JPH07317200A - Lightweight decorative board and manufacturing method thereof - Google Patents

Abstract

(57) [Summary] [Purpose] To obtain a lightweight architectural decorative board having a decorative layer on the surface and having heat insulating properties. [Structure] Two binders are applied on a resin film 1, and an inorganic aggregate 3 is sprayed before the applied binder is cured,
Further, the backing layers 4 and 5 are applied thereon, and the adhesive 6 is applied thereon to form the decorative layer A with the resin film 1. The decorative layer A is placed in a molding die C with the resin film 1 on the outside, and then the granular expanded particles 10 are filled, and the granular expanded particles 10 are integrally molded with the decorative layer A simultaneously with foaming. And [Effect] The decorative layer A and the foamed resin layer B are firmly integrated and a lightweight decorative material can be obtained, which can be effectively used as an outer wall material and an inner wall material that can be easily installed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight decorative board and a method for manufacturing the same, and more particularly to a lightweight decorative board that can be effectively used as an interior material or an exterior material such as flooring and wall materials, and a method for manufacturing the same.

[0002]

2. Description of the Related Art In order to improve the appearance of a building and enhance its waterproofness, it is common to apply various kinds of beauty to the inner wall, outer wall or floor of the building. BACKGROUND ART Conventionally, when constructing an inner wall, an outer wall or a floor surface at a construction site, after coating concrete or mortar on the site, the surface is finished, coated with a paint, or tiled. This dressing work requires a skilled worker, and due to the nature of the work, it cannot be done on a rainy day, and there is a problem that it depends on the weather.

In the case of a large-scale building, a large-scale precast concrete panel whose interior and exterior are finished in advance is prepared in a factory, which is then brought to a construction site and installed on the inner and outer walls. In this case, although the above-mentioned problem can be avoided for some time, there is a problem that the finished outer surface is easily scratched or soiled during transportation from the factory to the site or construction at the site.

As means for solving the above-mentioned problems, a resin film or sheet, a surface layer composed of an inorganic aggregate and a binder formed on the film or sheet, and a backing layer provided on the surface layer. There is known a technique of forming a precast concrete panel having a decorative sheet on its surface by casting concrete, mortar or the like from the backing layer in a factory using the decorative sheet made of (Japanese Patent Laid-Open No. 2-299833). Japanese Patent Application 5-1
61555). After this precast concrete panel is installed at a predetermined place in a construction site, the resin film or sheet on the surface is peeled off to obtain a wall surface having a beautiful appearance such as a granite pattern on the surface.

As still another example, a lower layer having a waterproof layer formed on a wooden substrate, an intermediate layer obtained by kneading an inorganic binder and foamed synthetic resin particles, and an inorganic binder and a fine aggregate are kneaded. There is also known an exterior material in which an outer surface of the outer layer formed by sequentially laminating the surface layer is formed with an uneven pattern by a template (see Japanese Patent Laid-Open No. 3-232777). By using such an exterior material, it is possible to easily dress the inner wall, the outer wall, and the floor surface at the construction site, and it is possible to work without being influenced by the weather. Furthermore, because the surface is covered with a resin film or sheet,
The problem of scratches and stains on the decorative surface was also avoided when the manufactured precast concrete panels were transported from the factory to the site or during construction at the site.

[0006]

In any of the exterior materials or interior materials having the decorative layer or decorative sheet on the surface as described above, the base portion is concrete or mortar and is a heavy object. It is difficult to transport the product or handle it at the construction site. Also, in a relatively small-scale building, without using concrete as a wall member, insert a heat insulating material made of a foamed resin material between the pillars such as between the pillars, and then insert an appropriate surface layer material on it. Although the outer wall and the floor surface are finished to be attached after installation, it is difficult to adhere and integrate the heat insulating material, which is a foamed resin material, and the surface layer material, which is a decorative board, and the heat insulating material and the surface layer material after the construction. A gap may occur between the two. Condensed water or the like is likely to stay in such gaps, which accelerates damage to the walls.

