminates are used for a vertical surface, in which each of at least two paired decorative laminates has a double-sided adhesive tape pasted along the outer peripheral portion on the back side of the decorative laminate, and a double-sided adhesive tape pasted on the inner portion inwardly from the outer peripheral region to form a section. The elastic adhesive comprising a solvent-free, one-component elastic adhesive based on a modified silicone resin is applied on the outside of the double-sided adhesive tape for the outer peripheral region on the rear side, and elastic adhesive is also applied inside the section formed by the double-sided adhesive tape for the interior. At least two paired decorative laminates include a space between them and are fixed to the base material on their respective rear sides. The double-sided adhesive tape has a total thickness of from 0.03 to 10 mm and has an adhesive strength of from 3 to 30 N/20 mm at a temperature of 23°C or adhesive strength from 1 to 20 N/20 mm at a temperature of 0° according to the 90-degree peel test based on the JIS Z 0237 standard. The technical result is also achieved by another embodiment of the decorative laminate attachment structure, in which each of the at least two paired decorative laminates includes a decorative layer and a core layer. The core layer is configured as a prepreg containing a fiber-based material, an organic binder component and an inorganic filler, in which the total particle diameter Dv(10) of the inorganic filler according to the particle size distribution measuring method using laser diffraction/scattering is 0.5 mcm or more and the total volume particle diameter Dv(90) of the inorganic filler according to the particle size distribution measurement method using laser light diffraction/scattering is 40.0 mcm or less. The technical result is achieved by a method of applying a decorative laminate to a base material to obtain such a structure attachment point for decorative laminate.

EFFECT: adhesion strength.

29 cl, 25 dwg, 6 tbl

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This international application claims the benefit of Japanese Patent Application No. 2020-040431 filed on March 10, 2020 with the Japan Patent Office, and the entire contents of Japanese Patent Application No. 2020-040431 are incorporated herein by reference.

Field of technology to which the invention relates

[0002] The present invention relates to a fastener structure and a method for applying decorative laminates.

State of the art

[0003] Decorative thermoset resin laminates, such as melamine decorative laminates, are generally known. Decorative thermoset resin laminates are widely used as interior finishing materials on horizontal surfaces such as backsplashes and counters, and on vertical surfaces such as wall surfaces. Decorative thermoset resin laminates are difficult to attach to the base material by nails, screws or the like when they are applied. For this reason, decorative thermoset resin laminates were applied to base materials using an adhesive. As a suitable application configuration, Applicant discloses in Patent Document 1 the structure of an attachment assembly for decorative laminates for which both double-sided adhesive tape and elastic adhesive are used.

Decorative laminates exhibit significant dimensional variation. When adjacent decorative laminates become abutted to an attachment point, the decorative laminates sometimes peel away from each other in areas where the decorative laminates are abutted. To solve this problem, it has been proposed to create a joint between decorative laminates in the form of a loose-fit structure, and fill the joint with a connector formed from vinyl chloride resin, as shown in Patent Document 2.

List of cited literature

Patent literature

[0004] PTL 1: Patent Document 1: Publication of Chinese Unexamined Patent Application No. 1955425

PTL 2: Patent Document 2: Publication of Japanese Unexamined Patent Application No. H10-61144A

PROBLEMS SOLVED BY THE INVENTION

[0005] However, according to the traditional attachment structures disclosed in Patent Document 1, the double-sided adhesive tape produces weakened adhesive strength. The problem is that the decorative laminate slides down under its own weight, even if you try to temporarily attach the decorative laminate to the base material. The adhesive strength tends to weaken during low temperature periods, particularly in winter.

The decorative laminate exhibits significant dimensional change, which also creates the problem that the decorative laminate cannot be secured to the base material with double-sided adhesive tape, which loses its adhesive strength when deformation occurs in the decorative laminate.

[0006] In addition, there is the problem that a small decorative laminate can be handled by one person during installation work, whereas the larger the decorative laminate, the more labor and time will be required for precise placement, which will require additional two or more people. In addition, when large-size decorative laminate is cut, cutting the decorative laminate causes deterioration in dimensional accuracy, making it difficult to finish the cutting surface in a straight line shape. This thus leads to the problem that the joint portion formed by the loose connection is not obtained as a straight line.

[0007] The present invention is discussed in light of the above-mentioned circumstances. It is desirable to provide a fastener structure and method for applying decorative laminates that allows decorative laminates to be installed on a base material with ease and a fine finish.

PROBLEM SOLVING TOOLS

[0008] The present invention provides a decorative laminate attachment structure comprising at least two paired decorative laminates attached to a base material. Paired decorative laminates can be used for vertical surfaces.

Each of the at least two paired decorative laminates has double-sided adhesive tape applied to an outer peripheral portion on the rear side of the decorative laminate, and double-sided adhesive tape applied to an inner portion inwardly from the outer peripheral portion to form a section. Elastic adhesive is applied on the outside of the double-sided adhesive tape for the outer peripheral area on the back side. Elastic adhesive is also applied inside the section formed by double-sided adhesive tape on the inside.

At least two paired decorative laminates are secured to the base material on their respective rear sides while being spaced apart from each other.

Double-sided adhesive tape has a total thickness of 0.03 to 10 mm, and has an adhesive strength of 3 to 30 N/20 mm at a temperature of 23ºC, or has an adhesive strength of 1 to 20 N/20 mm at a temperature of 0ºC, according to the 90°C test. -degree peel based on JIS Z 0237. Moreover, the present invention provides a method of applying decorative laminates to a base material to obtain the above-mentioned decorative laminate attachment structure. The method includes the following steps (A) to (D):

(A) cutting one decorative laminate from at least two paired decorative laminates to a predetermined size, using an element that has a rectangular shape in plan view, the element including a height difference in the form of one step, having an upper planar portion, a lower planar portion part and side wall;

(B) sticking double-sided adhesive tape on the outer peripheral portion on the back side of one decorative laminate obtained by cutting (A), and sticking double-sided adhesive tape on the inner portion inward from the outer peripheral portion to form a section, and applying elastic adhesive to the outside of the double-sided adhesive tape for the outer peripheral part on the back side, and applying elastic adhesive inside the section formed by the double-sided adhesive tape for the inner part;

(C) attaching a vacuum lifter to the front surface of the one decorative laminate obtained in the gluing step (B) and pressing the rear side against the base material, thereby fixing the one decorative laminate to the base material; And

(D) treating another decorative laminate of at least two paired decorative laminates in the same manner as in the above steps (A), (B), and (C), and attaching the other decorative laminate to the base material with a space formed between one decorative laminate and other decorative laminate.

RESULTS OF THE INVENTION

[0009] According to the structure of the decorative laminate fastening unit according to the present invention, each of the decorative laminates is temporarily fixed to the base material in an appropriate manner. Therefore, there is no chance of a problem occurring until the elastic adhesive is cured, for example preventing the decorative laminate from sliding down under its own weight.

Even when the decorative laminate exhibits a significant change in size and deformation of the decorative laminate occurs, the elastic adhesive absorbs the change in size of the decorative laminate. Therefore, it is possible to fix the decorative laminate to the base material, reducing the deformation of the decorative laminate.

According to the method of applying decorative laminates according to the present invention, each decorative laminate has improved dimensional accuracy when cut. As a result, it is possible to finish the cut surface in the shape of a straight line.

Brief description of drawings

[0010] FIG. 1 is a top view of a decorative laminate having four sections, the decorative laminate having double-sided adhesive tapes applied to its back side and elastic adhesive applied to its back side.

FIG. 2 is an enlarged view of the main portion of FIG. 1.

FIG. 3 is a top view of a decorative laminate having six sections, the decorative laminate having double-sided adhesive tapes applied to its back side and elastic adhesive applied to its back side.

FIG. 4 is a sectional view of a structure according to the present invention.

FIG. 5 is a cross-sectional view of the structure of a decorative laminate fastening unit in which the joint portion is processed by means of a flat type connector.

FIG. 6 is a sectional view of a flat type connector according to FIG. 5.

FIG. 7 is a cross-sectional view of the structure of a fastening unit for decorative laminates, which is made by filling the joint area with a sealing agent.

FIG. 8 is a cross-sectional view of the structure of the decorative laminate fastening unit, which is made by gluing the bottom seam sealing tape to the joint area.

FIG. 9 is an enlarged sectional view of the main part showing the part indicated by the dotted line in FIG. 8.

FIG. 10 is a cross-sectional view of the structure of an outer corner decorative laminate attachment assembly using an outer corner outer tip type connector.

FIG. 11A is a cross-sectional view of the structure of an outer corner decorative laminate attachment assembly using an outer corner L type connector.

FIG. 11B is a front perspective view viewed from the Z direction of FIG. 11A.

FIG. 12 is a cross-sectional view of the structure of a decorative laminate fastening assembly that is made using an inner corner landing type connector.

FIG. 13 is a cross-sectional view of the structure of an interior corner decorative laminate attachment assembly using an L-type interior corner connector.

FIG. 14 is a top view of a step member according to the present invention.

FIG. 15 is a perspective view of a step member according to the present invention.

FIG. 16 is an explanatory view for explaining step (A) according to the present invention.

FIG. 17 is an explanatory view for explaining step (A) according to the present invention.

FIG. 18 is a top view of a decorative laminate for explaining step (B) according to the present invention.

FIG. 19 is an enlarged plan view of the main body of FIG. 18.

FIG. 20 is a perspective view of a vacuum window lifter used for step (C) according to the present invention.

FIG. 21 is an explanatory view showing how work is performed using the vacuum window lifter.

FIG. 22 is an enlarged sectional view of the main part according to FIG. 5.

FIG. 23 is an enlarged sectional view of the main part according to FIG. 10.

FIG. 24 is an enlarged sectional view of the main part according to FIG. 12.

FIG. 25 is an enlarged sectional view of the main part according to FIG. 13.

EXPLANATION OF REFERENCE POSITIONS

[0011] 1 - elastic adhesive, 2 - double-sided adhesive tape, 3 - empty gap, 4 - joint, 5a - flat type connector, 5b - outside corner tip type connector (also called outside corner connector), 5c - connector L type for outside corner (also called outside corner connector), 5c1 - decorative laminate, 5c2 - aluminum based material, 5d - landing type connector for inside corner (also called inside corner connector), 5d1 - cap element (fitting male thread), 5d2 - base piece (female thread fitting), 5e - internal corner L connector (also called internal corner connector), 6 - sealing agent, 7 - bottom seam sealing tape, 9 - decorative laminate, 11 - decorative laminate, on which double-sided adhesive tape is glued, and elastic adhesive is applied, 12 - decorative laminate, on which double-sided adhesive tape is glued, and elastic adhesive is applied, 15 - step element, 15a - body of the first panel, 15b - body second panel, 15c - upper planar part, 15d - lower planar part, 15e - side wall, 16 - electric circular saw, 16a - electric circular saw blade guide, 16b - electric circular saw blade, 17 - vacuum window lifter, 21 - base material , L - distance between the blade facing the end surface and the blade, w - width of the lower planar part, 30 - gap, 31 - gap, 32 - gap, 32' - gap, t - gap width, t1 - gap width, t2 - gap width, t2' - gap width, t3 - gap width.

