JP2017087621A - Noncombustible decorative laminate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative laminate having noncombustibility.SOLUTION: A noncombustible decorative laminate 1 includes: a base material 10 having an inorganic base material layer 11 having a first inorganic layer containing a volcanic glassy sediment and a second inorganic layer and a third inorganic layer formed on both sides of the first inorganic layer and containing artificial mineral fiber material and a front face layer 12 containing a metal layer and formed on a surface of the third inorganic layer of the inorganic base material layer 11; a sealer layer 20 formed on a surface of the front face layer 12 side of the base material 10; a front face adhesive layer 30 formed on a surface of the sealer layer 20; and a decorative sheet 40 formed on a surface of the front face adhesive layer 30 and including a resin film, a printing layer and a surface protective layer sequentially formed on a surface opposite to the front face adhesive layer 30 of the resin film, and a rear face primer layer formed on a side of the front face adhesive layer 30 of the resin film.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a non-combustible decorative board that can be used on surfaces of interiors, exteriors, furniture, joinery, vehicle interiors, and the like of buildings, and can give a textured feeling and a three-dimensional feel to the surface.

Conventionally, a decorative sheet made by laminating a paper-based or resin-based sheet on which a pattern is formed on a substrate, and applying or impregnating a transparent resin paint on the sheet, or a pattern and a surface protective layer on the substrate. A decorative board in which the formed synthetic resin base material layers are laminated is known. As a decorative sheet to be affixed to a base material, there is a decorative sheet excellent in design as described in Patent Document 1 below, for example.
Here, in recent years, there has been an increasing demand for nonflammability for decorative plates used for interiors of houses such as wall surfaces and ceilings of buildings in order to ensure safety when a fire or the like occurs. Standards for wall and ceiling finishing materials such as evacuation routes such as living rooms, corridors and stairs in buildings such as residential buildings, commercial facilities, station buildings, airports, etc. Is provided. For example, for finishing materials for walls and ceilings such as evacuation routes such as living rooms, corridors, and stairs for a certain scale and application, fireproof materials (non-combustible materials, semi-incombustible materials and flame-retardant materials) according to the required performance ) Must be used by law (Enforcement Order Article 129).

JP 2008-087158 A

  The present invention has been made paying attention to the above-described points, and an object thereof is to provide a decorative board having incombustibility.

In order to solve the problems, a non-combustible decorative board according to one embodiment of the present invention includes a first inorganic layer containing a volcanic glassy deposit, and an artificial mineral fiber material formed on both surfaces of the first inorganic layer. A substrate having an inorganic base layer having a second inorganic layer and a third inorganic layer, and a surface layer provided on the surface of the third inorganic layer of the inorganic base layer including a metal layer;
A sealer layer formed on the surface layer side surface of the substrate;
A surface adhesive layer formed on the surface of the sealer layer;
Formed on the surface of the surface adhesive layer, the resin film, the printed layer and the surface protective layer formed in order on the surface opposite to the surface adhesive layer of the resin film, and the surface of the resin film on the surface adhesive layer side A decorative sheet having a back primer layer formed on
It is characterized by providing.

  According to one embodiment of the present invention, a decorative board having incombustibility can be obtained.

It is sectional drawing explaining the structure of the nonflammable decorative board which concerns on embodiment based on this invention. It is sectional drawing explaining the structure of the nonflammable board | substrate of the nonflammable decorative board which concerns on embodiment based on this invention. It is sectional drawing explaining the structure of the moisture-proof sheet | seat of the nonflammable decorative board which concerns on embodiment based on this invention.

Embodiments of the present invention will be described with reference to the drawings.
Here, FIG. 1 is a cross-sectional view schematically showing the decorative sheet according to the present embodiment, and the relationship between the thickness and the planar dimension, the ratio of the thickness of each layer, and the like are different from the actual ones. Further, the embodiment described below exemplifies a configuration for embodying the technical idea of the present invention, and the technical idea of the present invention is that the material, shape, structure, etc. of the component parts are as follows. It is not something specific. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims. The same applies to FIGS. 2 and 3 described later.

As shown in FIG. 1, the incombustible decorative board 1 of the present embodiment includes an incombustible base material (hereinafter referred to as a base material) 10, a sealer layer 20 provided on one surface of the base material 10, and a surface. An adhesive layer 30, a decorative sheet 40, a back surface adhesive layer 50 provided on the other surface of the substrate 10, and a moisture-proof sheet 60 are provided.
Hereinafter, each layer of the non-combustible decorative board 1 will be described in detail with reference to FIGS.

<Nonflammable substrate>
Hereinafter, the substrate 10 will be described with reference to FIGS. 1 and 2. FIG. 2 is a cross-sectional view showing in detail the configuration of the base material 10 provided in the non-combustible decorative board 1 shown in FIG.
The base material 10 has an inorganic base material layer 11 containing an inorganic material, and a surface layer 12 containing a metal layer and provided on the surface of the inorganic base material layer.
Although arbitrary thickness can be selected for the base material 10, it is preferable that it is 4 to 9 mm in thickness, for example. In this embodiment, the thickness of the base material 10 is 6 mm.