An object of the present invention is to obtain an exterior material or an interior material which solves the above-mentioned inconveniences of the conventional exterior material or interior material itself and the above-mentioned inconveniences associated with the conventional exterior or interior construction method. More specifically, more specifically, by firmly adhering and integrating the decorative layer to the surface of the foamed resin layer, it is lightweight and easy to handle, and there is no gap between the foamed layer and the decorative layer after construction. It is to obtain a lightweight decorative board that does not occur and a manufacturing method thereof. Another object of the present invention is to obtain a method for manufacturing a lightweight decorative board in which a surface material for protecting the surface of a decorative layer is laminated in a peelable state.

[0008]

In order to solve the above problems and achieve the object, the present invention provides a surface layer comprising an inorganic aggregate and a binder, and a backing layer laminated on the back surface of the surface layer. A lightweight decorative plate comprising a decorative layer having at least an adhesive layer applied to the back surface of the backing layer, and a foamed resin layer integrally formed at the same time as foaming granular foam particles on the back surface side of the decorative layer Is disclosed.

Further, the present invention is characterized in that on a resin film,
Or on the back side of a resin mold with an uneven pattern on the surface,
Apply the binder, spray the inorganic aggregate before the applied binder hardens, and then apply the backing layer on it.
Further, a decorative layer having a resin film or a mold on the surface is formed by applying an adhesive from above, and the decorative layer having the resin film or the mold is placed with the resin film or the mold outside. A method for manufacturing a lightweight decorative board, which comprises placing the foam particles in a molding die, filling the foam particles, and simultaneously molding the foam particles together with the resin film or the decorative layer with a mold frame at the same time. Disclose.

In the lightweight decorative board according to the present invention,
Immediately after the production, a resin film or a resin frame having an uneven pattern on the surface is laminated on the surface of the decorative layer in a peelable state. Then, the resin film or frame is peeled off and separated from the lightweight decorative board when necessary. Hereinafter, the present invention will be described in detail.

In the present invention, the resin film and the resin mold having an uneven pattern on the surface are for protecting the decorative layer on the surface side of the manufactured lightweight decorative board, and if necessary after construction. It is peeled off from the lightweight decorative board. As the resin for the resin film, polypropylene, polyethylene, polystyrene, polyvinyl chloride, polyamide or the like can be used as the resin. Of these, olefin resins, polypropylene, and polyethylene are particularly preferable because they have good releasability from the surface layer of the lightweight decorative board after molding.

The thickness is preferably 0.5 to 5 mm, and the thickness is 0.
If the thickness is less than 5 mm, the surface of the decorative layer may be insufficiently protected during transportation and construction of the lightweight decorative plate. Further, if it is about 5 mm, the surface protection property is sufficient, and if it is more than that, the cost becomes high and there is a problem that it does not follow the shape when used as a surface decorative plate of a building having a curved surface.

The resin film may be foamed or non-foamed. The foamed film is effective as a protective material for the surface of the decorative layer made of a light-weight decorative board, and the non-foamed film can give the surface of the decorative layer excellent luster as compared with the case of the foamed film. A foamed film having a density of about 0.01 to 0.6 is particularly effective as a protective material for the decorative surface.

The resin film may be a film having a flat surface or a film having an uneven pattern or embossing. As will be described later, when a film having a flat surface is used, a lightweight decorative plate having a smooth decorative layer surface is obtained, and when a film having an uneven pattern or embossed is used, an uneven pattern or a decorative pattern is formed on the decorative layer surface. A lightweight decorative board with an embossed pattern can be obtained.

Further, as a resin mold having an uneven pattern on its surface, a lightweight decorative board can be manufactured using a foamed or non-foamed product made of the same material as the resin film. An uneven pattern can also be applied arbitrarily. The resin film or resin frame can be repeatedly used when manufacturing the lightweight decorative board. In particular, when a resin mold is made of a foamed resin, polypropylene and polyethylene are particularly preferable because they can be more easily used repeatedly.