OPTIONS FOR IMPLEMENTING THE INVENTION

[0012] FIG. 1 is a top view of a decorative laminate (9) that has been cut to size. Decorative laminate has double-sided adhesive tapes applied to the back side and elastic adhesive applied to the back side. FIG. 2 is an enlarged top view of the main portion of FIG. 1. On the back side of the decorative laminate, double-sided adhesive tape (2) for the outer side of the decorative laminate is pasted on the peripheral portion at a position of 1 to 300 mm inward, and more preferably 25 to 35 mm inward from the outer edge of the back side. In addition, the double-sided adhesive tape (2) for the inside of the decorative laminate is glued to the inside, which is located inside the double-sided adhesive tape (2) for the outside. The inside is sectioned with double-sided adhesive tape (2) for the inside, thereby forming sections (four sections).

[0013] The back side of the decorative laminate includes an empty space (3) having a width of 1 to 300 mm, and more preferably 10 to 20 mm. The blank space is at a position of 1 to 300 mm inward, and more preferably 20 to 30 mm inward, from the outer edge of the back side of the decorative laminate, between the outer edge and the double-sided adhesive tape (2) for the outer side. Elastic adhesive (1) is applied to the empty space (3) in the shape of a straight line. The same elastic adhesive is also applied inside each section of sections separated by double-sided adhesive tape (2) for the inside, in the shape of a sinuous line. The use of both double-sided adhesive tape and elastic adhesive prevents the decorative laminate from peeling off from the base material.

[0014] Each of the double-sided adhesive tapes is designed to temporarily adhere the decorative laminate to the base material until the elastic adhesive is cured. The double-sided adhesive tape for use may be in a wound state in which adhesive layers are placed on both sides of the backing body, and a release release sheet is adhered to one adhesive layer. Alternatively, the adhesive tape for use may consist of a single adhesive layer without a backing body.

[0015] Examples of the substrate body are paper, non-woven material, metal foil, textile material formed from natural fiber, synthetic fiber, or the like, resin film formed from polyester, soft polyvinyl chloride, hard polyvinyl chloride, acetate, or the like, polyolefin plastic film such as PET (polyethylene terephthalate) and OPP (oriented polypropylene), flat yarn, polystyrene foam, or the like. In addition, adjusting the thickness of the backing body to between 0.001 and 8.00 mm, and preferably between 0.004 mm and 3.80 mm, results in an increase in the overall thickness of the double-sided adhesive tape without peeling off the backing body when the decorative laminate is applied. It is desirable to ensure that the application area of the elastic adhesive, which is described below, is provided.

[0016] The adhesive layer preferably includes an adhesive agent. The adhesive component that constitutes the adhesive agent may be an acrylic-based resin, a urethane-based resin, a polyester-based resin, a silicone-based resin, butyl rubber, an epoxy-based resin. Acrylic-based resin is particularly preferred for reasons of ease of handling, excellent adhesion, heat and water resistance, and cost. It is desirable to adjust the thickness of each adhesive layer to between 0.001 and 3.00 mm, and more preferably between 0.013 and 0.10 mm, since these ranges provide favorable bond strength of the adhesive layer without peeling of the adhesive layer when the decorative laminate is applied. The total thickness of the double-sided adhesive tape is preferably 0.03 to 10 mm, and more preferably 0.1 to 4 mm. Double-sided adhesive tape that has a thickness within these ranges does not cause the adhesive agent to bulge, and is capable of creating the bonding area of the elastic adhesive described below. Here, the total thickness is the sum of the thickness of the substrate body and the thickness of the adhesive layer, and does not take into account the thickness of the detachable release sheet.

[0017] In particular, the double-sided adhesive tape desirably has an adhesive strength of 3 to 30 N/20 mm, and more preferably 5 to 14 N/20 mm, at a temperature of 23°C, according to a 90-degree peel test based on JIS Z 0237 Alternatively, in a low temperature environment (0°C), the adhesive strength is desirably 1 to 20 N/20 mm, and more preferably 5 to 13 N/20 mm.

In addition, double-sided adhesive tape, which has adhesive strength within the above ranges at 23ºC or 0ºC, is strong enough to support the decorative laminate itself (about 5.6 kg/ ^m2 ) in a 23ºC or 23ºC environment. environment at 0ºC until the adhesive is initially cured.

Therefore, slippage or problems such as warping and peeling of the applied decorative laminate under operating temperature can be prevented. Double-sided adhesive tape, which has the above-mentioned strength at 23ºC, is capable of securely temporarily fixing decorative laminate to the base material when applied in a room temperature environment. Double-sided adhesive tape, which has the above-mentioned strength at 0ºC, is capable of reliably temporarily securing decorative laminate to the base material when applied in a cold environment. In addition, it is desirable that the double-sided adhesive tape has an adhesive strength of 3 to 30 N/20 mm at a temperature of 23ºC, and from 1 to 20 N/20 mm in a low-temperature environment (at a temperature of 0ºC). In these cases, the decorative laminate can be securely temporarily fixed to the base material in both room temperature and cold environments.

[0018] In the present invention, the substrate body for the adhesive layer is preferably a film made of polyethylene or PET (polyethylene terephthalate) foam. And for the adhesive layer, an adhesive agent containing acrylic-based resin or butyl rubber is used.

[0019] In the present invention, elastic adhesive is applied to the outer peripheral portion on the rear side of the decorative laminate and to the internal portions within the sections formed in the inner portion of the decorative laminate, inwardly from the outer peripheral portion.

Flexible adhesive is an adhesive that has a rubber-like elasticity once cured. Examples of the elastic adhesive include modified silicone resin, polyurethane resin, polysulfide-modified epoxy resin, acrylic resin, SBR (styrene butadiene rubber), and vinyl acetate resin. Modified silicone resin adhesive is preferred due to its superior water resistance, durability and adhesion, and ability to follow the shrinkage and expansion of the decorative laminate in dimensions, which shrinks and expands easily when wet and dry. The elastic adhesive may be a moisture-curing reactive adhesive agent.

[0020] Examples of the modified silicone resin elastic adhesive include moisture-curing, solvent-free, one-component modified silicone resin elastic adhesive and solvent-containing modified silicone resin elastic adhesive. Moisture-curing, solvent-free, one-component modified silicone resin flexible adhesive reacts with atmospheric moisture and then hardens. In particular, the moisture-curable, solvent-free, one-component modified silicone resin elastic adhesive can be applied in a thicker layer than the solvent-containing modified silicone resin elastic adhesive, and is preferred for environmental reasons.

[0021] The elastic adhesive is preferably applied thicker than double-sided adhesive tape. More specifically, the elastic adhesive has an application thickness of preferably 1 mm or more and 5 mm or less. Application thicknesses within these ranges provide sufficient adhesive action and ability to follow dimensional changes. As a result, the decorative laminate is adhered with double-sided adhesive tape when it is attached to the base material under pressure and permanently, and the elastic adhesive and decorative laminate are firmly bonded to each other. In addition, the double-sided adhesive tape acts as a barrier to the elastic adhesive. The elastic adhesive that is applied to the outer peripheral portion of the decorative laminate is applied in a straight line shape to stably form the application surface of the decorative laminate after application. It is desirable that the elastic adhesive has an adhesive strength, more specifically a tensile strength of 0.1 to 0.9 kN, and more preferably 0.2 to 0.73 kN, relative to a metal clamp such as cast iron having a size of 40 mm ×40 mm, using the Building Research Institute Adhesion Strength Tester (manufactured by Oxjack Co., Ltd.). According to these tensile strength ranges, sufficient adhesive action and ability to follow dimensional changes can be obtained.

[0022] IN FIG. 1 sections formed by double-sided adhesive tape for the inside include four sections. However, there is no limit to the number of sections. The sections are suitably configured into six sections, eight sections, nine sections or the like, depending on the size of the decorative laminate. FIG. 3 is a top view of a decorative laminate divided equally into six sections. As in FIG. 1, elastic adhesive is applied to the outer periphery of the decorative laminate in a straight line shape, and elastic adhesive is applied to the inside sections in a curved line shape.

[0023] FIG. 4 is a cross-sectional view of the structure of a decorative laminate fastening assembly structure in which a loose fit structure is formed between two decorative laminates (9, 9) which are then secured to a base material (21). In a loose-fit design, a joint (4) is formed between two decorative laminates (9, 9), and the joint (4) includes a gap. The joint (4) created by the loose-fit design is made using a connector, sealing agent, or bottom tape to seal the joints to improve the visual quality of the joint.

If the base material is planar, as shown in FIG. 5, for example, uses a flat type connector (5a) so that dust does not accumulate in the gap. Two decorative laminates (9, 9) are connected to each other by a flat type connector and fixed to the base material (21), while at the same time being spaced from each other. The use of a flat type connector does not create problems with respect to the appearance of the decorative laminates, and is therefore advantageous even if the decorative laminates expand and contract slightly and/or the end of each decorative laminate is not in the shape of a straight line.

FIG. 6 is a sectional view of a flat type connector (5a).

[0024] FIG. 7 is a cross-sectional view of the structure of a decorative laminate fastening unit, in which a sealing agent (6) is applied at the joint (4). Two decorative laminates (9, 9) are fixed to the base material (21), and the joint (4) is filled with a sealing agent (6). As a sealing agent, a sealing agent based on silicone resin is particularly recommended, which can more easily accommodate changes in the dimensions of the decorative laminate and is advantageous in terms of water resistance.

[0025] FIG. 8 is a cross-sectional view of the structure of the decorative laminate fastening unit, in which the joint (4) is covered with a bottom tape (7) to seal the seams. FIG. 9 is a sectional view of the main part of FIG. 8. Two decorative laminates (9, 9) are secured to the base material (21), and the joint (4) has a bottom seam sealing tape (7) glued underneath so that the base material (21) is not exposed. The bottom seam sealing tape (7) can be easily applied using a thin decorative tape, in particular a decorative tape that includes an adhesive layer on its back side.

[0026] Accordingly, descriptions have been given of the structure of the decorative laminate attachment assembly according to the present invention, in which the decorative laminates are applied to the base material in one plane. The formation of the structure of the decorative laminate attachment unit according to the present invention is not limited to a plane of the structure that has an outer surface or an inner surface extending in the same plane on which the decorative laminates are placed. The structure of the fastening unit according to the present application can advantageously be created by forming an outer and/or an inner corner. The outer corner is the angle between the outer surfaces of the planes of the structure on which decorative laminates are applied, in other words, the intersection plane along which the outer surfaces lie. An internal angle is the angle between the internal surfaces of planes.

[0027] For example, FIG. 10 is a cross-sectional view of the structure of an outer corner decorative laminate attachment assembly using an outer corner outer tip type connector (5b). FIG. 11A is a cross-sectional view of the structure of an outer corner decorative laminate attachment assembly using an outer corner L type connector (5c). FIG. 12 is a cross-sectional view of the structure of the decorative laminate fastening unit at the inner corner. FIG. 12 is a cross-sectional view of the structure of a decorative laminate fastening unit at an inner corner using an inner corner landing type connector (5d). FIG. 13 is a cross-sectional view of the structure of a decorative laminate fastening assembly at an inner corner using an L-type connector (5e) for the inner corner. The shape of the connector is not limited to the above shapes. The shape and color of the connector are appropriately selected depending on where the decorative laminate is applied. For example, the connector material is aluminum or resin.