Substrate 10 can select any of the mass per square meter, it is preferable for example mass per square meter is 3.0 kg / ^{m 2} or more 6.0 kg / ^{m 2} or less. In this embodiment, the mass per square meter of the base material 10 is 4.5 kg / m ² .
Although arbitrary bulk specific gravity can be selected for the base material 10, it is preferable that bulk specific gravity is 0.5 or more and 1.2 or less, for example. In this embodiment, the bulk specific gravity of the base material 10 is 0.77.

(Surface layer)
As shown in FIG. 2, the surface layer 12 is made of a laminate including a metal layer 124, and has an adhesive layer 121 for attaching the surface layer 12 to the inorganic base material layer 11. As shown in FIG. 2, in the present embodiment, the surface layer 12 of the substrate 10 includes the metal layer 124, the resin layers 123 and 125, the paper layers 122 and 126, and the adhesive layer 121 from the inorganic substrate layer 11 side. The adhesive layer 121 / paper layer 122 / resin layer 123 / metal layer 124 / resin layer 125 / paper layer 126 are laminated in this order.

Although the surface layer 12 can select arbitrary thickness, For example, it is preferable that it is 0.05 mm or more and 0.5 mm or less in thickness. In the present embodiment, the thickness of the surface layer 12 is 0.1 mm.
Surface layer 12 can select any of the mass per square meter, it is preferably, for example 1 weight per square meter is 100 g / ^{m 2} or more 200 g / ^{m 2} or less. In this embodiment, the mass per square meter of the surface layer 12 is 110 g / m ² .

(Metal layer)
The metal layer 124 is made of, for example, steel, aluminum, or stainless steel. In the present embodiment, the metal layer 124 is made of aluminum. The thickness of the metal layer 124 is preferably 4 μm or more and 50 μm or less. When the thickness of the metal layer 124 is 4 μm or more, nonflammability and heat resistance are improved. Moreover, when the thickness of the metal layer 124 is 50 μm or less, the metal layer 124 is prevented from becoming thickly thick to reduce the cost, and the non-combustible decorative board 1 can be cut and processed. In the present embodiment, the thickness of the metal layer 124 made of aluminum is 12 μm.

(Resin layer)
The resin layers 123 and 125 are made of a material having high adhesiveness between the metal layer and the paper layer, such as urethane resin or acrylic resin. In the present embodiment, the resin layer is formed of a urethane resin. Further, the resin layer 123 and 125, the mass (solid content) per square meter is preferably 2.0 g / ^{m 2} or more 15.0 g / ^{m 2} or less. In the resin layers 123 and 125 of the present embodiment, the mass (solid amount) of urethane resin per square meter is 4.0 g / m ² .

(Paper layer)
The paper layers 122 and 126 are not composed of a particularly limited material, and for example, thin paper, titanium paper, craft paper, linter paper or the like is used. Among them, it is preferable to use a paper material having a high resin impregnation property as the paper layers 122 and 126. In the present embodiment, thin paper is used for the paper layers 122 and 126. The mass (solid content) per square meter of the adhesive layer 121 is preferably 20.0 g / ^{m 2} or more 30.0 g / ^{m 2} or less. In the adhesive layer 121 of this embodiment, the mass per square meter of the thin paper is 23.0 g / m ² .

(Adhesive layer)
For the adhesive layer 121, for example, a material having high adhesiveness between the surface layer 12 and the inorganic base material layer 11 such as a urethane resin adhesive or an acrylic resin adhesive is used. In this embodiment, a urethane resin adhesive is used as the adhesive layer 121. Further, the adhesive layer 121, a mass (solid content) per square meter is preferably 20.0 g / ^{m 2} or more 30.0 g / ^{m 2} or less. The function as the adhesive layer 121 is enhanced by increasing the mass (solid amount) per square meter compared with the resin layers 123 and 125. In the adhesive layer 121 of the present embodiment, the mass (solid amount) of urethane resin per square meter is 24.0 g / m ² .

(Inorganic substrate layer)
As shown in FIG. 2, the inorganic base material layer 11 includes a middle layer 112 that is a first inorganic layer containing an inorganic material, a lower layer 111 that is a first inorganic layer containing an artificial mineral fiber material, and a third inorganic layer. It is a laminated body provided with the upper layer 113 which is.
The inorganic base material layer 11 can be selected to have an arbitrary thickness. For example, the thickness is preferably 3 mm or more and 8 mm or less, and 4.5 mm or more and 6.5 mm or less from the viewpoint of exothermic property and handling property. It is preferable that In this embodiment, the thickness of the inorganic base material layer 11 is 5.8 mm. In addition, these inorganic base materials may be subjected to a surface treatment such as sanding in order to enhance adhesion with other layers.

Inorganic substrate layer 11 can select any of the mass per square meter, it is preferable for example mass per square meter is 3.8 kg / ^{m 2} or more 5.0 kg / ^{m 2} or less. In this embodiment, the mass per square meter of the inorganic base material layer 11 is 4.38 kg / m ² .
The inorganic base material layer 11 can select arbitrary bulk specific gravity, For example, it is preferable that bulk specific gravity is 0.5 or more and 0.2 or less. In this embodiment, the bulk specific gravity of the inorganic base material layer 11 is 0.76.

