JP2011037040A - Decorative board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative board which is obtained by using an inorganic substance as a binder component and has noncombustibility. <P>SOLUTION: A base material layer (A) comprising an impregnated sheet obtained by impregnating an inorganic fiber sheet with slurry including an inorganic binder and an inorganic filler and drying the sheet thus impregnated, a prepreg (B) obtained by impregnating another inorganic fiber sheet with slurry including an organic binder (d) and another inorganic filler (e) and drying the sheet thus impregnated, and thermosetting resin-impregnated pattern paper (C) are integrated by hot pressing to obtain the decorative board. The slurry of the constituent (A) is prepared by blending alkali metal silicate, namely, sodium silicate as a component (a), metal oxide and/or metal hydroxide, namely, zinc oxide and/or aluminum hydroxide as a component (b), and the inorganic filler, namely, calcium carbonate as a component (c). <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a decorative board.

  Conventionally, a decorative board having an incombustible function is known, and a prepreg obtained by impregnating a fibrous base material with a slurry containing an organic resin as a binder component and a flame retardant is used as the base material.

JP 2008-290444 A JP 2005-336254 A JP 2006-336159 A

  However, there is a limit to the amount of organic resin added as a binder component in order to impart incombustibility. That is, when the organic resin is increased, the nonflammability tends to be lowered, and when it is decreased, the adhesion between the prepregs is deteriorated.

  The present invention has been studied in view of such circumstances, and (A) a base material layer composed of an impregnated sheet impregnated and dried with an inorganic fiber sheet impregnated with a slurry containing an inorganic binder and an inorganic filler, and (B) A prepreg impregnated and dried with a slurry containing a phenol resin and an inorganic filler in an inorganic fiber sheet and (C) a thermosetting resin-impregnated pattern paper are integrated by heat and pressure.

  The decorative board of the present invention has water resistance and nonflammability, and (B) an inorganic fiber sheet is impregnated with a slurry containing a phenol resin and an inorganic filler between the base material layer and the thermosetting resin impregnated pattern paper, and dried. Since the prepared prepreg is interposed, it has elasticity and the bending strength is improved. Moreover, in this application, since there is no need to use an organic flame retardant, there is no worry of toxicity.

The substrate layer of the component (A) of the present invention will be described. The base material layer is composed of an impregnated sheet impregnated and dried with a slurry containing an inorganic binder and an inorganic filler in an inorganic fiber sheet, and the inorganic fiber sheet includes glass fiber, rock wool, carbon fiber, ceramic fiber, etc. Nonwoven fabrics and woven fabrics made of inorganic fibers can be used, and the basis weight of the inorganic fiber base material is preferably in the range of 10 to ²⁰⁰ g / m2. In particular, it is preferable to use a glass fiber nonwoven fabric having excellent heat resistance and flame resistance and excellent impregnation of slurry. The impregnation rate (%) of the slurry is adjusted to 600 to 2000% by the calculation method shown in Equation 1.

The slurry (A) comprises (a) an alkali metal silicate, (b) a metal hydroxide and / or metal oxide, (c) an inorganic filler, and an appropriate amount of water. The alkali metal silicate of component (a) refers to a silicate compound of an alkali metal element, which is represented by the general formula M ₂ O · nSiO ₂ and is cured to form a glassy silicate polymer. In this invention, it becomes a main material of an inorganic binder. M is an alkali metal, n is a molar ratio of M ₂ O and SiO _2, and generally 1.0 ≦ n ≦ 4.5. Specific examples include potassium silicate, sodium silicate, and lithium silicate. Two or more kinds may be used. The bond strength decreases in the order of Na>K> Li, and the water resistance decreases in the order of Li>K> Na.

  The proportion of the component (a) in the total amount of ((a) + (b) + (c)) is preferably 9 to 13% by weight. I can't. On the other hand, if the upper limit is exceeded, the glass component will ooze out during hot pressing.