[0028] Descriptions are given with respect to the application method for obtaining the structure of the attachment assembly according to the present invention, which is carried out including the following steps:

(A) cutting a first decorative laminate of at least two paired decorative laminates to a predetermined size using a member that is rectangular in shape in plan view, the member including a single step height difference, having an upper planar portion, a lower planar portion, and side wall;

(B) applying double-sided adhesive tape to the back side of the first decorative laminate obtained by cutting (A), and applying elastic adhesive to several parts of the first decorative laminate on the back side;

(C) attaching a vacuum lifter to the front surface of the first decorative laminate obtained in the gluing step (B) and pressing the rear side against the base material to fix the first decorative laminate to the base material; And

(D) treating a second decorative laminate of at least two paired decorative laminates in the same manner as in the above steps (A), (B), and (C), and attaching the second decorative laminate to the base material with a space formed between the first decorative laminate and a second decorative laminate.

[0029] FIG. 14 is a top view of a rectangular shaped element (15), the stepped element including a height difference in the form of a single step, having an upper planar portion (15c), a lower planar portion (15d) and a side wall (15e) along the longitudinal direction (hereinafter called the stepped element). The stepped element (15) is continuous in the upward and downward directions in top view. FIG. 15 is a perspective view of the step element (15). The stepped element includes a single step height difference to bring the electric circular saw blade guide (16), which is described below, into contact with the side wall (15a) created by the one step height difference. This difference plays an important role in cutting decorative laminate and improving the accuracy of a straight line. The stepped element (15) is obtained by connecting the first panel body (15a) and the second panel body (15b) to each other. The body of the first panel and the body of the second panel have different widths, respectively. Once connected, one end surface of the first panel body (15a) and one end surface of the second panel body (15b) become flush with each other, thereby making it easier to hold the step member with one hand, as shown in FIG. 16. Examples of step member materials include plastic sandwich panel and plywood. However, there is no limitation on the material of the step member. There is also no restriction on the method of connecting the first and second panel bodies. The first panel body and the second panel body in each case may have any width, which is in the range from about 300 to 450 mm, and any thickness, which is in the range from about 3 to 12 mm. The lengths of the first panel body and the second panel body are preferably equal to or greater than the size of the decorative laminate being cut.

[0030] In step (A), the first decorative laminate of at least two paired decorative laminates is cut to a predetermined size. When cutting the decorative laminate to a specified size, an electric circular saw (16) is placed on the lower planar portion (15d) as shown in FIG. 16. The electric circular saw blade guide (16a) is brought into contact with the side wall (15e). The upper planar portion (15c) is held with one hand while an electric circular saw is passed with the other hand along the side wall (15e) so that the blade (16b) protrudes from the stepped element (15), thereby cutting the decorative laminate. It is desirable that the width (w) of the lower planar portion (15d) be the same as the distance (L) from the end surface facing the blade (16b) of the electric circular saw blade guide (16a) (16) to the blade (16b). Step (A) allows one to quickly obtain the desired first decorative laminate, which advantageously has a precise dimension. In addition, the cut surface is obtained in the form of a straight line, which is preferable in a loose-fit design and for mounting the connector described below.

[0031] FIG. 18 and FIG. 19, which shows step (B), are identical to the above-described FIGS. 1 and FIG. 2, respectively. The elastic adhesive (1) is preferably applied in a straight line shape when applied to the outer peripheral portion of the back side of the decorative laminate. In addition, elastic adhesive (1) is applied to the areas (within sections) defined by double-sided adhesive tapes on the inside of the back side of the decorative laminate. In this case, examples of applicable adhesive application methods include spot coating, in which the adhesive is applied at fixed intervals (called bead bonding); so-called scratching, in which the adhesive is applied using a metal plate having a comb front end, and crimping, in which the adhesive contained in the cartridge is applied by extruding to apply in a crimped line, as shown in FIG. 19. Of these methods, applying the adhesive in the shape of a sinuous line is preferable. By applying it in the shape of a curved line, it is possible to obtain a larger bonding area compared to the area of the decorative laminate, and ensure adhesive strength over the entire area of the decorative laminate. In addition, the adhesive can be applied efficiently and quickly.

[0032] Descriptions are given for step (C). The decorative laminate, to which double-sided adhesive tapes (2) and elastic adhesive (1) are applied in step (B), is picked up by a vacuum lifter, as shown in FIG. 21. For example, a vacuum lifter is the vacuum window lifter shown in FIG. 20. The decorative laminate is temporarily fixed to the base material using double-sided adhesive tapes, and then pressed against the base material. The vacuum lifter can be any vacuum lifter that is attached to the decorative laminate. For example, a vacuum window lift is preferred. The vacuum window lifter is used to position the glass panel at the proper installation location and is also suitable for use when placing decorative laminate flooring. It is desirable that the vacuum window lifter has a maximum load capacity of 5 to 600 kg, and more preferably 30 to 350 kg. These lifting capacity ranges allow the decorative laminate to be placed without damaging its surface, while the vacuum lifter provides suction strength when placed on the decorative laminate. In addition, the use of suction cups allows for favorable accuracy in maintaining the position of the decorative laminate.

Vacuum window lift (17) according to FIG. 20 has two suction cups. However, the number of suckers is not limited to two. A vacuum window lifter with the appropriate number of suction cups is selected depending on the size and weight of the decorative laminate to be attached.

[0033] In step (D), the second decorative laminate of the two paired decorative laminates is also pressed against the base material in the same manner as the first decorative laminate. The second decorative laminate is attached to the base material at a distance from the first decorative laminate (loose-fit design). The two paired decorative laminates are spaced apart because even if an error occurs regarding the width of the gap, the presence of the gap may render the error indistinguishable or undetectable by the finishing method described below. In contrast, in a butt-joint design in which two paired decorative laminates are applied without a gap, the joint can easily be disrupted by contraction or expansion as the decorative laminates change in size; a gap appears between decorative laminates, which causes a visual deterioration in quality; decorative laminates are squeezed upward due to tension in the joint under the influence of the environment, which leads to delamination of decorative laminates from the base material; and application requires a high level of skill and a lot of time. For these reasons, butt joint designs are not preferred. The two paired decorative laminates preferably have a gap of 2 to 4 mm between them.

[0034] A joint that includes a gap formed by the space between two paired decorative laminates can be used to fill the connector on the base material after the connector is inserted between the ends of the decorative laminates, or such that the connector has been laid in advance. In the case of a loose fit design, in order to make a joint with a more uniform width, it is preferable to place a plate element having a width of about 3 to 5 mm as a spacer at the joint, and use the plate element as a support to create a joint with a precise width. When two paired decorative laminates are placed spaced apart (loosely), the gap width is adjusted to 3 mm or more. When two paired decorative laminates are processed using a connector, it is desirable that, as shown for example in FIG. 22, create a gap (30) between the end surfaces of each decorative laminate (9), and position a connector to accommodate contraction and expansion of the decorative laminate (9). In this case, the width (t) of the gap is from 1.0 to 3.5 mm, and more preferably from 1.5 to 3.0 mm. If decorative laminates, each of which has no gap with the connector, are stressed by temperature and humidity, the stress will be applied to the connector but cannot be relieved. The tension is directed and applied inward, causing the decorative laminates to lift and thus, in some cases, damage the decorative laminates.

[0035] The base material on which the decorative laminate is applied is preferably, for example, an inorganic base material, a wood base material, or an organic base material. Examples of the inorganic base material include metal panel, tile, cement panel, volcanic vitreous sandwich panel, calcium silicate panel, magnesium silicate panel, magnesium oxide panel, and stucco board.

Examples of wood base material include plywood, insulation board, MDF (medium density fiberboard), hardboard, particle board, and oriented strand board.

Examples of the organic base material include a plastic panel such as a thermosetting resin or a thermoplastic resin. Specific examples include phenolic resin panel, polycarbonate panel, acrylic resin panel, hard PVC panel, soft PVC panel, polypropylene resin panel, polystyrene resin panel, and polyethylene terephthalate resin (PET) panel.

[0036] In particular, if the base material and the double-sided adhesive tapes or elastic adhesive do not adhere to each other properly, a primer may be used to treat the base material. Examples of the primer include acrylic-based, urethane-based, polyester-based, silicone-based, butyl rubber-based, and epoxy-based primers. In the present invention, if the base material is a calcium silicate panel, plywood or mortar, a polyurethane resin primer or an acrylic resin primer is used in advance in step (A) to improve the strength of the elastic adhesive.

[0037] The decorative laminate applied to the base material is preferably a decorative thermoset resin laminate that includes a decorative layer and a core layer. This is because the thermoset resin decorative laminate advantageously has wear resistance, strength and heat resistance. Kraft paper impregnated with thermosetting resin can be used as the core layer of a decorative thermosetting resin laminate. The core layer may also be configured as a prepreg containing a fiber-based material, an organic binder component, and an inorganic filler. Preferably, a prepreg is used which is formed by impregnating an inorganic fibrous base material with a slurry containing a binder component and an inorganic filler and drying. Thus, such a prepreg makes the decorative laminate non-flammable.

[0038] Examples of inorganic fiber base material used for prepreg flame retardant decorative laminate include non-woven material and textile material made of inorganic fiber such as glass fiber, mineral wool, carbon fiber and ceramic fiber. The specific gravity per unit area of the inorganic fibrous base material is within the range of 10 to 200 g/m ² . In particular, it is preferable to use a glass fiber non-woven material which is advantageously heat resistant and flame retardant.

[0039] The binder component contained in the suspension includes an organic resin component. Examples of the organic resin component include a thermoset resin such as phenol-formaldehyde resin and melamine-formaldehyde resin, a thermoplastic resin emulsion such as an acrylic resin emulsion, a vinyl chloride resin emulsion, or a combination thereof.

[0040] As an inorganic filler, it is preferable to use an endothermic metal hydroxide and/or other inorganic substance rather than an endothermic metal hydroxide.

[0041] The endothermic metal hydroxide contains water of crystallization. Endothermic metal hydroxide decomposes at high temperature and absorbs heat to release water of crystallization, thereby increasing the fire resistance of the decorative laminate. Examples of endothermic metal hydroxide include aluminum hydroxide, magnesium hydroxide and calcium hydroxide. The average particle diameter of the endothermic metal hydroxide can be adjusted to a value within a range of, for example, 1 to 50 μm. This average particle diameter is the arithmetic mean diameter, which is calculated using the particle size distribution (volume distribution) measured by laser diffraction/scattering (Microtrac method). Because the average particle diameter of the endothermic metal hydroxide is within the above range, the dispersibility of the endothermic metal hydroxide in the slurry, and thereby the slurry impregnation performance of the fiber-based material, is improved.

[0042] Examples of inorganic matter other than endothermic metal hydroxide include carbonate such as calcium carbonate, magnesium carbonate, and zinc carbonate, silica, talc and fly ash. The average particle diameter of the inorganic substance (arithmetic mean diameter calculated using the particle size distribution (volume distribution)), measured by laser diffraction/scattering method (Microtrac method), can be adjusted to a value within a range of, for example, 0.05 up to 20 microns. In this case, the impregnation characteristics of the fiber-based material suspension are further improved.

[0043] In particular, it is preferable to select a carbonate (eg, calcium carbonate). In this case, the processability and machinability during the manufacturing process of the decorative laminate are further improved. Examples of calcium carbonate for use include heavy calcium carbonate and light calcium carbonate (precipitated calcium carbonate). The average diameter of the calcium carbonate particles can be adjusted to a value within a range of, for example, 0.05 to 10 µm, and more preferably 1 to 5 µm. When the average diameter of the calcium carbonate particles is 0.05 μm or more, the calcium carbonate hardly forms aggregates in the suspension, thereby improving the slurry impregnation performance of the fiber-based material. In addition, when the average diameter of the calcium carbonate particles is 10 µm or less, the decorative laminate has a flat, smoother surface, thereby improving the appearance of the decorative laminate.