(Middle layer)
The middle layer 112 includes, as an inorganic material, for example, volcanic glassy deposits such as shirasu foam, white clay, and pumice. The middle layer 112 includes, as inorganic materials, for example, inorganic fillers such as aluminum hydroxide, magnesium hydroxide, magnesium carbonate, and borax, and inorganic powders such as calcium carbonate, microsilica, and slag powder. It is out. Further, the middle layer 112 includes, for example, an organic binder such as starch, phenol resin, polyvinyl alcohol, and a wax sizing agent.
The intermediate layer 112 can be selected to have an arbitrary thickness, but is preferably 2.0 mm to 4.0 mm in thickness, for example. In the present embodiment, the thickness of the middle layer 112 is 3.4 mm.

For the middle layer 112, any mass per square meter can be selected. For example, the mass per square meter is preferably 1.0 kg / m ² or more and 1.8 kg / m ² or less. In this embodiment, the mass per square meter of the middle layer 112 is 1.84 kg / m ² .
The middle layer 112 can be selected to have an arbitrary bulk specific gravity. For example, the bulk specific gravity is preferably 0.3 or more and 1.0 or less. In this embodiment, the bulk specific gravity of the lower layer 111 is 0.5.

(Lower layer and upper layer)
The lower layer 111 and the upper layer 113 include rock wool, slag wool, glass wool, mineral wool and the like as artificial mineral fiber heat insulating materials. The lower layer 111 and the upper layer 113 include the same inorganic filler, inorganic powder, organic binder, and wax sizing agent as the middle layer 112.
Although arbitrary thickness can be selected for the lower layer 111 and the upper layer 113, it is preferable that it is 0.8 to 1.4 mm in thickness, for example. In the present embodiment, the thickness of the lower layer 111 and the upper layer 113 is 1.2 mm, respectively.

For the lower layer 111 and the upper layer 113, any mass per square meter can be selected. For example, the mass per square meter is preferably 0.8 kg / m ² or more and 1.8 kg / m ² or less. In this embodiment, the mass per square meter of the lower layer 111 and the upper layer 113 is 1.27 kg / m ² .
For the lower layer 111 and the upper layer 113, any bulk specific gravity can be selected. For example, the bulk specific gravity is preferably 0.5 or more and 1.3 or less. In this embodiment, the bulk specific gravity of the lower layer 111 and the upper layer 113 is 0.76.
Examples of such a substrate 10 include a plate such as a volcanic glassy multilayer board (conforming to JIS A5440 “incombustible volcanic glassy multilayer board”).

<Coating sheet>
The decorative sheet 40 includes a resin film 42, a printed layer 43 formed on the surface of the resin film 42 (a surface opposite to the base material 10), and a printed layer 43 (a surface opposite to the resin film 42). And a surface protective layer 44 formed on the surface. In addition, the decorative sheet 40 includes a back primer layer 41 on the back surface (surface on the base material 10 side) of the resin film 42.

(Resin film)
The resin film 42 contains, for example, 70.0 parts by mass or more and 95.5 parts by mass or less of a polyester resin by mass ratio. A known additive may be added to the resin film 42. For example, the resin film 42 may contain 4.5 to 30.0 parts by mass of an inorganic pigment.
The thickness of the resin film 42 is, for example, 0.05mm or 0.07mm or less, 1 weight per square meter, for example, 60.0 g / ^{m 2} or more 100.0 g / ^{m 2} or less (organic mass 58.2 g / m ² or more and 71.6 g / m ² or less).
The resin film 42 is preferably a polybutylene terephthalate resin film. Since the polybutylene terephthalate resin film is excellent in heat resistance, nonflammability is further improved.

(Print layer)
The printed layer 43 is formed on the resin film 42 in order to improve the design properties of the incombustible decorative board 1.
The printing layer 43 can be provided using a known printing method. Since the resin film 42 can be prepared in a wound state, printing for forming the printing layer 43 can be performed by a roll-to-roll printing apparatus. The printing method is not particularly limited, but for example, a gravure printing method can be used in consideration of productivity and picture quality.

By providing the printing layer 43, a pattern can be imparted to the incombustible decorative board 1. For the pattern of the print layer 43, any pattern that takes into account the design as a wall covering may be adopted.
Although it does not specifically limit about printing ink, The ink corresponding to a printing system can be selected suitably. In particular, it is preferable to select a printing ink in consideration of adhesion to the resin film 42, printability, or weather resistance as a wall covering material.
For example, the printing layer 43 contains, by mass ratio, 78 parts by mass or more and 100 parts by mass or less of urethane resin, and further contains 0 to 22 parts by mass or more of an inorganic pigment. The mass per square meter of the printing layer 43 is, for example, 6.73 g / m ² (solid amount) or less (organic mass 5.25 g / m ² or less).

