JPH11117505A - Inorganic decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inorganic decorative panel to simplify manufacture, facilitate processing, and be reduced in a cost by a method wherein a metallic foil with a specified thickness is stuck between an inorganic plate and a decorated layer formed on the surface thereof for integral formation. SOLUTION: Surface layer parts 14 and 15 formed such that mineral fibers and inorganic powdery substance forms a main substance and a proper amount of coupling material are added are integrally laminated on the surface and the back of a middle layer part 13 formed such that an inorganic foam forms a main substance and a proper amount of coupling materials are added to produce an inorganic plate 10 having total specific gravity of 0.6-0.9. A metallic foil 11 with a thickness of 0.05-0.2 mm is stuck between an inorganic plate 10 and a decorated layer 12 of an inorganic decorated panel where a decorated layer 12 is formed on the surface of the inorganic plate 10. This constitution simplifies an adhesion work by using a laminator and facilitates processing by using a laminator, resulting in production of a decorated substrate having mirror properties and the possibility to employ various decoration technics.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic decorative panel used for interior or exterior of a building, and more particularly to an inorganic decorative panel having a smooth decorative surface.

[0002]

2. Description of the Related Art Conventionally, when a decorative layer is formed on an inorganic base material having a rough surface, after applying a sealer treatment, the surface is ground with a sander to obtain a smooth surface, which is then used for coating, printing or decorative film. Pasting was performed.

[0003]

However, in order to obtain a mirror-finished decorative surface, only a sealer treatment and a sander treatment have been insufficient. In particular, when the coating film or the decorative film is thin, pinholes or sander marks of the inorganic plate appear on the surface (FIG. 3). For this reason,
In order to obtain a smooth decorative surface, it was necessary to apply a sealer thickly or to repeat the sealer treatment and the sander treatment a plurality of times. As a result, the production was troublesome and the production cost was high. On the other hand, a thin steel plate (thickness 0.5 ~
3 mm), a so-called pre-coated metal, which has been subjected to makeup, is also laminated and integrated on the inorganic plate.
There was a problem that cutting and screwing were not easy and processing was difficult.

[0004] In view of the above problems, an object of the present invention is to provide an inexpensive inorganic decorative plate which is simple to manufacture, easy to process, and inexpensive.

[0005]

Means for Solving the Problems In order to achieve the above object, an inorganic decorative plate according to the present invention comprises an inorganic decorative plate having a decorative layer formed on a surface of the inorganic plate, wherein a decorative layer is provided between the inorganic plate and the decorative layer. It has a configuration in which a metal foil having a thickness of 0.05 mm or more and 0.2 mm or less is stuck. Further, the inorganic plate is mainly composed of an inorganic foam, and, on the front and back surfaces of the middle layer portion obtained by adding an appropriate amount of a binder, mainly contains mineral fibers and an inorganic powder, and an appropriate amount of a binder. Are added to each other, and the total specific gravity is 0.6 to 0.1.
It may be nine.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, an embodiment according to the present invention will be described with reference to FIGS. In the first embodiment, as shown in FIG. 1, a decorative layer 12 is formed on one surface of an inorganic substrate 10 with a metal foil 11 interposed therebetween. The decorative layer 12 may be formed by laminating the metal foil 11 on the surface of the inorganic plate 10 and then providing the decorative layer 12, or by forming the metal foil 11 on which the decorative layer 12 is formed in advance on the surface of the inorganic plate 10. It may be laminated and integrated on the plate 10.

As the inorganic plate 10, for example, a calcium silicate plate, a slag gypsum plate, a rock wool plate, a slate plate, or a composite inorganic plate obtained by laminating and integrating these plates can be used. According to this embodiment, even if the surface has some irregularities, it can be used as it is,
It is convenient. However, when the degree of unevenness is remarkable, it is preferable to perform sealer treatment or sanding in advance. Further, it is desirable to perform a sealer treatment on the back surface in order to improve water resistance and prevent warpage.