[0044] The slurry preferably has an impregnation rate (%) within the range of 700 to 1200% into the inorganic fibrous material using the calculation method shown in Formula 1. In Formula 1, the term "weight after impregnation" means the weight of the inorganic material on the fibrous material. base after the inorganic fibrous material has been slurried and dried. The term "weight before impregnation" means the weight before impregnation with slurry and in the dried state, that is, the weight of the inorganic fibrous material. A slurry impregnation rate of 1200% or less can reduce the slurry solids reduction for the prepreg, thereby making the prepreg easy to handle. Slurry impregnation levels of 700% or greater result in less separation between prepreg layers.

Formula 1

[0045]

Degree of impregnation (%)=[(weight after impregnation - weight before impregnation)/weight before impregnation]×100

[0046] The mixing ratio of the organic resin component in the suspension to the inorganic filler comprising an endothermic metal hydroxide and/or an inorganic substance other than an endothermic metal hydroxide, by weight of the solid components, is desirably 1:1-25, and more preferably 1:5-20 . When the mixture ratio of organic resin component to inorganic filler is within these ranges, adhesion between the decorative layer and the prepreg, and/or between prepregs, can be enhanced. Moreover, the fire resistance of the decorative laminate can be improved.

[0047] The organic resin component contained in the prepreg fragment is from 30 to 100 g/m ² , and the organic resin component contained in the core layer is from 40 to 500 g/m ² . The organic resin component within these ranges gives the decorative laminate in which the prepreg is used favorable fire resistance. In addition, adhesion between the decorative layer and the prepreg, and/or between prepregs, becomes favorable.

[0048] Either one of the inorganic substances other than the endothermic metal hydroxide or the endothermic metal hydroxide can be used independently, or the inorganic substance other than the endothermic metal hydroxide and the endothermic metal hydroxide can be used in combination. In combined use, it is preferable that the mixture ratio of the endothermic metal hydroxide is from 0.2 to 20 parts by weight, and more preferably from 0.5 to 15 parts by weight, relative to 1 part by weight of an inorganic substance other than the endothermic metal hydroxide. When the endothermic metal hydroxide mixture ratio is within these ranges, a smooth and satisfactory surface appearance of the decorative laminate is achieved. In addition, an endothermic metal hydroxide mixing ratio of 0.2 parts by weight or more results in a decorative laminate with favorable fire resistance. An endothermic metal hydroxide mixing ratio of 20 parts by weight or less prevents precipitation of the endothermic metal hydroxide from the slurry, thereby making it easier to control the degree of impregnation of the slurry. An endothermic metal hydroxide mixture ratio of 20 parts by weight or less can reduce wear on a cutting tool used to cut decorative laminate.

[0049] With respect to the above-described inorganic filler, it is particularly preferred to use three types of inorganic fillers which include an inorganic substance other than an endothermic metal hydroxide and/or an endothermic metal hydroxide and which have correspondingly different average particle diameters.

[0050] Three types of inorganic fillers having respectively different average particle diameters include small particle diameter inorganic filler, medium particle diameter inorganic filler, and large particle diameter inorganic filler. The small particle diameter of the inorganic filler is 0.04 µm or more and less than 4 µm. The average particle diameter of the inorganic filler is 4 µm or more and less than 12 µm. The large diameter of the inorganic filler particles is 12 µm or more and less than 50 µm. These three types of inorganic fillers may be the same substance or different substances. The mixing ratio of the small particle inorganic filler to the medium particle diameter inorganic filler to the large particle diameter inorganic filler in the suspension is preferably from 1:0.1 to 20:0.1 to 20, and more preferably from 1::0.1 up to 10:0.1 up to 10. In these cases, a decorative laminate can be obtained which is favorable in terms of both smoothness and non-flammability.

[0051] The rationale for good smoothness is considered as follows. The inorganic filler is considered to be uniformly distributed on the surface of the nonwoven material or filling the spaces between the fibers of the nonwoven material. More specifically, the nonwoven fabric is an aggregate of fibers in which the short fibers of the nonwoven fabric are dispersed separately and enclosed by a binder component, either by thermal fusion or mechanically. The non-woven material is more porous than the kraft paper used as the paper core for conventional decorative laminates, thereby creating loose parts that are called cavities. Such cavities are heterogeneous in size. The cavities are filled with the above-described inorganic fillers, having correspondingly different average particle diameters. As a result, inorganic fillers, which have correspondingly different average diameters, enter cavities formed in the nonwoven material with different dimensions. In this way, inorganic fillers can be uniformly dispersed on the nonwoven material or fill the spaces between the fibers of the nonwoven material. In particular, a thermoplastic resin emulsion softens more easily compared to a thermoset resin contained in a suspension. Thus, when the thermoset resin emulsion is used as a binder component in the process of forming a nonwoven web, the bonding of the interwoven fibers is weakened. For this reason, the inorganic filler easily penetrates into the cavities in the nonwoven material during pressing such as hot pressing, accumulates tightly in the cavities, and fills the cavities. As a result, the smoothness of the finished decorative laminate is improved.

[0052] When the three types of inorganic fillers are mixed with each other, the aggregate particle diameters Dv(10), Dv(50), and Dv(90) of the inorganic filler according to the particle size distribution measuring method using laser diffraction/scattering, preferably 0.5 µm or more and 40.0 µm or less, and more preferably 0.78 µm or more and 36.9 µm or less. When the aggregate volume diameters of the inorganic filler particles containing the three types of inorganic fillers are within these ranges, the dispersion of the inorganic filler is good, the cavities in the nonwoven material are densely filled, and the smoothness of the decorative laminate is improved.

[0053] In addition, when the three types of inorganic fillers are mixed with each other, the specific surface area as measured by laser diffraction/scattering is preferably 800 to 4000 m ² /kg, and more preferably 900 to 3500 m ² /kg. When the specific surface area of the mixed inorganic filler is within these ranges, the inorganic filler readily absorbs the thermoset binder material in suspension. As the binder material flows, the inorganic filler in which the binder material is absorbed flows into the cavities in the nonwoven material, thereby helping to improve adhesion between the prepregs. As has been described thus far, selecting an inorganic filler having the proper particle diameter according to the thickness and density of the nonwoven material used results in a decorative laminate having favorable smoothness and sufficient adhesion compared to traditional laminates.

[0054] When the three types of inorganic fillers are used, it is particularly preferable that the small particle diameter inorganic filler be calcium carbonate. Calcium carbonate creates virtually no aggregates in the suspension, thereby improving the suspension impregnation properties of the fiber-based material. And then the decorative laminate has a flat, smooth surface, which improves the appearance of the decorative laminate. In addition, calcium carbonate is a readily available inexpensive material and is therefore preferred.

[0055] The thickness of the decorative laminate is preferably from 0.50 mm to 8.00 mm, and more preferably from 0.86 to 3.40 mm. Decorative laminate having a thickness within these ranges prevents warping, is advantageous in terms of ease of handling, and is advantageous in terms of workability.

Example 1

[0056] Two paired decorative laminates were produced. One decorative laminate of the two paired decorative laminates is the first decorative laminate, and the other decorative laminate is the second decorative laminate. Each of the two paired decorative laminates is a melamine decorative laminate. The melamine decorative laminate includes: a decorative layer formed from paper impregnated with melamine resin; and a core layer formed from phenolic resin impregnated paper. The following is a description of the method for producing melamine decorative laminate.

Production of melamine decorative laminate

Preparation of decorative paper impregnated with melamine resin

Wood grain patterned decorative paper was impregnated with a liquid resin mainly composed of melamine-formaldehyde resin so that the impregnation rate as determined by Formula 1 was 130%, and then dried to obtain melamine resin-impregnated decorative paper.

Preparation of phenolic resin impregnated paper

Kraft paper having a basis weight of 187 g/ ^m2 was impregnated with a liquid resin mainly consisting of phenol-formaldehyde resin so that the impregnation rate as determined by Formula 1 was 50%, and then dried to obtain a phenolic resin impregnated paper. core paper.

Production of melamine decorative laminate

The melamine decorative laminate was prepared by layering five sheets of phenolic resin-impregnated core papers and one sheet of melamine resin-impregnated decorative paper, in that order from the bottom, to form a multi-layer pouch, and molding the multi-ply pouch under heat and pressure.

Polywood panels were used as the body of the first panel and the body of the second panel. The Polywood panel as the body of the first panel was 300 mm wide, 1000 mm long and 6 mm thick. The Polywood panel as the body of the second panel was 450 mm wide, 1000 mm long and 6 mm thick. As shown in FIG. 14 and 15, these Polywood panels were glued to each other using rubber-based adhesive so that one end of the body of the first panel and one end of the body of the second panel were flush, creating a height difference in the form of one step between the bodies of the first and second panels, to obtain a stepped element (15), which includes an upper planar part (15c), a lower planar part (15d) and a side wall (15e) extending in the longitudinal direction. Here, the lower planar portion shown in FIG. 17, had a width (W) of 150 mm, which was calculated by subtracting the width of the first panel body (300 mm) from the width of the second panel body (450 mm).

The length (L), which is the distance from the end surface facing the blade (16b) of the electric circular saw (16) to the blade (16b), was also 150 mm.

The first decorative laminate, which is one of two paired decorative laminates, was cut to a width of 935 mm and a length of 1855 mm using a step piece and an electric circular saw according to the procedures described above.

A double-sided adhesive tape (2) for the outer side was applied to the outer peripheral portion on the rear side of the cut first decorative laminate, particularly at a position 30 mm inwardly from the outer edge, as shown in FIG. 1. Double-sided adhesive tape (2) for the inside was applied to the inside of the back side of the first decorative laminate, which is located inside of the double-sided adhesive tape (2) from the outside, so that uniformly divided four sections were formed. Each of the double-sided adhesive tape (2) for the outer side and the double-sided adhesive tape (2) for the inner side is an acrylic double-sided adhesive tape A, which has a total thickness of 1 mm. Acrylic double-sided adhesive tape A includes, as a backing body, a polyethylene foam body which has a thickness of 0.80 mm and a width of 20 mm. The adhesive layer on each side of the acrylic double-sided adhesive tape A has a thickness of 0.10 mm.

Then, elastic adhesive (1) was applied to the back side of the first decorative laminate at a position 15 mm inward from the outer edge, in the shape of a straight line so that the thickness of the elastic adhesive is 3 mm, and the same elastic adhesive was applied in the shape of a curved line inside the sections so that that the thickness of the elastic adhesive (1) is 3 mm, thereby obtaining a first decorative laminate for application to the base material. The elastic adhesive used was a moisture-curing, solvent-free, one-component modified silicone resin elastic adhesive contained in a cartridge.

A vacuum window lifter, which has a maximum suction load capacity of 60 kg, was then used to attach to the first decorative laminate for application to its front side. The back side of the first decorative laminate was then pressed against a base material formed from plaster board.