The inorganic aggregate constituting the surface layer is provided for the purpose of makeup, and the material and size thereof are not particularly limited, but crushed natural stones and ceramics are suitable for obtaining a good decorative pattern. In that case, it is a preferable mode to prepare a plurality of sets having different particle sizes and to spray the particles in descending order of particle size in order to obtain a more natural stone pattern.

The binder constituting the surface layer is appropriately selected and used depending on the material and thickness of the resin film or the mold which is releasably laminated on the surface layer and the material and thickness of the backing layer. The binder may be an acrylic, polyester, epoxy, urethane, fluororesin, or the like, and a water-soluble binder is preferable because it does not deteriorate the resin film or the mold. Also,
The higher the viscosity is, the more preferable it is, and it is preferable that it is about 8000 to 15,000 poise. In particular, by using a soap-free water-soluble acrylic resin, good adhesiveness and peelability between the decorative layer surface of the lightweight decorative board and the resin film or the mold can be simultaneously satisfied. The coating amount is 200 to 500 g / m ² , preferably 250 to 3
It is 50 g / m ² . According to the experiments by the present inventors, when the coating amount is less than 200 g / m ² , the viscosity is 5000
When the porosity was less than that, pinholes were easily formed, and a stone pattern was difficult to appear.

The backing layer is an adhesion between the decorative layer and the foamed resin layer when the foamed resin layer formed by secondary foaming of the granular expanded particles is integrally molded with the decorative layer at the same time as the secondary foaming as described later. It is laminated for the purpose of improving the property and reinforcing the decorative layer.As the material, cement-mixed type resin, soft cement paste, elastic type mortar, etc. can be appropriately selected and used. Mortar is particularly suitable. In any case, the amount used is about 500 to 1500 g / m ² , preferably about 1000 to 1200 g / m ² .

Dispersing the inorganic aggregate on the backing layer is a preferred embodiment, whereby the decorative surface can be made more compact and clean. The material is natural stone,
Although powdered stones such as ceramics are preferable, according to the experiments conducted by the present inventors, a crushed natural stone is particularly preferable, and a particle size of about 0.8 to 1.2 mm is preferable.

The adhesive applied to the backing layer is not particularly limited, but when a vinyl acetate adhesive such as polyvinyl acetate, polyvinyl acetate / vinyl chloride copolymer, ethylene / vinyl acetate copolymer is used. The adhesiveness between the decorative layer and the expanded particle layer can be made strong, and it is preferably used. In the method for manufacturing a lightweight decorative board according to the present invention, a decorative layer having a resin film or a mold on the surface side configured as described above is arranged in the mold with the resin film or the mold facing outward. After that, the granular foamed particles are filled and steam is supplied to carry out secondary foaming, and simultaneously with foaming, a foamed resin layer formed by the secondary foaming is integrally molded with the decorative layer.
Thereby, the decorative layer and the foamed resin layer are firmly integrated.

For foaming simultaneous molding, a conventionally known foaming molding machine can be appropriately used, but a longitudinal drive molding machine is particularly preferable. The reason for this is that when the foamed particles are filled in the molding die, it is necessary to take care so that the foamed particles do not wrap around the resin film or the mold frame side surface of the decorative layer arranged in the die. From this point as well, the vertical drive molding machine is particularly preferable. The surface of the metal mold on the side facing the resin film or the mold of the decorative layer may be flat or uneven. By using a mold having an uneven surface, it is possible to obtain a lightweight decorative board having an uneven pattern or an embossed pattern on the surface of the decorative layer. At that time, it is necessary to previously form the same uneven pattern or emboss as the uneven pattern or emboss formed on the mold on the resin film,
It is valid.