The metal foil 11 can be appropriately selected from, for example, iron foil, galvanized iron foil, stainless steel foil, aluminum foil and the like, and is adhered to the surface of the inorganic plate using a laminator with an adhesive. The thickness of the metal foil 11 is 0.05-0.
Use a 2 mm one. If the thickness is less than 0.05 mm, it is likely to be damaged during the work, and it is difficult to cover up the irregularities on the surface of the inorganic plate. On the other hand, if the thickness exceeds 0.2 mm, machining such as cutting becomes difficult, and furthermore, the entire inorganic decorative board becomes heavy and workability deteriorates.

The adhesive may be selected from those which are familiar to both the inorganic plate and the metal foil. For example, the adhesive may be selected from urethane, acrylic, epoxy and ethylene vinyl acetate adhesives. . In addition, the surface of the metal foil 11 may be subjected to a chemical or physical pretreatment in order to improve corrosion resistance or adhesion with an adhesive or a paint, if necessary.

The decorative layer 12 can be formed by printing, painting, or sticking a film alone or in combination. As a printing method, offset printing, transfer printing, direct printing, screen printing, and the like can be selected. In particular, according to the present embodiment, high smoothness can be secured on the surface to be printed, which is advantageous for performing offset printing or transfer printing.

The coating method can be appropriately selected from existing methods such as, for example, spraying, roll coater, flow coater, electrostatic coating and the like. And as a paint, for example,
An inorganic paint may be used in addition to a synthetic resin paint such as an acrylic, aminoalkyd, epoxy, or silicone resin. Although the method of curing the paint depends on the type of the paint, a method that can obtain a high-hardness coating film, such as ultraviolet curing, electron beam curing, or baking, is preferable.

Examples of the film include various synthetic resin films such as polyvinyl chloride (PVC) resin, polyethylene (PE) resin, polypropylene (PP) resin, fluorine resin, polyethylene terephthalate (PET) resin, decorative paper, Resin-impregnated decorative paper can also be used.
As the film, a cosmetic film which has been subjected to makeup in advance can be used. When a transparent film is used, for example, a coating, printing or decorative film may be previously laminated and integrated on a metal foil, and then laminated and integrated therewith. Furthermore, the adhesiveness may be improved by subjecting the front and back surfaces of the film to corona discharge treatment or chemical treatment as necessary.

In the second embodiment, as shown in FIG. 2, the inorganic plate 10 has a three-layer structure. The inorganic plate 10 is made of an inorganic foam and a mineral fiber and an inorganic powder on the front and back surfaces of the middle layer 13 having a specific gravity of 0.3 to 0.7 to which an appropriate amount of a binder is added. The surface layers 14, 15 each having a specific gravity of 0.8 to 1.2, which is a main component and to which an appropriate amount of a binder is added, are laminated and integrated, respectively, to form an overall specific gravity 0.6.
~ 0.9.

That is, the inorganic foam forming the middle layer 13 is added for weight reduction while maintaining the compressive strength. For example, pearlite, shirasu foam,
There are silica flower, glass foam, vermiculite, obsidian foam and the like, and these can be used alone or in combination of two or more. It is preferable that the amount of the inorganic foam to be added is 40 to 80 parts by weight of the entire middle layer 13. If the amount is less than 40 parts by weight, the desired weight reduction effect cannot be obtained. If the amount exceeds 80 parts by weight, the ratio of the inorganic powder and the binder becomes small, and the desired compressive strength cannot be obtained. It is.

The binder forming the middle layer 13 is added for binding and integrating the inorganic foam. For example, a synthetic resin such as polyvinyl alcohol resin, phenol resin, epoxy resin or starch or the like is used. These can be used alone or in combination of two or more. The amount of the binder added is preferably 5 to 20 parts by weight of the entire middle layer 13. If the amount is less than 5 parts by weight, sufficient strength cannot be obtained, and if it exceeds 20 parts by weight, fire resistance is impaired.

In general, the more the binder, the more
Although the flexural strength is improved, the total amount of the organic components in the middle layer 13 needs to be 15 parts by weight or less including the binder in order to obtain a base plate as a semi-combustible material. Further, in order to obtain a base plate as a non-combustible material, the total amount of the organic components needs to be 7 parts by weight or less including the binder.