(Surface protective layer)
The surface protective layer 44 is provided so as to cover the printing layer 43. The surface protective layer 44 may be a single layer or may be formed of a plurality of layers. In this embodiment, the case where the surface protective layer 44 is a single layer is illustrated.
The surface protective layer 44 includes a curable resin such as a thermosetting type or an ionizing radiation curable type. The surface protective layer 44 is applied using a known coating apparatus according to the type of curable resin as a material, and the coating film is cured using an ionizing radiation apparatus such as a thermal drying apparatus or ultraviolet irradiation. It is formed by.

The surface protective layer 44 has an important role that determines the superiority and inferiority of bending workability, scratch resistance, and cleanability. The surface protective layer 44 is mainly composed of a curable resin. That is, it is preferable that the resin component is substantially composed of a curable resin. “Substantially constituted” means that, for example, 80 parts by mass or more is included when the total resin is 100 parts by mass. The surface protective layer 44 may contain an anti-glare agent, a plasticizer, a stabilizer, a filler, a dispersant, a colorant such as a dye or a pigment, a solvent, or the like, if necessary.
The surface protective layer 44 of this embodiment is mainly composed of an ionizing radiation curable resin such as an ultraviolet curable resin. In order to adjust the 60-degree specular gloss to a desired gloss, silica or other matting agents may be added to the surface protective layer 44.

The surface protective layer 44 may further contain a thermosetting resin. However, even when a thermosetting resin is included, the ionizing radiation curable resin is contained in an amount of 50% by mass or more based on the total amount of the ionizing radiation curable resin. The surface protective layer 44 is substantially composed of a mixture of an ionizing radiation curable resin and a thermosetting resin, so that the scratch resistance of the surface protective layer 44 is improved and the surface protective layer 44 is bent during bending. Whitening and cracking are less likely to occur, which is preferable.
Furthermore, when the surface protective layer 44 is formed of a plurality of layers, for example, an anchor coat layer (not shown) is formed on the lower layer (the layer on the printing layer 43 side) of the resin layer mainly composed of the above-described ultraviolet curable resin. ) May be provided. The anchor coat layer is formed of, for example, a urethane resin.

Here, the ionizing radiation curable resin is not particularly limited, and includes prepolymers (including oligomers) containing radically polymerizable double bonds capable of undergoing a crosslinking reaction by irradiation with ionizing radiation such as ultraviolet rays and electron beams. Transparency resin which has a monomer as a main component can be used. These prepolymers or monomers can be used alone or as a mixture of a plurality of materials. The curing reaction of the prepolymer or monomer is usually a crosslinking curing reaction.
For example, the surface protective layer 44 contains 80 to 86 parts by mass of an acrylic curable resin by mass ratio, and further contains 14 to 20 parts by mass of an inorganic additive.

For example, the surface protective layer 44 preferably has a thickness of 0.04 mm or less and a mass of 16.3 g / m ² (solid amount) or less (organic mass of 13.0 g / m ² or less).
Further, unevenness may be formed on the surface of the surface protective layer 44 (surface opposite to the printing layer 43) in order to impart a given design property. The irregularities are usually formed by embossing. The embossing method is not particularly limited. For embossing, a known single-wafer or rotary embossing machine is used. Examples of the concavo-convex shape include a wood grain plate conduit groove, a stone plate surface unevenness (such as granite cleaved surface), a cloth surface texture, a satin texture, a grain, a hairline, a ridge line, and the like.

(Back primer layer)
The back surface primer layer 41 is provided on the back surface of the resin film 42 for the purpose of improving the adhesion between the decorative sheet 40 and the substrate 10.
For the back primer layer 41, various resin materials such as urethane, polyester, acrylic, and epoxy are used, and among them, a urethane coating agent containing a polyol component and a polyisocyanate is preferable.
The polyol component in the urethane-based coating agent is preferably a polyester-based polyol, and examples of the polyester-based polyol include polyester-based polyols obtained by reacting a polyvalent carboxylic acid and the like with glycols. Examples of polyisocyanates include 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, m-phenylene diisocyanate, p-phenylene diisocyanate, 4,4′-diphenylmethane diisocyanate, hexamethylene diisocyanate, xylylene diisocyanate, isophorone diisocyanate, and the like. Is exemplified.

Although the thickness of the back surface primer layer 41 can be selected as appropriate, it is preferably 0.01 μm or more and 10 μm or less, and more preferably 0.05 μm or more and 5 μm or less. When the thickness of the back surface primer layer 41 is less than 0.01 μm, the bonding property of the decorative sheet 40 to the base material 10 is insufficient, and when the thickness of the back surface primer layer 41 exceeds 10 μm, the productivity of the incombustible decorative board 1 Decreases.
The back surface primer layer 41 of this embodiment contains, for example, 62 parts by mass of a urethane-based resin and 38 parts by mass of an inorganic pigment by mass ratio.
Moreover, the back surface primer layer 41 shall be mass 1.3g / m < ² > (solid amount) or less (organic mass 0.8g / m < ² > or less), for example.