The granular expanded particles preferably have a bulk ratio of 2 to 50 times, and particularly preferably 5 to 20 times in terms of light weight and strength. As the resin, those obtained by foaming polystyrene-based resin including polystyrene-based heat resistant resin, polypropylene-based resin, polyethylene-based resin, etc. to the above expansion ratio are preferably used. The polystyrene-based resin is not limited to a homopolymer of a styrene-based monomer and includes a copolymer. The styrene-based monomer includes methylstyrene, ethylstyrene and the like in addition to styrene. Further, the copolymer contains a copolymer containing 50 mol% or more of a styrene-based monomer. As the counterpart monomer of the copolymer, methacrylic acid ester such as methyl methacrylate,
Examples thereof include acrylic acid ester, acrylic acid, methacrylic acid, acrylonitrile, maleic anhydride and the like. The polypropylene-based resin and polyethylene-based resin also include polyethylene, polypropylene, polymers thereof, copolymers with other polymers copolymerizable therewith, and mixtures thereof. Among these resins, polystyrene-based foamed particles are most preferably used from the viewpoint of strength of the foamed layer and ease of flame retardation. Further, various additives such as a flame retardant, a deterioration inhibitor, and a coloring agent can be used in the foamed particles, if necessary.

The specific gravity of the obtained lightweight decorative board is determined on condition that the strength required at the time of construction is satisfied,
Considering that the specific gravity of the conventional precast concrete board made of mortar concrete is about 2.3, the average specific gravity of the lightweight decorative board is preferably about half or less than 1.3. In the experiment, one having a specific gravity of about 0.1 to 1.5 was the most preferable in view of the required strength and workability. For example, 300mm x 300
In the case of manufacturing a product of mm × 15 mm, a concrete board weighs about 3.1 kg, but the lightweight decorative board according to the present invention can reduce the weight by about 50% or more. Sex is greatly improved.

Next, one embodiment of the method for manufacturing a lightweight decorative board according to the present invention will be described in the order of steps with reference to FIG. As shown in FIG. 1a, a predetermined binder 2 is applied onto a resin film 1 having a predetermined thickness in consideration of the adhesiveness with the inorganic aggregate to be used. Next, as shown in FIG. 1b, the inorganic aggregate is sprinkled before the applied binder 2 is cured. It is preferable to prepare a large number of types (three types in the figure) having different particle sizes, and spray the particles in descending order of particle size. As a result, it is possible to avoid the inconvenience that those having a large particle size do not exist on the back surface of the resin film 1. For example, when an exterior wall for building is constructed, inorganic aggregates having different diameters are formed on the surface thereof. It is possible to obtain a densely arranged product.

Next, as shown in FIG. 1c, any one of cement-mixed type resin, soft cement paste, elastic type mortar and the like is applied as a backing material to form a backing layer 4. Before the backing layer 4 is solidified, the aggregate 5 which is a crushed material of natural stone may be dispersed. After drying, for example, a vinyl acetate adhesive 6 is applied to obtain a decorative layer A in which the resin film 1 as a protective layer is laminated on the surface (FIG. 1d).

The decorative layer A obtained by laminating the obtained resin film 1 is placed in the molding die 10 with the resin film 1 side as the inner surface side of the molding die 10, and then the granular foamed particles 7 are filled (see FIG. 1e), steam is supplied for secondary foaming, and simultaneously with foaming, the foamed resin layer B formed by the secondary foaming is integrally molded with the decorative layer. Thereby, a lightweight decorative board C in which the decorative layer A and the foamed resin layer B are firmly integrated is obtained (FIG. 1).
f).

The lightweight decorative board C having a resin film laminated on the surface thereof is carried into a construction site and required assembly is performed. After assembly,
The resin film 1 as the surface layer is not peeled off and is left as it is until the whole construction is completed. The presence of the resin film 1 as the surface layer as described above ensures that the surface decorative portion of the lightweight decorative board C is not scratched during the transportation of the lightweight decorative board C, during the construction, or after the construction. You can Then, by peeling the resin film 1 when necessary, it is possible to obtain an exterior wall having a beautiful decorative pattern such as a stone pattern.