A second decorative laminate, which is the other of the two paired decorative laminates, was then prepared for application to the base material by cutting the resulting melamine decorative laminate, applying double-sided adhesive tapes to it, and applying elastic adhesive to it as for the first decorative laminate. A loose fitting structure was formed, in which the second decorative laminate was placed at a distance from the first decorative laminate, and fixed to the base material. As shown in FIG. 5, a flat type connector (5a), which has an elongated shape and is made of aluminum, was provided at the joint (4) between the first decorative laminate (9) and the second decorative laminate (9), which are spaced apart from each other. As shown in FIG. 6, the flat type connector (5a) includes a bottom portion (5a1), a cover portion (5a2), and a tie portion (5a3) that connects the bottom portion (5a1) and the cover portion (5a2) at their respective middle portions. The lower section (5a1) and the cover section (5a2) in each case have a planar shape. The lower portion (5a1) was inserted between the base material (21) and the first decorative laminate (9). And the lower portion (5a1) was inserted between the base material (21) and the second decorative laminate (9). The connecting part (5a3) was inserted into the joint (4). The covering area (5a2) clogged the joint (4). The gap (30) shown in FIG. 22, between the connecting part (5a3) and the end surface of each decorative laminate (9) has a width (t) of 1.5 mm.

Example 2

[0057] Two paired decorative laminates were prepared in the same manner as in Example 1, except that instead of acrylic double-sided adhesive tape A, acrylic double-sided adhesive tape B was used. Acrylic double-sided adhesive tape B has a total thickness of 0.1 mm. Acrylic double-sided adhesive tape B includes, as a backing body, PET film, which has a thickness of 0.02 mm. The adhesive layer on each side of the acrylic double-sided adhesive tape B has a thickness of 0.04 mm.

Example 3

[0058] Two paired decorative laminates were prepared in the same manner as in Example 1, except that instead of acrylic double-sided adhesive tape A, acrylic double-sided adhesive tape C was used. Acrylic double-sided adhesive tape C has a total thickness of 4 mm. The acrylic double-sided adhesive tape C includes, as a backing body, a polyethylene-based foam body, which has a thickness of 3.80 mm. The adhesive layer on each side of the acrylic double-sided adhesive tape C has a thickness of 0.10 mm.

Example 4

[0059] Preparation of melamine resin impregnated decorative paper

Wood grain patterned decorative paper was impregnated with a liquid resin mainly composed of melamine-formaldehyde resin so that the impregnation rate as determined by Formula 1 was 130%, and then dried to obtain melamine resin-impregnated decorative paper.

[0060] Getting the prepreg

Non-woven fiberglass material having a basis weight of 75 g/m² (binder: thermoplastic resin emulsion, thickness 0.585 mm, and density 0.130 g/cm³), impregnated with a suspension so that the degree of impregnation the suspension, as determined according to Formula 1, was 1200%, and then dried to obtain a prepreg. The suspension was a mixture of 4.5 parts by weight phenol-formaldehyde resin, 3.5 parts by weight melamine-formaldehyde resin, 16.5 parts by weight calcium carbonate having an average particle diameter of 1.4 microns, as an inorganic filler with low particle diameter, 37.5 parts by weight of aluminum hydroxide having an average particle diameter of 8 μm as an inorganic filler with an average particle diameter, and 37.5 parts by weight of aluminum hydroxide having an average particle diameter of 20 μm as an inorganic filler with large particle diameter. Here, the average particle diameter of an inorganic filler with a small particle diameter was measured using an electron microscope. The corresponding particle diameters of the medium-diameter inorganic filler and the large-diameter inorganic filler were measured using laser diffraction/scattering technique.

[0061] Preparation of a non-flammable decorative laminate

The flame retardant decorative laminate was prepared by layering one sheet of melamine resin impregnated wood grain decorative paper, five sheets of prepregs, and one sheet of melamine resin impregnated wood grain decorative paper, in that order, from the bottom of the laminate composite, and molding the laminate by heating and under pressure.

Two paired decorative laminates were produced in the same manner as in Example 1, except that a non-flammable laminate was used instead of a melamine decorative laminate.

Example 5

[0062] Two paired decorative laminates were prepared in the same manner as in Example 2, except that a non-flammable decorative laminate was used instead of a melamine decorative laminate.

Example 6

[0063] Two paired decorative laminates were prepared in the same manner as in Example 3, except that a non-flammable decorative laminate was used instead of a melamine decorative laminate.

Example 7

[0064] Two paired decorative laminates were prepared in the same manner as in Example 4, except that instead of a flat type connector (5a), the joint (4) was filled with a silicone-based sealing agent (6), as shown in FIG. 7.

Example 8

[0065] Two paired decorative laminates were prepared in the same manner as in Example 4, except that instead of a flat type connector (5a), a bottom seam sealing tape (7) was applied to the underside of the joint (4), which to some extent is larger relative to the joint (4), as shown in FIG. 8 and 9. The bottom tape (7) for sealing seams is a decorative sheet with an adhesive agent, which has a thickness of 0.3 mm. The adhesive decorative sheet is a decorative laminate having an adhesive layer on one side thereof, wherein the decorative laminate is formed by layering a decorative layer that is formed from a resin-impregnated decorative paper and a core layer that is formed from a resin-impregnated fibrous base material.

Example 9

[0066] Example 9 differs from Example 4 in that two paired decorative laminates (9, 9) were attached to the outer corner portion (A) of the base material (21), as shown in FIG. 10.

In Example 9, the two paired decorative laminates (9, 9) were each a non-combustible decorative laminate as in Example 4. The first decorative laminate (9), which was one of the two paired decorative laminates (9, 9), was applied onto the first surface of the outer corner portion (A) of the base material (21). The second decorative laminate (9), which is the other of the two paired decorative laminates, was adhered to the second surface of the outer corner portion (A) of the base material (21), which intersects with the first surface of the outer corner portion (A). Two paired decorative laminates (9, 9) were spaced apart at the outer corner portion (A) to form a joint (4). The joint (4) is equipped with a connector (5b) for the outer corner, which is made of aluminum. The outer corner connector (5b) includes a bottom portion (5b1) and a cover portion (5b2), and a tie portion (5b3) that connects the bottom portion (5b1) and the cover portion (5b2) to each other. Each of the bottom portion (5b1) and the cover portion (5b2) is L-shaped. A lower portion (5b1) was inserted between the base material (21) and each decorative laminate (9, 9). The connecting part (5b3) was inserted into the joint (4). The covering area (5b2) plugged the joint (4). FIG. 23 is an enlarged sectional view of the main part of FIG. 10. Each end surface of the two paired decorative laminates (9, 9) and the connecting portion (5b3) of the outer corner tip type connector (5b) has a gap (31) in a narrow range having a width (t1) of 1.5 mm.

Example 10

[0067] Example 10 differs from Example 9 in that two paired decorative laminates (9, 9) are spaced apart at the outer corner portion (A) filled by an outer corner connector (5c), which is made of aluminum, and a sealing silicone-based agent (6) between them, as shown in FIG. 11A. The outer corner connector (5c) includes an aluminum element (5c2) as a base material, and a decorative laminate (5c1) impregnated with melamine resin, which is glued to the surface of the aluminum element (5c2). A silicone-based sealing agent (6) is placed filling the gap between the outer corner connector (5c) and the two paired decorative laminates (9, 9).

FIG. 11B is a front perspective view as seen along the Z direction of FIG. 11A. The outer corner portion (A) of the base material (21) is successively coated with elastic adhesive and acrylic double-sided adhesive tape A (for adhesion to the outer corner connector (5c)). The elastic adhesive for bonding the outside corner connector (5c) to the base material was a moisture-curing, solvent-free, one-component modified silicone resin elastic adhesive.

Example 11

[0068] Example 11 is an example in which two paired decorative laminates (9, 9) were attached to the inner corner portion (B) of the base material (21), as shown in FIG. 12. The joint (4) between the two paired decorative laminates (9, 9) is provided with an inner corner connector (5d), which is made of polymer. The connector (5d) for the inner corner includes a cover element (5d1) and a base element (5d2). The base element (5d2) includes the bottom section (5d3) and fitting (5d4). The fitting (5d4) includes a fitting receiving portion (5d5) that protrudes from the center of the cap member (5d1). Two paired decorative laminates (9, 9) were secured to the bottom portion (5d3) at both ends of the bottom portion (5d3), and were secured by a cap member (5d1) at both ends of the cap member (5d1). FIG. 24 is an enlarged sectional view of the main part of FIG. 12. The respective end surfaces of the two paired decorative laminates (9, 9) and the curved part of the lower portion (5d3) have a gap (32) and a gap (32'), respectively, which have a width (t2, t2') of 2.5 mm and 1.5 mm.

Example 12

[0069] Example 12 differs from Example 11 in that the joint (4) between the two paired decorative laminates (9, 9) was provided with an inside corner connector (5e) as shown in FIG. 13.

The first decorative laminate (9), which is one of two paired decorative laminates (9, 9), is brought into contact with the inner corner portion (B) of the base material (21) and the end surface of the second decorative laminate, which is the other of two paired decorative laminates, which was spaced from the outer edge of the inner surface of the first decorative laminate, forming a joint (4) and creating a situation where the outer edge of the first decorative laminate (9) and the end surface of the second decorative laminate (9) face each other to a friend.

The back side of the decorative laminate (9), which was a non-flammable decorative laminate, was treated in the same manner as in Example 4. A vacuum window lifter was used to attach to the decorative laminate (9) on its front side in the same manner as in Example 4. AND then an inner corner treatment was carried out, in which the inner corner connector (5e), which is made of aluminum, and two paired decorative laminates (9, 9) were attached to the inner corner part (B), as shown in FIG. 13.

FIG. 25 is an enlarged sectional view of the main part of FIG. 13. The end surface of the second decorative laminate (9) and the inner corner connector (5e) had a gap (33) which has a width (t3) of 1.5 mm.

Example 13

[0070] The decorative laminate was prepared in the same manner as in Example 4, except that a non-flammable decorative laminate was used to apply to the base material, which has a width of 935 mm and a length of 2455 mm, and was divided into six sections.

Example 14

[0071] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 16.5 parts by weight of calcium carbonate having an average particle diameter of 1.4 μm, 37 .5 parts by weight of calcium carbonate having an average particle diameter of 8 microns, and 37.5 parts by weight of calcium carbonate having an average particle diameter of 17 microns. And instead of the acrylic double-sided adhesive tape A, a butyl rubber-based adhesive agent having a total thickness of 1 mm was used. The butyl rubber-based adhesive agent includes a polyethylene-based foam body having a thickness of 0.80 mm as a backing body. The adhesive layer on each side of the butyl rubber-based adhesive agent has a thickness of 0.10 mm.

Example 15

[0072] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 16.5 parts by weight of aluminum hydroxide having an average particle diameter of 1.0 μm, 37 .5 parts by weight of aluminum hydroxide having an average particle diameter of 8 microns, and 37.5 parts by weight of aluminum hydroxide having an average particle diameter of 20 microns. And instead of a plaster board, a calcium silicate panel with a thickness of 9 mm was used as the base material.

Example 16

[0073] A decorative laminate was prepared in the same manner as in Example 14, except that the prepreg binder components were 0 parts by weight phenol-formaldehyde resin and 8 parts by weight melamine-formaldehyde resin. And instead of a plaster board, a calcium silicate panel with a thickness of 9 mm was used as the base material. In addition, the calcium silicate panel was applied with an acrylic primer on its surface using a roller coater such that the application amount of the material was 10 g/m ² in solids content.

Example 17

[0074] A decorative laminate was prepared in the same manner as in Example 14, except that the prepreg binder components were 8 parts by weight phenol-formaldehyde resin and 0 parts by weight melamine-formaldehyde resin. And instead of a plaster board, a calcium silicate panel with a thickness of 9 mm was used as the base material. In addition, the calcium silicate panel was applied with a polyurethane-based primer on its surface using a roller coater such that the application amount of the material was 10 g/m ² in solids content.