<Sealer layer>
The sealer layer 20 is provided on the surface of the substrate 10 in order to improve the adhesion between the substrate 10 and the decorative sheet 40. The sealer layer 20 of this embodiment is made of, for example, 100% by mass of a urethane resin. The mass per square meter of the sealer layer 20 is, for example, 1.4 g / m ² or more and 5.4 g / m ² or less (solid amount) (organic mass 1.4 g / m ² or more and 5.4 g / m ² or less). Preferably there is. When the mass per 1 square meter of the sealer layer 20 is too small, the adhesiveness of the decorative sheet 40 and the base material 10 may fall. Moreover, when the mass per square meter of the sealer layer 20 is too large, the sealer layer 20 becomes unnecessarily thick, and the manufacturing cost may increase.

<Surface adhesive layer, back adhesive layer>
The front surface adhesive layer 30 and the back surface adhesive layer 50 are each formed of any type of resin adhesive such as a thermoplastic resin system, a thermosetting resin system, and a rubber (elastomer) system. As these resin adhesives, known ones or commercially available products can be appropriately selected and used. Examples of the thermoplastic resin adhesive include polyvinyl acetate resin, polyvinyl alcohol, polyvinyl acetal (polyvinyl formal, polyvinyl butyral, etc.), cyanoacrylate, polyvinyl alkyl ether, polyvinyl chloride, polyamide, polymethyl methacrylate, nitrocellulose. , Cellulose acetate, thermoplastic epoxy, polystyrene, ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, etc., and thermosetting resin adhesives include urea resin, melamine resin Phenol resin, resorcinol resin, furan resin, epoxy resin, unsaturated polyester resin, polyurethane resin, polyimide resin, polyamideimide, polybenzimidazole, polybenzothiazole, etc. That. Rubber-based adhesives include natural rubber, recycled rubber, styrene-butadiene rubber, acrylonitrile-butadiene rubber, chloroprene rubber, butyl rubber, polysulfide rubber, silicone rubber, polyurethane rubber, stereo rubber (synthetic natural rubber), ethylene propylene rubber, block Examples include copolymer rubber (SBS, SIS, SEBS, etc.).

The surface adhesive layer 30 that bonds the base material 10 and the decorative sheet 40 is, for example, 95.7 parts by mass of an ethylene-vinyl acetate copolymer resin and 4. 4 an organic curing agent (isocyanate type). Contains 3 parts by weight. In this case, the mass per square meter of the surface adhesive layer 30 is 11.9 g / m ² or more and 17.8 g / m ² or less (solid amount) (organic mass 11.9 g / m ² or more and 17.8 g / m ^2. The following.
The back surface adhesive layer 50 that bonds the base material 10 and the moisture-proof sheet 60 contains, for example, 100 parts by mass of a vinyl acetate resin. In this case, the mass per square meter of the back adhesive layer 50, 26.7 g / ^{m 2} or more 32.7 g / ^{m 2} or less (solid content) (organic mass 26.7 g / ^{m 2} or more 32.7 g / ^{m 2} It is preferable that In this embodiment, the mass per square meter of the back surface adhesive layer 50 is 29.7 g / m ² .

<Dampproof sheet>
FIG. 3 is a cross-sectional view showing in detail the configuration of the moisture-proof sheet 60 provided in the non-combustible decorative board 1 shown in FIG.
As shown in FIG. 3, the moisture-proof sheet 60 includes a resin layer 62, a paper base 61 that is a first paper base provided on both surfaces of the resin layer 62, and a paper base that is a second paper base. 63. That is, the moisture-proof sheet 60 is formed by sequentially laminating a paper base 61, a resin layer 62, and a paper base 63. The moisture-proof sheet 60 is provided on the other surface of the substrate 10, that is, the surface on the inorganic substrate layer 11 side.
The moisture-proof sheet 60 is, for example, a sheet having a moisture-proof performance with a water vapor permeability of 3.0 g / m ² · day · atm or less, preferably 1.0 g / m ² · day · atm or less. The non-combustible decorative board 1 including the moisture-proof sheet 60 is less likely to be warped due to changes in environmental temperature and humidity. The thickness of the moisture-proof sheet 60 is preferably 50 μm or more and 130 μm or less, for example. In the present embodiment, the moisture-proof sheet 60 has a thickness of 70 μm.

(Paper substrate)
The paper bases 61 and 63 are not made of a particularly limited material, and for example, thin paper, titanium paper, kraft paper, linter paper or the like is used. Among these, it is preferable to use a paper material having a high resin impregnation property as the paper layer. In the present embodiment, thin paper is used as the paper bases 61 and 63.
The thickness of the paper bases 61 and 63 is, for example, in the range of 12.5 μm to 40 μm. For example, the thickness of the paper bases 61 and 63 is preferably 21.5 μm. At this time, the mass per square meter of the paper substrates 61 and 63 is preferably 24.0 g / m ² .