The lightweight decorative board according to the present invention can be laid by a dry method using an adhesive on the surface of a wall portion or a floor portion on which concrete is cast on the side of the frame, and a wall or floor having a heat insulating property can be constructed. Can be completed in a short time. In addition, it is also effective to use it for partitioning a room by taking advantage of its light weight. Furthermore, since the base portion is a foamed resin layer, it has heat insulating properties and some cushioning properties, and by making use of these properties, it can be used as a floor material for kitchens, bathrooms, balconies, or even as an office floor material.

In the above description, the case where the resin film 1 is used as the surface protective layer of the decorative layer A has been described, but instead of the resin film 1, a resin mold frame having an uneven pattern on the surface can be used. Also in this case, it will be easily understood that the decorative layer A can be obtained in the same step, and the lightweight decorative plate X can be obtained by similarly arranging the decorative layer A in the molding die and performing the same step. Then, the resin mold frame is peeled off from the lightweight decorative board X when necessary, as in the case of the resin film.

[0030]

EXAMPLE An actual example will be described below. [Example 1] A 300 mm x 300 mm polypropylene foam sheet (thickness: 1.5 mm, density: 0.1) (Microlen, manufactured by Sekisui Plastics Co., Ltd.) was prepared, and a viscosity of 10,000 was used as an adhesive on the sheet. Soap-free acrylic resin (AD-1, manufactured by Kanebo) adjusted to Poise 3
It was applied at a rate of 00 g / m ² .

Next, as the inorganic aggregate, the average particle size is 5.0 m.
m (A), average particle size 3.0 mm (B) and average particle size 1.0 mm
Prepare natural stone crushed stone of (C), before the adhesive cures
(A) was sprayed at 900 g / m ² , then (B) was sprayed at 800 g / m ² , and then (C) was sprayed at 420 g / m ² . It was dried in hot air at 60 ° C. for 60 minutes. After that, as a backing layer, a mixture of a cement-based powder obtained by adding a pigment to 50 parts by weight of white cement and 50 parts by weight of crushed stone and a resin emulsion for cement admixture (cationic alkali-curing type) in a weight ratio of 40:17 was used. 1200g / m ² applied and before the backing layer hardens, the average particle size is 1.0mm
g / m ² was sprinkled. After drying it in hot air at 60 ° C. for 120 minutes, a vinyl acetate adhesive was applied by 50 g / m ² spray to obtain a decorative layer having a polypropylene foam sheet laminated on the surface.

The obtained decorative layer is laid in a molding die of a vertical drive type foam molding machine, and then polystyrene foam particles having a bulk ratio of about 5 times are densely filled in the molding die and steam is used to simultaneously expand the foam. Molded. At this time, the vertical dimension is 300 mm and the horizontal dimension is 3
A mold having a depth of 00 mm and a depth of 15 mm was used. When the polypropylene foam sheet was peeled off after co-molding, it can be easily peeled off, and the surface is made of a dense stone pattern. I was able to get a board.

This lightweight decorative board has an overall thickness of 15 mm,
The plate had a length and width of 300 mm, and the total weight was 425 g. Therefore, the average specific gravity of the lightweight decorative board is 0.319, which is about 1/7 of the weight of the conventional precast concrete panel. The decorative layer had a thickness of about 2 mm and a weight of about 360 g, and the foamed resin layer had a thickness of about 13 mm and a weight of about 65 g.

[Example 2] A polypropylene sheet having a thickness of 1.0 mm (non-foamed) was used in place of the polypropylene foam sheet, and a color mica (having an average particle size of 3 to
A decorative layer was obtained in the same manner as in Example 1 except that 5 mm) was mixed. Using the obtained decorative layer, a lightweight decorative board was obtained in the same manner as in Example 1. After simultaneous molding, when the polypropylene sheet was peeled off, it can be easily peeled off,
It was possible to obtain a lightweight decorative board in which a decorative layer having a fine stone pattern on the surface and having a surface gloss and an excellent decorative surface without scratches and a resin foam layer were integrated.