Example 18

[0075] A decorative laminate was prepared in the same manner as in Example 15, except that the prepreg binder components were 0 parts by weight phenol-formaldehyde resin and 8 parts by weight melamine-formaldehyde resin. And instead of a calcium silicate panel having a thickness of 9 mm, plywood having a thickness of 9 mm was used as the base material. The plywood was applied with an acrylic primer on its surface using a roller coater such that the amount of material applied was 10 g/m ² solids content.

Example 19

[0076] The decorative laminate was prepared in the same manner as in Example 15, except that the prepreg binder components were 8 parts by weight phenol-formaldehyde resin and 0 parts by weight melamine-formaldehyde resin. And instead of a calcium silicate panel having a thickness of 9 mm, mortar having a thickness of 9 mm was used as the base material. In addition, the mortar was applied with an acrylic primer on its surface using a roller coater such that the amount of material applied was 10 g/m ² in solids content.

Example 20

[0077] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 16.5 parts by weight of calcium carbonate having an average particle diameter of 1.4 μm, 37 .5 parts by weight of calcium carbonate having an average particle diameter of 8 microns, and 37.5 parts by weight of calcium carbonate having an average particle diameter of 17 microns. And instead of modified silicone resin glue, rubber-based glue was used.

Example 21

[0078] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 16.5 parts by weight of aluminum hydroxide having an average particle diameter of 1.0 μm, 37 .5 parts by weight of aluminum hydroxide having an average particle diameter of 8 microns, and 37.5 parts by weight of aluminum hydroxide having an average particle diameter of 20 microns. And instead of a modified silicone resin adhesive, a urethane-based adhesive was used.

Example 22

[0079] The decorative laminate was prepared in the same manner as in Example 14, except that the prepreg binder components were 0 parts by weight phenol-formaldehyde resin and 8 parts by weight melamine-formaldehyde resin. And instead of a modified silicone resin glue, an epoxy-based glue was used.

Example 23

[0080] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 6.5 parts by weight of aluminum hydroxide having an average particle diameter of 1.0 μm, 42 .5 parts by weight of aluminum hydroxide having an average particle diameter of 8 microns, and 42.5 parts by weight of aluminum hydroxide having an average particle diameter of 20 microns.

Example 24

[0081] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 51.5 parts by weight of aluminum hydroxide having an average particle diameter of 1.0 μm, 20 parts by weight of aluminum hydroxide having an average particle diameter of 8 microns, and 20 parts by weight of aluminum hydroxide having an average particle diameter of 20 microns.

Example 25

[0082] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 6.5 parts by weight of calcium carbonate having an average particle diameter of 1.4 μm, 42 .5 parts by weight of calcium carbonate having an average particle diameter of 8 microns, and 42.5 parts by weight of calcium carbonate having an average particle diameter of 17 microns.

Example 26

[0083] A decorative laminate was prepared in the same manner as in Example 4, except that a slurry for use as an inorganic prepreg filler was formed by mixing 51.5 parts by weight of calcium carbonate having an average particle diameter of 1.4 μm, 20 parts by weight of calcium carbonate having an average particle diameter of 8 microns, and 20 parts by weight of calcium carbonate having an average particle diameter of 17 microns.

Comparative Example 1

[0084] A decorative laminate was prepared in the same manner as in Example 4, except that instead of acrylic double-sided adhesive tape A, acrylic double-sided adhesive tape A- was used. Acrylic double-sided adhesive tape A- has a total thickness of 0.02 mm and includes, as a backing body, PET film, which has a thickness of 0.004 mm. The adhesive layer on each side of the acrylic double-sided adhesive tape A- was thinner than the elastic adhesive, which caused the elastic adhesive to bulge. This caused dirt to form around the decorative laminate. In addition, the elastic adhesive could not be applied thickly. As a result, when the decorative laminate was glued to the base material, only the portion of the decorative laminate that had the elastic adhesive applied appeared to pop up. This worsened the appearance of the decorative laminate. In addition, it was impossible to maintain adhesive strength, which caused the decorative laminate to slip off when curing was carried out.

Comparative Example 2

[0085] The decorative laminate was prepared in the same manner as in Example 4, except that instead of acrylic double-sided adhesive tape A, acrylic double-sided adhesive tape A ⁺ was used. The A ⁺ acrylic double-sided adhesive tape has a total thickness of 20 mm and includes, as a backing, a polyethylene-based foam body having a thickness of 11.80 mm. The adhesive layer on each side of the acrylic double-sided adhesive tape A ⁺ was 0.10 mm thick. Acrylic double-sided adhesive tape A ⁺ was thicker than elastic adhesive, which reduced the bonding area of elastic adhesive. This made it impossible to maintain adhesive strength, which caused the decorative laminate to slip off when curing was carried out.

Comparative Example 3

[0086] The decorative laminate was prepared in the same manner as in Example 4, except that instead of acrylic double-sided adhesive tape A, acrylic double-sided adhesive tape X ^- was used. Acrylic Double Sided Adhesive Tape X ^- has the adhesive strength as shown in Table 3-2 and has a total thickness of 0.03mm. Acrylic double-sided adhesive tape X ^- includes, as a backing body, a body of PET film, which has a thickness of 0.004 mm. The adhesive layer on each side of the acrylic double-sided adhesive tape X ^- has a thickness of 0.013 mm. The adhesive strength of the acrylic double-sided adhesive tape X ^- was weak, causing the decorative laminate to slip off when curing. Therefore, the decorative laminate was fixed to the base material using gummed paper tapes at some locations at the end portions of the decorative laminate.

Comparative Example 4

[0087] The decorative laminate was prepared in the same manner as in Example 4, except that instead of acrylic double-sided adhesive tape A, acrylic double-sided adhesive tape X ⁺ was used. Acrylic double-sided adhesive tape X ⁺ has the adhesive strength as shown in Table 3-2 and has a total thickness of 0.2mm. Acrylic double-sided adhesive tape X ⁺ includes, as a backing body, a PET film body, which has a thickness of 0.12 mm. The adhesive layer on each side of the X ⁺ acrylic double-sided adhesive tape is 0.04mm thick. The adhesive strengths of the acrylic double-sided adhesive tape X ⁺ at temperatures of 23ºC and 0ºC were high, which prevented the decorative laminate from slipping when applied to the base material. As a result, it was difficult to place the decorative laminate in the correct position.

[0088] Configurations of base materials and decorative laminates are shown in Table 1.

[Table 1]

Base material Primer Decorative laminate Example 1 Plasterboard - Melamine decorative laminate Example 2 Plasterboard - Melamine decorative laminate Example 3 Plasterboard - Melamine decorative laminate Example 4 Plasterboard - Non-flammable decorative laminate Example 5 Plasterboard - Non-flammable decorative laminate Example 6 Plasterboard - Non-flammable decorative laminate Example 7 Plasterboard - Non-flammable decorative laminate Example 8 Plasterboard - Non-flammable decorative laminate Example 9 Plasterboard - Non-flammable decorative laminate Example 10 Plasterboard - Non-flammable decorative laminate Example 11 Plasterboard - Non-flammable decorative laminate Example 12 Plasterboard - Non-flammable decorative laminate Example 13 Plasterboard - Non-flammable decorative laminate Example 14 Plasterboard - Non-flammable decorative laminate Example 15 Calcium silicate panel Acrylic based Non-flammable decorative laminate Example 16 Calcium silicate panel Polyurethane based Non-flammable decorative laminate Example 17 Calcium silicate panel Acrylic based Non-flammable decorative laminate Example 18 Plywood Acrylic based Non-flammable decorative laminate Example 19 Building mixture - Non-flammable decorative laminate Example 20 Plasterboard - Non-flammable decorative laminate Example 21 Plasterboard - Non-flammable decorative laminate Example 22 Plasterboard - Non-flammable decorative laminate Example 23 Plasterboard - Non-flammable decorative laminate Example 24 Plasterboard - Non-flammable decorative laminate Example 25 Plasterboard - Non-flammable decorative laminate Example 26 Plasterboard - Non-flammable decorative laminate Comparative Example 1 Plasterboard - Non-flammable decorative laminate Comparative Example 2 Plasterboard - Non-flammable decorative laminate Comparative Example 3 Plasterboard - Non-flammable decorative laminate Comparative Example 4 Plasterboard - Non-flammable decorative laminate

[0089] Application methods are shown in Tables 2.

[Table 2]

Application Processing the back side of decorative laminate Joint processing Double Sided Adhesive Tape Elastic glue Connector Sealing agent Bottom seam sealing tape Example 1 Acrylic A Modified silicone MS Flat type - - Example 2 Acrylic B Modified silicone Flat type - - Example 3 Acrylic C Modified silicone Flat type - - Example 4 Acrylic A Modified silicone Flat type - - Example 5 Acrylic B Modified silicone Flat type - - Example 6 Acrylic C Modified silicone Flat type - - Example 7 Acrylic A Modified silicone - Silicone based - Example 8 Acrylic A Modified silicone - - Decorative leaf Example 9 Acrylic A Modified silicone External tip type for outside corner - - Example 10 Acrylic A Modified silicone L type for outside corner - - Example 11 Acrylic A Modified silicone Landing type for internal corner - - Example 12 Acrylic A Modified silicone L type for inside corner - - Example 13 Acrylic A Modified silicone Flat type - - Example 14 Butyl rubber Modified silicone Flat type - - Example 15 Acrylic A Modified silicone Flat type - - Example 16 Acrylic A Modified silicone Flat type - - Example 17 Acrylic A Modified silicone Flat type - - Example 18 Acrylic A Modified silicone Flat type - - Example 19 Acrylic A Modified silicone Flat type - - Example 20 Acrylic A Rubber based R Flat type - - Example 21 Acrylic A Urethane U based Flat type - - Example 22 Acrylic A Based on epoxy E Flat type - - Example 23 Acrylic A Modified silicone Flat type - - Example 24 Acrylic A Modified silicone Flat type - - Example 25 Acrylic A Modified silicone Flat type - - Example 26 Acrylic A Modified silicone Flat type - - Comparative Example 1 Acrylic A ^- Modified silicone Flat type - - Comparative Example 2 Acrylic A ⁺ Modified silicone Flat type - - Comparative Example 3 Acrylic X ^- Modified silicone Flat type - - Comparative Example 4 Acrylic X ⁺ Modified silicone Flat type - -

[0090] The evaluation results are shown in Tables 3-1 to 3-3.