If necessary, an inorganic powdery material may be added to the middle layer 13 as a filler to increase the hardness and the screwing performance while maintaining fire resistance. Examples of such an inorganic powder include calcium carbonate, aluminum hydroxide, silica sand, microsilica, and slag. The content of the inorganic powder in the middle layer 13 is preferably set to 40 parts by weight or less of the entire middle layer 13. If the amount exceeds 40 parts by weight, the amount of the inorganic foam decreases and the plate material becomes heavy.

Further, a fibrous material for connecting the inorganic foam may be added to the middle layer portion 13 in order to improve the bending strength. Examples of the fibrous material include synthetic resin fibers such as polypropylene and polyester, and natural fibers such as pulp, hemp and flax. These can be used alone or in combination of two or more. And when adding the said fibrous material, normally, 1
About 15 parts by weight can be added. In addition, you may use the heat fusion fiber which also has the function as a binder as needed.

The mineral fibers forming the surface layers 14, 15 include, for example, rock wool, slag wool, mineral wool, and glass wool. These may be used alone or in combination of two or more. Can be used. And the content of the mineral fiber is
It is preferred that the total amount be 20 to 70 parts by weight based on the total weight of 4,15.
If the amount is less than 20 parts by weight, the desired bending strength cannot be obtained. If the amount exceeds 70 parts by weight, the ratio of the inorganic powdery material relatively decreases, so that the desired surface hardness cannot be obtained. It is.

It is conceivable that the inorganic powder added to the surface layers 14 and 15 is to increase the hardness and the screwing performance while maintaining fire resistance. Examples of the inorganic powder include calcium carbonate, aluminum hydroxide, silica sand, microsilica, slag, and the like, and these can be used alone or in combination of two or more. Then, these inorganic powders are coated on the surface layers 14 and 15.
The total amount is preferably 20 to 70 parts by weight. If the amount is less than 20 parts by weight, the desired surface hardness cannot be obtained. If the amount exceeds 70 parts by weight, the ratio of the mineral fibers imparting strength is reduced, and the desired bending strength cannot be obtained.

The binder forming the surface portions 14 and 15 is for binding and integrating the mineral fiber and the inorganic powdery material.
It is the same as that of the binder.

Further, in addition to the mineral fibers, other fibrous materials may be added to the surface portions 14, 15 in order to improve the bending strength. As another fibrous material, for example, polypropylene, synthetic resin fibers such as polyester, pulp,
Natural fibers such as hemp and flax can be mentioned, and these can be used alone or in combination of two or more. When the fibrous material is added, the surface layer 1 is usually used.
About 4 to 15 parts by weight of about 1 to 15 parts by weight can be added. In addition, you may use the heat fusion fiber which also has the function as a binder as needed.

According to this embodiment, it is lightweight and strong,
In addition, there is an advantage that an inorganic decorative board excellent in nailing property can be obtained. The other parts are the same as those of the first embodiment, and the description is omitted.

[0024]

【Example】

(Example 1) A stainless steel foil having a thickness of 0.07 mm was adhered and integrated with a 6-mm-thick calcium silicate plate having a front and back surface subjected to a urethane sealer treatment using a water-based vinyl urethane resin adhesive using a laminator. Then, the surface of the stainless steel foil was previously subjected to a primer treatment using a laminator, and then a urethane resin paint was applied as a base coat by a flow coater and dried and cured. Next, a pattern was formed by transfer printing, and a UV curable acrylic clear paint was applied thereon with a roll coater, and then cured by UV irradiation. Thereby, an inorganic decorative plate having a beautiful decorative surface by transfer printing was obtained.

(Example 2) A mineral fiber and an inorganic powdery material are mainly formed on the front and back surfaces of a middle layer portion which is mainly composed of an inorganic foam and to which an appropriate amount of a binder is added, and has an appropriate amount of bonding. A 6 mm thick inorganic plate was obtained by laminating and integrating the surface layers formed by adding the materials. Then, a urethane sealer was applied to the front and back surfaces of the inorganic plate and dried. Further, a stainless foil having a thickness of 0.07 mm was adhered and integrated on the surface of the inorganic plate with a water-based vinyl urethane resin adhesive using a laminator. Next, after a primer treatment was previously performed on the surface of the stainless steel foil using a laminator, a thermosetting fluororesin paint was applied by a flow coater, and baked at a temperature of 80 ° C. for 10 minutes to be cured. As a result, a decorative plate having a smooth surface and excellent stain resistance was obtained.