Example 3 A decorative layer was obtained in the same manner as in Example 1 except that a foamed polypropylene sheet having a thickness of 1.5 mm was formed in an uneven pattern as shown in FIG. By using the obtained decorative layer having a concavo-convex pattern on the surface and using a vertical drive type foam molding machine provided with a molding die having the same shape as the concavo-convex pattern of the decorative layer, the same method as in Example 1 was used to reduce the weight. I got a veneer. After the co-molding, when the above-mentioned expanded polypropylene sheet was peeled off, it could be easily peeled off, and the surface consisted of a fine stone pattern and had an excellent aesthetic appearance of the surface gloss and the uneven pattern with excellent surface gloss. It was possible to obtain a lightweight decorative board in which a decorative layer having a decorative surface and a foamed resin layer were integrated. Further, the expanded polypropylene sheet having an uneven pattern used in Example 3 could be peeled off easily after the simultaneous molding, so that it could be reused.

[Comparative Example] A natural stone is sliced into about 2 mm and the length and width are 300 mm × 300 mm, and a foam plate foam-molded to about 5 times the thickness of 13 mm that has been foam-molded under the condition of an acrylic resin is bonded with a vinyl acetate adhesive. It was used and press-bonded to obtain a laminate. This laminated board was not preferable because the adhesive strength between the natural stone and the foamed board was weak, and it was easily peeled off.

[0037]

As is clear from the above description, according to the lightweight decorative board and the method for producing the same of the present invention, since it has the resin film or the resin mold as the surface layer, Hard to get scratches and dirt during construction. As a result, it is possible to obtain a floor surface or a wall surface without scratches on the surface after construction. In addition, since the base portion is made of the foamed resin layer, it is lightweight as a whole, and construction as an exterior or interior material is quick and easy, and the wall or floor after construction can have excellent heat insulating properties. Furthermore, since the decorative layer and the foamed resin layer are integrally molded at the same time as foam molding, they are firmly bonded and do not separate after construction,
No damage to the walls or floors due to dew condensation or deterioration of heat insulation.

[Brief description of drawings]

FIG. 1 is a diagram illustrating a manufacturing process of a lightweight decorative board according to the present invention.

FIG. 2 is a cross-sectional view showing another example of the decorative layer portion of the lightweight decorative board.

[Explanation of symbols]

A ... Decorative layer, B ... Foamed resin layer, C ... Mold, 1 ... Resin film, 2 ... Adhesive layer, 3 ... Inorganic aggregate, 4 ... Backing layer, 5 ... Aggregate, 10 ... Granular foamed resin

Claims (3)

[Claims] 1. A decorative layer having at least a surface layer comprising an inorganic aggregate and a binder, a backing layer laminated on the back surface of the surface layer, and an adhesive layer applied on the back surface of the backing layer, A lightweight decorative board composed of a foamed resin layer integrally formed at the same time as foamed granular foamed particles on the back side of the decorative layer. 2. A binder is applied on a resin film,
Spray the inorganic aggregate before the applied binder hardens,
Further, a backing layer is applied thereon, and an adhesive is further applied thereon to form a decorative layer with a resin film, and the decorative layer with a resin film is placed inside the molding die with the resin film on the outside. The method for producing a lightweight decorative board, characterized in that the expanded foamed particles are filled with the expanded foamed particles, and the expanded foamed particles are integrally formed with the decorative layer with a resin film at the same time as foaming. 3. A binder is applied to the back side of a resin mold having an uneven pattern on the surface, an inorganic aggregate is sprinkled before the applied binder is cured, and a backing layer is applied on it. Further, an adhesive is applied from the above to form a decorative layer with a resin mold frame, and the decorative layer with a resin mold frame is placed inside the molding die with the resin mold frame facing outward, and then the granular expanded particles are formed. And a method of manufacturing a lightweight decorative board, characterized in that the granular expanded particles are integrally molded with the resin-made decorative layer with a frame simultaneously with foaming.