[Table 3-1]

Appearance Suitability During application After application No glue ridges Positioning Slippage of decorative laminate Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Example 8 Example 9 Example 10 Example 11 Example 12 Example 13 Example 14 Example 15 Example 16 Example 17 Example 18 Example 19 Example 20 Example 21 Example 22 Example 23 Example 24 Example 25 Example 26 Comparative Example 1 × × × Comparative Example 2 - × Comparative Example 3 × × × Comparative Example 4 ×

: good, ×: bad

[Table 3-2]

90 degree peel test Decorative laminate-adhesive tape Base material is adhesive tape 23ºС 0ºС 23ºС 0ºС [N/20 mm] [N/20 mm] [N/20 mm] [N/20 mm] Example 1 eleven 10 7 7 Example 2 14 13 6 5 Example 3 14 12 6 5 Example 4 eleven 10 7 7 Example 5 14 13 6 5 Example 6 14 12 6 5 Example 7 eleven 10 7 7 Example 8 eleven 10 7 7 Example 9 eleven 10 7 7 Example 10 eleven 10 7 7 Example 11 eleven 10 7 7 Example 12 eleven 10 7 7 Example 13 eleven 10 7 7 Example 14 14 13 7 6 Example 15 eleven 10 5 5 Example 16 eleven 10 12 9 Example 17 eleven 10 13 8 Example 18 eleven 10 10 8 Example 19 eleven 10 6 5 Example 20 eleven 10 7 7 Example 21 eleven 10 7 7 Example 22 eleven 10 7 7 Example 23 eleven 10 7 7 Example 24 eleven 10 7 7 Example 25 eleven 10 7 7 Example 26 eleven 10 7 7 Comparative Example 1 - - - - Comparative Example 2 - - - - Comparative Example 3 2.9 2.7 2.5 2.1 Comparative Example 4 34 32 31 thirty

[Table 3-3]

Tensile testing by Building Research Institute Thickness of double-sided adhesive tape [kN] [mm] Example 1 0.43 1 Example 2 0.43 0.1 Example 3 0.43 4 Example 4 0.43 1 Example 5 0.43 0.1 Example 6 0.43 4 Example 7 0.43 1 Example 8 0.43 1 Example 9 0.43 1 Example 10 0.43 1 Example 11 0.43 1 Example 12 0.43 1 Example 13 0.43 1 Example 14 0.43 1 Example 15 0.73 1 Example 16 0.48 1 Example 17 0.65 1 Example 18 0.68 1 Example 19 0.47 1 Example 20 0.20 1 Example 21 0.57 1 Example 22 0.49 1 Example 23 0.43 1 Example 24 0.43 1 Example 25 0.43 1 Example 26 0.43 1 Comparative Example 1 - 0.02 Comparative Example 2 - 20 Comparative Example 3 0.43 0.03 Comparative Example 4 0.43 0.2

[0091] Mixing ratios of suspensions according to Examples Example 4 to Example 26

are shown in Tables 4-1 to 4-3.

[Table 4-1]

(A) Organic resin components
[parts by weight] Phenol-formaldehyde resin Melamine-formaldehyde resin Example 1 - - Example 2 - - Example 3 - - Example 4 4.5 3.5 Example 5 4.5 3.5 Example 6 4.5 3.5 Example 7 4.5 3.5 Example 8 4.5 3.5 Example 9 4.5 3.5 Example 10 4.5 3.5 Example 11 4.5 3.5 Example 12 4.5 3.5 Example 13 4.5 3.5 Example 14 4.5 3.5 Example 15 4.5 3.5 Example 16 0 8 Example 17 8 0 Example 18 0 8 Example 19 8 0 Example 20 4.5 3.5 Example 21 4.5 3.5 Example 22 0 8 Example 23 4.5 3.5 Example 24 4.5 3.5 Example 25 4.5 3.5 Example 26 4.5 3.5 Comparative Example 1 4.5 3.5 Comparative Example 2 4.5 3.5 Comparative Example 3 4.5 3.5 Comparative Example 4 4.5 3.5

: good, ×: bad

[Table 4-2]

(B) Inorganic filler (b1) Inorganic substance other than endothermic metal hydroxide Small diameter
particles [µm] Average particle diameter [µm] Large particle diameter [µm] Example 1 - - - Example 2 - - - Example 3 - - - Example 4 16.5 - - Example 5 16.5 - - Example 6 16.5 - - Example 7 16.5 - - Example 8 16.5 - - Example 9 16.5 - - Example 10 16.5 - - Example 11 16.5 - - Example 12 16.5 - - Example 13 16.5 - - Example 14 16.5 37.5 37.5 Example 15 - - - Example 16 16.5 37.5 37.5 Example 17 16.5 37.5 37.5 Example 18 - - - Example 19 - - - Example 20 16.5 37.5 37.5 Example 21 - - - Example 22 16.5 37.5 37.5 Example 23 - - - Example 24 0 0 0 Example 25 6.5 42.5 42.5 Example 26 51.5 20 20 Comparative Example 1 16.5 - - Comparative Example 2 16.5 - - Comparative Example 3 16.5 - - Comparative Example 4 16.5 - -

O: good, ×: bad

[Table 4-3]

(B) Inorganic filler (b2) Endothermic metal hydroxide Small particle diameter [µm] Average particle diameter [µm] Large particle diameter [µm] Example 1 - - - Example 2 - - - Example 3 - - - Example 4 - 37.5 37.5 Example 5 - 37.5 37.5 Example 6 - 37.5 37.5 Example 7 - 37.5 37.5 Example 8 - 37.5 37.5 Example 9 - 37.5 37.5 Example 10 - 37.5 37.5 Example 11 - 37.5 37.5 Example 12 - 37.5 37.5 Example 13 - 37.5 37.5 Example 14 - - - Example 15 16.5 37.5 37.5 Example 16 - - - Example 17 - - - Example 18 16.5 37.5 37.5 Example 19 16.5 37.5 37.5 Example 20 - - - Example 21 16.5 37.5 37.5 Example 22 - - - Example 23 6.5 42.5 42.5 Example 24 51.5 20 20 Example 25 0 0 0 Example 26 0 0 0 Comparative Example 1 - 37.5 37.5 Comparative Example 2 - 37.5 37.5 Comparative Example 3 - 37.5 37.5 Comparative Example 4 - 37.5 37.5

: good, ×: bad

[0092] The results of the evaluation of the flame retardant decorative laminate are shown in Table 5.

[Table 5]

Non-flammability test 10 minute test 20 minute test Total heat dissipation Saving the form Total heat dissipation Saving the form MJ/ ^m2 - MJ/ ^m2 - Example 4 3.8 4.8 Example 14 6.4 6.8 Example 15 4.5 6.4 Example 16 6.2 6.3 Example 17 4.0 7.6 Example 23 3.7 6.4 Example 24 3.4 6.0 Example 25 4.5 7.2 Example 26 4.4 7.1

: good, ×: bad

[0093] The aggregate diameters of the inorganic filler particles by volume,

in which three types of inorganic fillers are mixed are shown in Table 6.

[Table 6]

Total particle diameter by volume [µm] Dv(10) Dv(50) Dv(90) Example 4 2.49 12.6 31.8 Example 14 1.48 10.8 36 Example 15 1.53 10.7 30.9 Example 23 2.5 13.6 36.6 Example 24 0.78 3.48 25.9 Example 25 1.84 12.8 30.6 Example 26 1.12 5.72 31

[0094] A method for evaluating the applied decorative laminate according to the above-described Examples and Comparative Examples is explained below.

(1) Appearance

The surface of the applied decorative laminate was visually examined. If the surface was flat, the appearance was rated as good. If irregularities due to the adhesive agent and/or elastic adhesive were found, the appearance was rated as poor.

[0095] (2) Suitability

If the elastic adhesive does not protrude from the end portion of the decorative laminate during application of the decorative laminate, the suitability is judged to be good. If the elastic adhesive protruded from the end portion of the decorative laminate during application of the decorative laminate, the suitability was assessed as poor. In addition, if it was possible to place the decorative laminate and base material in the correct position during gluing, the suitability was assessed as good. If positioning was difficult, suitability was assessed as poor.

If there were no problems such as slipping or warping of the decorative laminate occurring one day after application, the suitability was assessed as good. If it was not possible to maintain adhesive strength, as evidenced by slippage of the decorative laminate, the suitability was assessed as poor. If minor slippage occurred and it was necessary to reinforce the decorative laminate using gummed paper tape, the suitability was assessed as moderate.

[0096] (3) 90 degree peel test

The peel test was carried out based on the JIS Z 0237 standard. An adhesive tape that has a PET film (25 µm thick) taped on one side was cut to a size of 20 mm (width)×150 mm (length). The cut adhesive tape was then applied and attached to the base material and decorative laminate using a 2kg pressure roller, rolled back and forth twice, and then left for three hours at 0ºC or 23ºC. The adhesive tape was then pulled in a 90 degree direction at a pull speed of 300 mm/minute in a 23 degree Celsius, 50% RH (relative humidity) environment to measure the force of the 90 degree peel test. This measurement was carried out three times, and the average of the results according to the three measurements was taken as the 90-degree peel test force.

[0097] (4) Building Research Institute tensile test (measuring the adhesive strength of elastic adhesive)

A fragment measuring 40 mm×40 mm was cut out of the decorative laminate. Elastic adhesive was applied to the base material in the form of a ball so that the application height was 4 mm. The cut fragment and the base material were glued together with a spacer between them adjusted to a height of 1 mm (the adhesive layer had a thickness of 1 mm). The glued cut fragment and the base material were cured for three days at a temperature of 23ºC and 50% relative humidity. The product obtained by the above procedures was considered as a sample. The surface of the decorative laminate, which is part of the sample, was glued to a clamp with a size of 40 mm x 40 mm using glue (cyanoacrylate). The sample was cured for one day at a temperature of 23ºC and 50% relative humidity. The Building Research Institute Method Adhesive Strength Tester (manufactured by Oxjack Co., Ltd.) was then used to apply force to the sample in the direction in which the cut piece and the base material were peeled apart, thereby measuring the tensile strength. The same measurement was carried out three times, and the average of the results according to three measurements was taken as the tensile strength.

[0098] (5) Non-flammability test (10 minutes)

Ten minute heat release test was carried out in accordance with ISO5660 standard using a cone calorimeter. The method for assessing non-flammability was as follows. If the total heat release was 8 MJ/m ² or less, the maximum heat release rate did not exceed 200 kW/m ² for 10 seconds or more continuously, and the test sample had no damage and/or cracks that penetrated the back of the sample, non-flammability was assessed as good. If even one of these three conditions was not satisfied, the non-flammability was assessed as poor.

(6) Non-flammability test (20 minutes)

The twenty minute heat release test was carried out in accordance with ISO5660 standard using a cone calorimeter. The method for assessing non-flammability was as follows. If the total heat release was 8 MJ/m ² or less, the maximum heat release rate did not exceed 200 kW/m ² for ten seconds or more continuously, and the test sample had no damage and/or cracks that penetrated the back of the sample, non-flammability was assessed as good. If even one of these three conditions was not satisfied, the non-flammability was assessed as poor.

[0099] (7) Volumetric aggregate particle diameter

The total particle diameters of the inorganic filler particles in which the three types of inorganic fillers (B) are mixed in the mixing ratios according to Examples and Comparative Examples were measured using a particle size distribution measuring device by laser light diffraction (manufactured by Malvern Instruments Ltd., Model No.: Mastersizer 3000).

According to the results of the above-described measurement, the attachment structures of the decorative laminates according to the present invention (Examples 1-26) provide better appearance of the decorative laminate after application to the base material compared to the configurations of the Comparative Examples. In addition, the fastener structures of the present application do not cause the elastic adhesive to bulge during and after application. And the attachment structures of the present application exhibited favorable adhesion in a peel test at 23°C or 0°C, and showed higher tensile strength of the decorative laminate.

As shown in Table 3-2, Example 14 in particular showed high adhesion between the decorative laminate and the adhesive tape. This is believed to be due to the use of a butyl rubber based adhesive agent.

In particular, Examples 16-18 showed high adhesion between the base material and the double-sided adhesive tape. This is believed to be the result of a primer treatment applied to the base material.