(Resin layer)
The resin layer 62 is made of, for example, olefinic thermoplastic resin such as polyethylene, polypropylene, ethylene-propylene copolymer, ethylene-vinyl alcohol copolymer, or a mixture thereof, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyethylene naphthalate. Ester thermoplastic resins such as phthalate-isophthalate copolymer, polycarbonate, polyarylate, acrylic thermoplastic resins such as polymethyl methacrylate, polyethyl methacrylate, polybutyl acrylate, or polyimide, polyurethane, polystyrene, acrylonitrile -It is made of non-halogen thermoplastic resin such as butadiene-styrene resin. In the present embodiment, a polyethylene resin is used as the resin layer 62.
The resin layer 62 may be a sheet uniaxially or biaxially stretched or may be unstretched, but is stretched biaxially for reasons such as high mechanical strength and excellent dimensional stability. Sheets are preferred.
The thickness of the resin layer 62 is, for example, in the range of 9 μm to 100 μm. For example, the thickness of the resin layer 62 is preferably 27 μm. At this time, the mass per square meter of the resin layer 62 is preferably 25.4 g / m ² (organic mass 25.4 g / m ² ).

<Effect>
The incombustible decorative board 1 of this embodiment mentioned above has nonflammability by providing the base material 10 which has the inorganic base material layer 11 containing an inorganic material. Moreover, the adhesion performance of the base material 10 and the decorative sheet 40 is improved by providing the sealer layer 20 on the non-combustible base material 10 and bonding the decorative sheet 40.
In particular, the non-combustible decorative board 1 can reliably ensure non-combustibility by laminating the inorganic base material layer 11 including the volcanic glassy deposit and the surface layer 12 including the metal layer 124. Become.

Moreover, when a polybutylene terephthalate resin film is used as the resin film 42 of the decorative sheet 40, the heat resistance is improved and the nonflammability is further improved.
Here, the nonflammability referred to in the present embodiment is based on a corn calorie combustion test based on ISO5660-1, and when the total calorific value with respect to time and the heat generation rate with respect to time of the nonflammable decorative board 1 are determined, (i) The total calorific value for 20 minutes after the start of heating is 8 MJ / m ² or less, (ii) 20 minutes after the start of heating, the maximum heat generation rate continues for 10 seconds or more and does not exceed 200 kW / m ² , and (iii) the heating It is non-flammable that satisfies the absence of cracks and holes penetrating to the rear side, which is harmful to fire prevention, for 20 minutes after the start.

Next, the Example of the noncombustible decorative board based on this invention is demonstrated.
<Example 1>
The incombustible decorative board of Example 1 was prepared so as to have the following configuration. As shown in FIG. 1, the non-combustible decorative board includes a non-combustible base material, a sealer layer, a surface adhesive layer and a decorative sheet provided in this order on one surface of the non-combustible base material, and a non-combustible group. A back adhesive layer and a moisture-proof sheet provided in this order on the other surface of the material.

(Decorative sheet)
A polybutylene terephthalate resin film was used as the resin film of the decorative sheet. The resin film was formed of a resin material in which 95.5 parts by mass of a polyester resin and 4.5 parts by mass of an inorganic pigment were mixed. The resin film has a thickness of 0.06 mm and a mass per square meter (hereinafter may be referred to as mass) of 75.0 g / m ² (organic mass 71.6 g / m ² ). A resin film was formed.
Next, a printing layer was provided on the surface of the resin film by printing. The ink used for printing was prepared by mixing 85 parts by weight of a urethane resin and 15 parts by weight of an inorganic pigment. The print layer was formed so that the mass was 6.73 g / m ² (solid amount) (organic mass 5.25 g / m ² ).

Subsequently, a back primer layer was formed on the back surface of the resin film. The back primer layer was formed by mixing 62 parts by mass of urethane resin and 38 parts by mass of inorganic pigment. The back primer layer was formed so that the mass was 1.3 g / m ² (solid amount) (organic mass 0.8 g / m ² or less).
Finally, a surface protective layer was provided on the printed layer. The surface protective layer was formed of a material obtained by mixing 80 parts by mass of an acrylic ultraviolet curable resin and 20 parts by mass of an inorganic additive. The surface protective layer was formed to have a thickness of 0.04 mm and a mass of 16.3 g / m ² (solid amount) (organic mass of 13.0 g / m ² ).

(Non-combustible substrate)
A mass of 23.02 mm and a mass of 32.0 g / m ² are formed on both sides of a metal layer made of an aluminum foil and a resin layer made of urethane resin having a mass of 4.0 g / m ² (solid amount). A paper layer consisting of 0 g / m ² thin paper was applied. Subsequently, an adhesive layer made of a urethane-based adhesive having a mass of 24.0 g / m ² was provided on the surface of the paper layer. This obtained the surface layer of the nonflammable base material.
Next, in order to obtain an upper layer and a lower layer of the inorganic base material layer, 50 parts by mass of rock wool as an artificial mineral fiber heat insulating material, 34 parts by mass of aluminum hydroxide as an inorganic filler, and calcium carbonate 10 as an inorganic powder. 0.1 parts by mass of a wax-based sizing agent was added to a mixed material obtained by mixing 6 parts by mass of a phenol resin as an organic binder, and dispersed in water to obtain a slurry. The slurry was made into paper to obtain a surface layer wet mat and a back layer wet mat to be an upper layer and lower layer precursor.