The component (b) metal oxide and / or metal hydroxide functions as a curing agent for the (a) alkali metal silicate, and is appropriately selected from those having an affinity for the component (a). . Examples of the metal oxide include zinc oxide, zinc borate (2ZnO.3B ₂ O ₃ .3.5H ₂ O), magnesium oxide, calcium oxide, aluminum oxide, and the like. Examples of the metal hydroxide include aluminum hydroxide. And metal hydroxides such as magnesium hydroxide and tricalcium aluminate hexahydrate. For water resistance, zinc oxide or aluminum hydroxide is largely involved.

  The average particle size of component (b) is preferably 0.3 to 50 μm, more preferably 0.5 to 10 μm. On the other hand, if the upper limit is exceeded, unevenness on the surface of the non-combustible substrate tends to be noticeable. In addition, (b) component may use 2 or more types together, and may use together the same type and different average particle diameter.

  The blending ratio of the components (a) and (b) is preferably (a) :( b) = 100: 30-100 in weight ratio. If the blending ratio of the component (b) is less than the lower limit, the water resistance of the incombustible substrate is lowered. On the other hand, if the upper limit is exceeded, the mixture thickens and it becomes difficult to control the impregnation rate.

  The metal hydroxide may be surface-treated with a coupling agent such as aminosilane, acrylic silane, or epoxysilane for the purpose of improving interfacial adhesion with alkali metal silicate (inorganic binder).

  In addition to the aggregates of the components (a) and (b), an inorganic filler is blended as the component (c). (C) Examples of the inorganic filler include calcium carbonate, magnesium carbonate, silica, talc, fly ash and the like. Among these, it is desirable to use calcium carbonate that is superior in terms of workability and machinability.

  There is no restriction | limiting in particular as calcium carbonate, Heavy calcium carbonate, light calcium carbonate (precipitation calcium carbonate), etc. can be used. Heavy calcium carbonate having an average particle diameter of 0.05 to 20 μm, more preferably 1 to 8 μm is preferable. If the lower limit is not reached, secondary agglomeration is likely to occur and agglomeration is likely to occur, and impregnation is likely to deteriorate. The surface of the material is not smooth, resulting in poor appearance. Light calcium carbonate refers to calcium carbonate that is chemically produced by firing limestone, and heavy calcium carbonate refers to finely powdered calcium carbonate prepared by dry or wet pulverization of white crystalline limestone. In addition, (c) component may use 2 or more types together, and may use together the same type and different average particle diameter.

  The mixing ratio of the components (a) and (c) is preferably (a) :( c) = 100: 500 to 900 in weight ratio. If the blending ratio of the component (c) is less than the lower limit, the glass component oozes out during pressing. On the other hand, if the upper limit is exceeded, the mixture thickens and it becomes difficult to control the impregnation rate.

  In addition, a dispersant for improving the dispersibility of the components (a), (b) and (c), a penetrant, an antifoaming agent and a thickening agent for improving the permeability to the inorganic fiber sheet. An agent or the like may be added and mixed at a ratio of 1 to 10 parts by weight with respect to 100 parts by weight of component (a).

  Examples of the dispersant include anionic, cationic, nonionic and amphoteric dispersants. As the anionic dispersant, a carboxylic acid polymer or a salt thereof, naphthalene sulfonate formaldehyde condensate, melamine sulfonate formaldehyde condensate, lignin sulfonate, tripolyphosphate, hexametaphosphate and the like are preferable. As the cationic dispersant, alkyltrimethylammonium salt, dialkyldimethylammonium salt and the like are preferable. As the nonionic dispersant, polyoxyalkylene alkyl ether is preferable, and as the amphoteric dispersant, alkylbetaine is preferable.