(Example 3) A urethane sealer was applied to the front and back surfaces of the same inorganic plate used in Example 2 and dried. Then, a galvanized iron foil having a thickness of 0.07 mm was bonded to the surface of the inorganic plate with an aqueous vinyl urethane resin adhesive. Then, a vinyl chloride decorative film having a thickness of 0.05 mm and a transparent PET film having a thickness of 0.05 mm were sequentially laminated and integrated. This allows
An inorganic decorative plate having a smooth surface and hardly scratching was obtained.

(Example 4) A decorative vinyl chloride film having a thickness of 0.05 mm and a colorless transparent PET film having a thickness of 0.05 mm were successively laminated and integrated by dry lamination on an iron foil having a thickness of 0.1 mm. Prepare a decorative film in advance. Then, this decorative film was laminated and integrated on one surface of a 6 mm-thick slate plate having a front and back surface subjected to a urethane sealer treatment using a laminator. Note that an aqueous vinyl urethane resin adhesive was used as the adhesive. As a result, an inorganic decorative plate having a smooth surface and excellent stain resistance was obtained. Further, according to this embodiment, since the laminated and integrated decorative film is prepared in advance, there is an advantage that the productivity is high.

[0028]

According to the first aspect of the present invention, since the metal foil is adhered to the inorganic substrate having a rough surface, a decorative base having a mirror surface can be obtained. For this reason, it has become possible to adopt various makeup techniques. In addition, metal foil is 0.05-
Since it is 0.2 mm, not only the bonding operation can be easily performed using a laminator, but also an inorganic decorative plate that can be easily processed can be obtained. Further, when the surface layer of the inorganic plate is flexible, the metal foil supplements the surface strength. For this reason, when fastening with fixing hardware such as nails, screws, tuckers, etc.
Depression and penetration are less likely to occur, and the effectiveness of these fixtures is improved. And since the surface of the inorganic decorative board of the present invention is smoother, an inorganic decorative board excellent in stain resistance can be obtained. Next, since the surface of the inorganic plate is covered with the metal foil and the decorative layer, the bending stress is increased and the strength is improved.

According to the second aspect of the present invention, the mineral fiber and the inorganic powdery material are mainly contained on the front and back surfaces of the middle layer, which is mainly composed of an inorganic foam and to which an appropriate amount of a binder is added. The surface layer portion obtained by adding the binder is laminated and integrated, and an inorganic plate having an overall specific gravity of 0.6 to 0.9 is used as a base material. For this reason, despite being a material that is easy to nail, the nail head is less likely to collapse and a lightweight inorganic decorative board that can be firmly fixed can be obtained. Further, since the surface strength is increased, there is an effect that an inorganic decorative plate which can prevent dents due to impact can be obtained.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a first embodiment of an inorganic decorative board according to the present invention.

FIG. 2 is a cross-sectional view showing a second embodiment of the inorganic decorative board according to the present invention.

FIG. 3 is a sectional view showing an inorganic plate according to a conventional example.

[Explanation of symbols]

10: inorganic decorative board, 11: metal foil, 12: decorative layer, 1
3 ... middle part, 14, 15 ... surface part.

Claims (2)

[Claims] 1. An inorganic decorative plate having a decorative layer formed on the surface of an inorganic plate, wherein a metal foil having a thickness of 0.05 mm to 0.2 mm is adhered and integrated between the inorganic plate and the decorative layer. Characterized inorganic decorative board. 2. The method according to claim 1, wherein the inorganic plate is mainly composed of an inorganic foam, and is mainly composed of mineral fibers and inorganic powder on the front and back surfaces of a middle layer to which an appropriate amount of a binder is added. 2. The inorganic decorative board according to claim 1, wherein the total specific gravity is 0.6 to 0.9, in which the surface layers formed by adding the binders are laminated and integrated.