Subsequently, in order to obtain a middle layer of the inorganic base material layer, 50 parts by mass of volcanic glassy sediment powder, 34 parts by mass of aluminum hydroxide as an inorganic filler, and 10 parts by mass of calcium carbonate as an inorganic powder. And 0.1 mass part of wax-type sizing agents were added with respect to the mixed material which mixed 6 mass parts of phenol resins as an organic binder, and it disperse | distributed in water and obtained slurry. The slurry was made into a core layer wet mat to be an intermediate layer precursor.
Subsequently, each of the surface layer wet mat, the back layer wet mat, and the core layer wet mat was pressurized while being heated to gel the organic binder in each wet mat. Thereafter, each wet mat was cut into a predetermined size and dried by blowing hot air.

Subsequently, a surface layer wet mat, a back layer wet mat and a core layer wet mat in which the organic binder was gelled were laminated in the order of the surface layer wet mat / core layer wet mat / back layer wet mat and pressed. Accordingly, the upper layer and the lower layer of the thickness 1.2 mm, the mass 1.27 kg / m ² , the bulk specific gravity 1.1, and the middle layer of the thickness 3.4 mm, the mass 1.84 kg / m ² , the bulk specific gravity 0.5 The inorganic base material layer was obtained.
Finally, a surface layer was laminated on the inorganic base material layer, and the inorganic base material layer and the surface layer were adhered by the adhesive layer of the surface layer to obtain a nonflammable base material.

(Dampproof sheet)
Thickness 0.027 mm, on both sides of a polyethylene resin layer of the mass 25.4 g / ^{m 2} (organic mass 25.4g / ^{m 2),} the moisture-proof sheet comprising a paper substrate comprising a thin paper of weight 24.0 g / ^{m 2} Prepared. The moisture-proof sheet was formed by co-extrusion of polyethylene resin with thin paper using a ruder. This moisture-proof sheet had a thickness of 0.070 mm and a mass of 73.4 g / m ² (organic mass of 73.4 g / m ² ). The moisture-proof sheet having this configuration is referred to as a moisture-proof sheet A.
(Sealer layer)
A sealer layer composed of 100% by mass of a urethane-based resin and having a mass of 2.3 g / m ² (solid amount) (an organic mass of 2.3 g / m ² ) was formed on one surface of the nonflammable substrate. .

(Surface adhesive layer)
The sealer layer formed on one surface of the noncombustible substrate and the one surface of the decorative sheet were bonded together via a surface adhesive layer. The composition of the surface adhesive layer was 95.7 parts by mass of an ethylene-vinyl acetate copolymer resin / 4.3 parts by mass of an organic curing agent (isocyanate type). At this time, the surface adhesive layer was formed so that the mass was 15.1 g / m ² (solid amount) (organic mass 15.1 g / m ² ).
(Back adhesive layer)
The other surface of the nonflammable substrate (the surface on which the sealer layer is not provided) and one surface of the moisture-proof sheet were bonded together via a back surface adhesive layer. The composition of the back surface adhesive layer was 100% by mass of vinyl acetate resin. At this time, the back surface adhesive layer was formed so that the mass was 29.7 g / m ² (solid amount) (organic mass 29.7 g / m ² ).

<Example 2>
The incombustible decorative board of Example 2 was prepared so as to have the following configuration.
(Decorative sheet)
The surface protective layer of the decorative sheet was formed of a plurality of layers (two layers). Using a material obtained by mixing 80 parts by mass of an acrylic ultraviolet curable resin and 20 parts by mass of an inorganic additive, a layer on the surface side of the surface protective layer has a thickness of 0.04 mm and an organic mass of 15.5 g / m ² . It formed so that it might become. Moreover, the undercoat layer of organic mass 5.35g / m < ² > was formed in the surface of the back surface side (printing layer side) of a surface protective layer using urethane type resin. Moreover, the organic mass of the printing layer was 7.14 g / m ² . Furthermore, the organic mass of the back surface primer layer was 1.0 g / m ² . Except for this, a decorative sheet similar to the decorative sheet described in Example 1 was used.

(Non-combustible substrate)
As the non-combustible base material, the same non-combustible base material as that described in Example 1 was used.
(Dampproof sheet)
The moisture-proof sheet, thickness 0.040 mm, mass on both sides of a resin film made of a polyethylene resin film of 40.0 g / ^{m 2} (organic mass 40.0 g / ^{m 2),} a mass 29.5 g / ^{m 2} thin paper A moisture-proof sheet provided with a paper base made of The moisture-proof sheet had a mass of 99.0 g / m ² (organic mass of 99.0 g / m ² ). The moisture-proof sheet having this configuration is referred to as a moisture-proof sheet B.

(Sealer layer)
A sealer layer similar to the sealer layer described in Example 1 was formed except that the mass was changed to 5.4 g / m ² (solid amount) (organic mass 5.4 g / m ² ).
(Surface adhesive layer)
A surface adhesive layer similar to the surface adhesive layer described in Example 1 was formed except that the mass was changed to 16.5 g / m ² (solid amount) (organic mass 16.5 g / m ² ).
(Back adhesive layer)
A back adhesive layer similar to the back adhesive layer described in Example 1 was formed except that the mass was changed to 58.5 g / m ² (solid amount) (organic mass 58.5 g / m ² ).