  Examples of penetrants used in the present invention include anionic, cationic, nonionic, and amphoteric penetrants. As the anionic penetrant, alkylbenzene sulfonate, alkyl sulfate ester salt, polyoxyalkylene alkyl sulfate ester salt, and dialkyl sulfosuccinate are preferable. As the cationic penetrant, alkyltrimethylammonium salt, dialkyldimethylammonium salt and the like are preferable. As the nonionic penetrant, polyoxyalkylene alkyl ether is preferable. As the amphoteric penetrant, alkyl betaines are preferred.

  In particular, as the penetrant, it is preferable to use a nonionic surfactant that is not easily affected by acids, alkalis, and inorganic salts and has good compatibility with water and a solvent, particularly an ether type nonionic surfactant. it can.

  In the case where different ions coexist (cation type and anion type), a complex is formed. Therefore, the dispersing agent and the penetrating agent are selected to be the same ionic or nonionic type.

  Next, the prepreg of the component (B) of the present invention will be described. As the prepreg, the same inorganic fiber sheet as in (A) is used, but it is particularly preferable to use a glass fiber nonwoven fabric excellent in heat resistance and flame resistance. (D) A phenol resin is used for the organic binder component. When a melamine resin is used, since the inorganic binder applied to the base material layer is basic, it inhibits the curing of the melamine resin, making it difficult to form a surface design layer made of thermosetting resin-impregnated patterned paper. (E) Inorganic fillers include metal hydroxides such as aluminum hydroxide and magnesium hydroxide, calcium carbonate, magnesium carbonate, silica, talc, fly ash and the like. Among these, it is desirable to use calcium carbonate that is superior in terms of workability and machinability. When obtaining a prepreg, it operates so that the impregnation rate (%) of a slurry may become 800-2000% by the calculation method shown in Formula 1.

  (D) The blending ratio of the organic binder and (e) inorganic filler is desirably 5 to 20:95 to 80, and when the inorganic filler increases with respect to the organic binder, the incombustibility is improved, but the adhesion is improved In addition, when the inorganic filler is decreased, the nonflammable performance is lowered although the adhesion is improved.

  The thermosetting resin-impregnated patterned paper of the component (C) of the present invention is impregnated with a resin liquid made of thermosetting resin such as amino-formaldehyde resin, diallyl phthalate resin, unsaturated polyester resin on decorative paper for decorative board. A conventionally known product that has been dried and applied can be applied.

The decorative board of the present invention comprises: (A) a base material layer composed of an impregnated sheet impregnated and dried with an inorganic fiber sheet impregnated with a slurry containing an inorganic binder and an inorganic filler; and (B) an organic fiber sheet. A prepreg impregnated and dried with a slurry containing a binder and an inorganic filler and (C) a thermosetting resin-impregnated pattern paper are laminated, and usually obtained by a known hot-press molding method. The temperature may be 120 to 150 ° C., the pressure is 30 to 70 kg / cm ² , and the time is 60 to 120 minutes.

Production of Impregnated Sheet (I) A slurry (A1) containing the following components is impregnated into a glass fiber nonwoven fabric of 78 g / m ² so that the impregnation amount shown in Equation 1 is 1130% and dried to obtain an impregnated sheet (I). It was.
Slurry (A1)
Inorganic binder component (a) 80 parts by weight of sodium silicate (No. 1 sodium silicate, manufactured by Toso Sangyo Co., Ltd.)
Curing agent (b) Zinc oxide 30 parts by weight (average particle size 0.6 μm)
50 parts by weight of aluminum hydroxide (average particle size 8 μm)
Inorganic filler (c) 600 parts by weight of calcium carbonate (average particle size 1-8 μm, manufactured by Maruo Calcium Co., Ltd.)
Water 200 parts by weight Dispersant 3.5 parts by weight (Polycarboxylic acid type polymer surfactant, trade name Demol EP, manufactured by Kao Corporation)