In contrast, Comparative Examples 1 and 3 showed that the decorative laminate had a poor appearance after application. In addition, the adhesive agent protruded during application and slippage of the decorative laminate occurred after application.

(Other)

1. The structure of the decorative laminate fastening unit includes at least two paired decorative laminates attached to the base material, being spaced apart from each other. The at least two paired decorative laminates in each case include: double-sided adhesive tape for the outer side applied to the back side of the decorative laminate that faces the base material, in a position inward from the outer edge of the decorative laminate; double-sided adhesive tape for the inside side, pasted on the back side in a position inward from the double-sided adhesive tape for the outside side; elastic adhesive applied between the outer edge of the back side and the double-sided adhesive tape for the outer side; and elastic adhesive applied to a portion of the back side at a position inward from the double-sided adhesive tape for the outer side, and where the double-sided adhesive tape for the inner side is not pasted.

Double sided adhesive tape for the outside is preferably applied along the outside edge of the back side of the decorative laminate.

The inner side double-sided adhesive tape is preferably applied to the back side of the decorative laminate so that the portion that is inward of the outer side double-sided adhesive tape is substantially evenly divided into sections.

2. The method of applying decorative laminates includes the stages of: (a) placing a stepped element, which has a side wall extending in specified cutting directions, on each decorative laminate of at least two paired decorative laminates, and moving the saw along specified cutting directions using a guide saw blades adjacent to the side wall, thereby cutting the decorative laminate with the saw blade to the size for application;

(b) after step (a), pasting the double-sided adhesive tape for the outside of the decorative laminate in a position inward from the outer edge of the decorative laminate, and pasting the double-sided adhesive tape for the inside onto the back side of the decorative laminate in a position inward from the double-sided adhesive tapes for the outside;

(c) after step (c), applying elastic adhesive to the rear side portion of the decorative laminate at a position between the outer edge and the double-sided adhesive tape for the outer side, and applying elastic adhesive to the rear side portion of the decorative laminate at a position inward of the double-sided adhesive tape for the outside, and where the double-sided adhesive tape for the inside is not pasted; and (d) after step (c), fixing at least two paired decorative laminates to the base material, maintaining a distance between the at least two paired decorative laminates. In step (d), each decorative laminate of the at least two paired decorative laminates is preferably pressed against the base material using a vacuum lifter.

Claims (64)

1. The structure of the attachment unit for decorative laminates, including at least two paired decorative laminates attached to the base material, wherein at least two paired decorative laminates are used for a vertical surface, wherein each of the at least two paired decorative laminates has double-sided adhesive tape applied along the outer peripheral region on the back side of the decorative laminate, and double-sided adhesive tape applied on the inner portion inwardly from the outer peripheral region to form a section, wherein an elastic adhesive comprising a solvent-free, one-component modified silicone resin elastic adhesive is applied on the outside of the double-sided adhesive tape for the outer peripheral region on the rear side, and an elastic adhesive is also applied inside the section formed by the double-sided adhesive tape for the inner portion, wherein at least two paired decorative laminates include a space between them and are fixed to the base material on their respective rear sides and wherein the double-sided adhesive tape has a total thickness of 0.03 to 10 mm and has an adhesive strength of 3 to 30 N/20 mm at a temperature of 23°C or an adhesive strength of 1 to 20 N/20 mm at a temperature of 0°C according to the test for 90 degree peel based on JIS Z 0237 standard. 2. The structure of the attachment unit for decorative laminates, including at least two paired decorative laminates attached to the base material, wherein at least two paired decorative laminates are used for a vertical surface, wherein each of the at least two paired decorative laminates includes a decorative layer and a core layer, and wherein the core layer is configured as a prepreg containing a fibrous-based material, an organic binder component and an inorganic filler, wherein the volumetric aggregate particle diameter Dv(10) of the inorganic filler according to the particle size distribution measuring method using laser diffraction/scattering is 0.5 μm or more, and the volumetric aggregate particle diameter Dv(90) of the inorganic filler according to the distribution measurement method particle size using laser diffraction/scattering is 40.0 µm or less, wherein each of the at least two paired decorative laminates has double-sided adhesive tape applied along the outer peripheral region on the back side of the decorative laminate, and double-sided adhesive tape applied on the inner portion inwardly from the outer peripheral region to form a section, wherein the elastic adhesive is applied on the outside of the double-sided adhesive tape for the outer peripheral region on the rear side and the elastic adhesive is also applied on the inside of the section formed by the double-sided adhesive tape for the inner portion, wherein at least two paired decorative laminates include a space between them and are fixed to the base material on their respective rear sides and wherein the double-sided adhesive tape has a total thickness of 0.03 to 10 mm and has an adhesive strength of 3 to 30 N/20 mm at a temperature of 23°C or an adhesive strength of 1 to 20 N/20 mm at a temperature of 0°C according to the test for 90 degree peel based on JIS Z 0237 standard. 3. Structure according to paragraph 1, wherein each of the at least two paired decorative laminates includes a decorative layer and a core layer, and wherein the core layer is configured as a prepreg containing a fibrous-based material, an organic binder component and an inorganic filler. 4. The structure according to claim 2 or 3, in which the ratio of the organic binder component to the inorganic filler in the core layer in terms of solids content is 1:1-25. 5. Structure according to any of the previous paragraphs. 2-4, in which the inorganic filler contains three types of inorganic fillers, which have correspondingly different average particle diameters. 6. The structure of claim 5, wherein the average particle diameter of the inorganic filler is 0.04 µm or more and less than 50 µm. 7. Structure according to paragraph 5 or 6, wherein three types of inorganic fillers that have correspondingly different average particle diameters include: inorganic filler with small particle diameter; inorganic filler with an average particle diameter and inorganic filler with large particle diameter, wherein the small particle diameter of the inorganic filler is 0.04 μm or more and less than 4 μm, wherein the average particle diameter of the inorganic filler is 4 microns or more and less than 12 microns and wherein the major particle diameter of the inorganic filler is 12 µm or more and less than 50 µm. 8. Structure according to any of the previous paragraphs. 2-7, wherein the inorganic filler is an endothermic metal hydroxide and/or an inorganic substance other than an endothermic metal hydroxide. 9. The structure according to claim 7, in which the mixture ratio of the inorganic filler with a small particle diameter to the inorganic filler with a medium particle diameter to the inorganic filler with a large particle diameter in the core layer is from 1:0.1 to 20:0.1 to 20 . 10. Structure according to any of the previous paragraphs. 2-9, wherein the volumetric aggregate particle diameter Dv(10) of the inorganic filler according to the particle size distribution measurement method using laser light diffraction/scattering is 0.5 μm or more, and the volumetric aggregate particle diameter Dv(90) of the inorganic filler according to the particle size distribution measurement method using laser diffraction/scattering, it is 40.0 µm or less. 11. Structure according to any of the previous paragraphs. 2-10, in which the specific surface area of the inorganic filler as measured by laser diffraction/scattering is from 800 to 4000 m ² /kg. 12. Structure according to any of the previous paragraphs. 2-11, in which the fibrous base material is made of a nonwoven material, which is a combination of an emulsion of a thermoplastic resin and fiber. 13. Structure according to any of the previous paragraphs. 1-12, in which the gap is in the plane, at the outer corner, or at the inner corner of the structure of the fastening unit. 14. Structure according to any of the previous paragraphs. 1-13, wherein the gap is provided with one or more of a bottom seam sealing tape, a connector, or a sealing agent. 15. Structure according to any of the previous paragraphs. 1-13, in which the double-sided adhesive tape has an adhesive strength of 3 to 30 N/20 mm at a temperature of 23°C and an adhesive strength of 1 to 20 N/20 mm at a temperature of 0° according to a 90-degree peel test based on the standard JIS Z 0237. 16. Structure according to any of the previous paragraphs. 1-15, wherein the base material is plaster board, calcium silicate panel, plywood or mortar. 17. Structure according to any of the previous paragraphs. 1-16, in which the base material is treated with a primer. 18. Structure according to any of the previous paragraphs. 1-17, wherein the elastic adhesive has a tensile strength of 0.1 to 0.9 kN relative to a metal clamp having a size of 40 mm×40 mm as measured using a Building Research Institute method adhesive strength tester. 19. Structure according to any of the previous paragraphs. 1-18, wherein the elastic adhesive is a moisture-curing reactive adhesive agent. 20. Structure according to any of the previous paragraphs. 2-19, wherein the elastic adhesive is a solvent-free, one-component, modified silicone resin elastic adhesive. 21. Structure according to any of the previous paragraphs. 1-20, wherein each of the at least two paired decorative laminates includes a decorative layer and a core layer, wherein the core layer is configured as a prepreg containing a fibrous-based material, an organic binder component and an inorganic filler, wherein the ratio of the organic binder component to the inorganic filler in the core layer in terms of solids content is 1:1-25, and in which the thickness of the decorative laminate ranges from 0.86 mm to 8.00 mm. 22. A method of applying decorative laminates to a base material to obtain the structure of a fastening unit for decorative laminates according to claim 1 or 2, including: (A) cutting one decorative laminate from at least two paired decorative laminates to a predetermined size; (B) sticking double-sided adhesive tape on the outer peripheral portion on the back side of one decorative laminate obtained by cutting (A), and sticking double-sided adhesive tape on the inside of the outer peripheral portion to form a section, and applying elastic adhesive on the outside of the double-sided adhesive tape to the outer peripheral portion on the back side, and also applying elastic adhesive inside the section formed by the double-sided adhesive tape for the inner portion; (C) fixing one decorative laminate obtained in the gluing step (B) to the base material, wherein the fastening is accomplished by pressing one decorative laminate to the base material, wherein one decorative laminate is attached to a vacuum lifter so that one decorative laminate is used for vertical surfaces; And (D) treating the outer decorative laminate of at least two paired decorative laminates in the same manner as in the above steps (A), (B) and (C), and attaching the other decorative laminate to the base material, where a gap is formed between one decorative laminate and another decorative laminate fixed to the base material. 23. The method of claim 22, wherein each of the at least two paired decorative laminates includes a decorative layer and a core layer, wherein the core layer is configured as a prepreg containing a fibrous-based material, an organic binder component and an inorganic filler wherein the ratio of the organic binder component to the inorganic filler in the core layer in terms of solids content is 1:1-25, and in which the thickness of the decorative laminate ranges from 0.86 mm to 8.00 mm. 24. The method of claim 22 or 23, wherein (A) cutting one decorative laminate from at least two paired decorative laminates to a predetermined size using an element that has a rectangular shape in plan view, the element including a height difference of in the form of one step, having an upper planar part, a lower planar part and a side wall. 25. Method according to any of the previous paragraphs. 22-24, in which the double-sided adhesive tape has a total thickness of 0.03 to 10 mm and has an adhesive strength of 3 to 30 N/20 mm at a temperature of 23 ° C or an adhesive strength of 1 to 20 N/20 mm at a temperature of 0 °C according to 90 degree peel test based on JIS Z 0237 standard. 26. The method according to any of the previous paragraphs. 22-25, in which the gap is in the plane, at the outer corner or at the inner corner of the structure of the fastening unit. 27. Method according to any of the previous paragraphs. 22-26, wherein the gap is provided with one or more of a bottom seam sealing tape, a connector, or a sealing agent. 28. The method according to any of the previous paragraphs. 22-27, wherein the base material is plaster board, calcium silicate panel, plywood or mortar. 29. The method according to any of the previous paragraphs. 22-28, the method further comprising treating the base material with a primer.

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