<Evaluation>
Each evaluation was performed as follows. Each evaluation was performed with two samples.
(Incombustible test)
The incombustibility of the incombustible decorative plates of Example 1 and Example 2 described above was confirmed by a test method using a corn calorimeter (based on ISO 5660-1). By the nonflammability test, the total calorific value (total calorific value), the maximum exothermic rate and the exothermic rate were measured over 200 kW / m ² . The test time of the nonflammable test was 20 minutes of the nonflammable material evaluation time.
Note that the total heat generation amount is preferably 8 MJ / m ² or less, and the time when the heat generation rate exceeds 200 kW / m ² is 10 seconds or less. Further, the maximum heat generation rate is set to 200 kW / m ² or less as a preferable range.

(Appearance evaluation)
The appearance after the incombustibility test was visually evaluated on the incombustible decorative plates of Example 1 and Example 2 described above. On the surface of the non-combustible decorative board, the presence or absence of cracks reaching the back surface was confirmed, and those having no crack reaching the back surface were marked with “◯”, and those with cracks reaching the back surface were marked with “X”.
Table 1 below shows the evaluation results of each example. Table 1 shows the determination based on the result of each evaluation. Among the examples, an example of an inappropriate configuration was evaluated as “X”, an example of a preferable configuration was “◯”, and an example of a particularly preferable configuration was evaluated as “◎”.

As shown in Table 1, in each of Example 1 and Example 2, the maximum heat generation rate was less than 200 kW / m ² , and the time when the heat generation rate exceeded 200 kW / m ² was 0 second. Further, in both Example 1 and Example 2, no crack reaching the back surface occurred after 20 minutes of non-flammability test. For this reason, it turns out that the incombustible decorative board provided with the incombustible base material based on this invention is provided with high incombustible performance.
Among them, in Example 1, the average value of the two samples was very low. For this reason, it turned out that the structure of the incombustible decorative board of Example 1 is especially preferable.

<Example 3>
The non-combustible makeup of Example 3 in the same manner as the non-combustible decorative plate described in Example 1, except that the mass of the surface adhesive layer was 15.5 g / m ² (solid amount) (organic mass 15.5 g / m ² ). A plate was formed.
<Evaluation>
Evaluation by a peeling test was performed as follows.
(Peeling test)
A peel strength test (JIS K 6854-2, 180 ° peel) was measured on the incombustible decorative board of Example 3 to confirm the adhesion between the decorative sheet and the incombustible base material.
Table 2 below shows the evaluation results of Example 3.

As shown in Table 2, Example 3 provided with a sealer layer having a mass of 2.3 g / m ² between the decorative sheet and the non-combustible substrate has a peeling strength of 23.9 N / 25 mm, It was found that the peeling strength between the non-flammable substrate was sufficiently high.
As described above, as shown in the examples, a non-combustible decorative board including a non-combustible base material including a metal layer and an inorganic material such as a volcanic glassy deposit has high incombustibility. Moreover, such a noncombustible decorative board is provided with a sealer layer between the noncombustible base material and the decorative sheet. This is because the adhesion between the noncombustible base material and the decorative sheet can be improved, and the quality of the noncombustible decorative board can be improved.

DESCRIPTION OF SYMBOLS 1 Incombustible decorative board 10 Base material 11 Inorganic base material layer 111 Lower layer 112 Middle layer 113 Upper layer 12 Surface layer 121 Adhesive layer 122 Paper layer 123 Resin layer 124 Metal layer 125 Resin layer 126 Paper layer 20 Sealer layer 30 Surface adhesive layer 40 Cosmetic sheet 41 Back surface primer layer 42 Resin film 43 Print layer 44 Surface protective layer 50 Back surface adhesive layer 60 Dampproof sheets 61, 63 Paper base material 62 Resin layer

Claims (4)

The 1st inorganic layer containing a volcanic glassy deposit, and the inorganic base material layer which has the 2nd inorganic layer and the 3rd inorganic layer which contain the artificial mineral fiber material formed in both sides of the 1st inorganic layer A base material having a metal layer and a surface layer provided on a surface of the third inorganic layer of the inorganic base material layer;
A sealer layer formed on the surface layer side surface of the substrate;
A surface adhesive layer formed on the surface of the sealer layer;
Formed on the surface of the surface adhesive layer, a resin film, a printed layer and a surface protective layer sequentially formed on the surface of the resin film opposite to the surface adhesive layer, and the surface adhesion of the resin film A decorative sheet having a back primer layer formed on the surface of the agent layer side;
Incombustible decorative board. The non-combustible decorative board according to claim 1, wherein the surface layer includes the metal layer and a first paper layer and a second paper layer provided on both surfaces of the metal layer. The noncombustible decorative board according to claim 1, further comprising a moisture-proof sheet provided on the surface of the base material on the inorganic base material layer side. The said moisture-proof sheet | seat is a nonflammable decorative board of Claim 3 which has a resin layer and the 1st paper base material and 2nd paper base material which were provided in both surfaces of this resin layer.

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