Production of Prepreg (I) A slurry (B1) containing the following components was impregnated into a glass fiber nonwoven fabric of 78 g / m ² so that the impregnation amount shown in Equation 1 was 1130% and dried to obtain prepreg (I).
Slurry (B1)
Organic binder component (d) Phenol resin 160 parts by weight Inorganic filler (e) Calcium carbonate 756 parts by weight (average particle size 1-8 μm, manufactured by Maruo Calcium Co., Ltd.)
Water 70 parts by weight Dispersant 3 parts by weight (Polycarboxylic acid type polymer surfactant, trade name Demol EP, manufactured by Kao Corporation)

Manufacture of patterned paper impregnated with melamine A plain paper decorative paper having a basis weight of 120 g / m ² is impregnated with a resin liquid mainly composed of melamine-formaldehyde resin so that the impregnation ratio shown in Equation 1 is 100%. A resin-impregnated pattern paper was obtained.

Manufacture of decorative board In order from the bottom, 1 sheet of melamine resin impregnated pattern paper, 1 sheet of prepreg (I), 3 sheets of impregnated sheet (I), 1 sheet of prepreg (I), 1 sheet of melamine resin impregnated pattern paper Then, using a flat finish plate, hot pressing was performed at 140 ° C. and 70 kg / cm ² for 100 minutes to obtain a decorative board.

  In Example 1, it implemented similarly except having made zinc oxide into 0 weight part.

  In Example 1, it implemented similarly except having made aluminum hydroxide 0 weight part.

  In Example 1, it implemented similarly except having made phenol resin into 100 weight part.

  In Example 1, it implemented similarly except having made phenol resin into 130 weight part.

  In Example 1, it implemented similarly except having made the (a) component into 70 weight part.

  In Example 1, it implemented similarly except having made 100 weight part of (a) component.

Comparative Example 1
In Example 4, it implemented similarly except having mix | blended 500 weight part of melamine resin with (d) component.

The blending and evaluation results are shown in Table 1.

The test method is shown below.
Adhesiveness: “O” indicates that there is no crack or peeling after press adhesion, “Δ” indicates that there is a slight crack in the interlayer or in the layer, and “X” indicates that there is a crack or peeling between the layers.
Boiling resistance: JIS K 6902; 1998 (Thermosetting resin high-pressure decorative board test method) boiling resistance test was carried out, and delamination and no cracks after boiling were evaluated as o, delamination and cracks as x.
Nonflammability: The total calorific value is 8 MJ / m ² or less and the maximum heat generation rate exceeds 200 kW / m ² for 10 seconds or more in the exothermic test / evaluation method of a 20 minute test using a corn calorimeter according to ISO 5660. The case where there is not is set as ◯.
Bending strength: Measured based on JIS K 6902; 1998 (Testing method for thermosetting resin high-pressure decorative board).
Elastic modulus: Measured based on JIS K 6902; 1998 (Testing method for thermosetting resin high-pressure decorative board).

1 is a configuration cross-sectional view of a decorative board of Example 1. FIG.

DESCRIPTION OF SYMBOLS 1 Thermosetting resin impregnation pattern paper 2 Prepreg 3 Impregnation sheet 6 Base material layer 9 Decorative board

Claims (4)

(A) a base material layer composed of an impregnated sheet impregnated and dried with a slurry containing an inorganic binder and an inorganic filler in an inorganic fiber sheet;
(B) a prepreg impregnated and dried with a slurry containing (d) an organic binder and (e) an inorganic filler in an inorganic fiber sheet;
(C) a thermosetting resin-impregnated pattern paper;
A decorative board characterized by being integrated with heat and pressure. The decorative board according to claim 1, wherein the slurry (A) comprises the following components (a), (b), (c) and an appropriate amount of water.
(A) alkali metal silicate (b) metal hydroxide and / or metal oxide (c) inorganic filler 2. The decorative board according to claim 1, wherein a blending ratio of (d) the organic binder resin and (e) the inorganic filler is 5 to 20:95 to 80 in the slurry (B). The decorative board according to claim 1, wherein the organic binder (B) is a phenol resin.