JP2008173773A - Flexible non-combustible decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a flexible non-combustible decorative sheet excellent in impact resistance and strength, having flexibility and adapted to a curved surface at a normal temperature without performing a special treatment such as watering or thermal processing. <P>SOLUTION: A soft fire-retardant core layer, a metal foil having an adhesive applied to both sides thereof and a surface decorative layer are successively laminated to be integrally molded. As the soft fire-retardant core layer, a resin impregnated prepreg prepared by impregnating a fiber base material with slurry composed of a thermoplastic resin and an inorganic filler is used and the solid compounding ratio of the thermoplastic resin and the inorganic filler is set to 1:3-1:10. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a flexible incombustible decorative board.

  Conventionally, when a non-combustible decorative material having a thickness of several millimeters is used for bending processing, a method of cutting a groove on the back surface is known.

However, if a groove is inserted from the back side of the non-combustible decorative material, there are cases where the bending process is not stable and may be damaged during bending, and the appearance of a beautiful curvature cannot be drawn due to the effect of the grooved part. It was.
JP 2005-212424 A JP-A-2005-169924 JP-A-5-51980 JP 62-59005 JP-A-9-224760

  The present invention has been studied in view of such circumstances, and an object of the present invention is to obtain a decorative board having nonflammability and excellent bending work, and is characterized by the following.

  That is, the invention according to claim 1 is a flexible product comprising a soft flame-retardant core layer, a metal foil coated with an adhesive on both sides, and a surface decorative layer, which are sequentially laminated and integrally molded. It is an incombustible decorative board.

  The invention according to claim 2 is the flexible non-combustible decorative board according to claim 1, wherein a reinforcing layer is interposed between the soft flame-retardant core layer and the metal foil.

  The invention according to claim 3 is characterized in that the soft flame-retardant core layer is made of a resin-impregnated prepreg in which a fiber base material is impregnated with a slurry made of a thermoplastic resin and an inorganic filler. It is a flexible incombustible decorative board as described.

  According to the present invention, it has excellent nonflammability, impact resistance and strength, is flexible, can be used for curved surfaces at room temperature without special treatment such as water hammering and heat processing, and has a groove on the back side. There is no need to form.

  Hereinafter, the present invention will be described in detail.

  The soft flame retardant core layer of the present invention comprises a slurry composed of a thermoplastic resin such as vinyl acetate resin, SBR, acrylic resin, styrene acrylic resin and an inorganic filler, and a fiber base such as an inorganic fiber base material or an organic fiber base material. The material is impregnated.

Examples of the inorganic fiber substrate include nonwoven fabrics and woven fabrics made of inorganic fibers such as glass fibers, rock wool, and carbon fibers. The basis weight of the inorganic fiber substrate is preferably in the range of 10 to ²⁰⁰ g / m ² , and it is particularly preferable to use a glass fiber nonwoven fabric that is excellent in heat resistance and flame resistance and excellent in impregnation of slurry.

  Examples of organic fibers include polyethylene, polypropylene, vinylon, polyvinyl chloride, polyvinylidene chloride, polyacrylonitrile, polyamide, polyester, polyurethane, etc., and their modified products and various copolymers represented by ethylene-vinyl acetate copolymer. Examples thereof include fibers made of coalescence and a mixture thereof, and composite fibers made of these polymers.

  Among thermoplastic resins, an acrylic resin or SBR latex having a glass transition temperature of 0 ° C. or less that is excellent in bendability, adhesion, and moldability is preferable, and polyester having excellent tensile strength is preferable among organic fibers.

The inorganic filler contained in the slurry is for the purpose of stabilizing moldability, improving strength, and flame retardancy, and specifically includes aluminum hydroxide, magnesium hydroxide, calcium carbonate, silica and the like. Those having an average particle size in the range of 0.5 to 200 μm can be impregnated into the fiber base material. Among them, those containing crystal water such as aluminum hydroxide and magnesium hydroxide decompose at high temperatures and endotherm. It is optimal in terms of nonflammability because it releases bound water.
Excellent water and heat resistance.

  The blending ratio of the thermoplastic resin component and the inorganic filler in the slurry is preferably in the range of 1: 3 to 1:10 in terms of solid content, and if the inorganic filler is more than the thermoplastic resin component, the slurry is in close contact. If the inorganic filler is reduced, the resin may ooze out during hot pressing.

  The slurry solid content (%) in the fiber substrate is a calculation method represented by Equation 1, and is preferably in the range of 700 to 1200%. If the upper limit is exceeded, the solid content will drop off, making it difficult to handle, and if the lower limit is not reached, delamination will easily occur.

  Between the soft flame retardant core layer and the metal foil coated with adhesive on both sides, a resin base impregnated with a thermosetting resin impregnated into a fiber base as a reinforcing layer in order to improve strength to withstand bending stress It is preferable to provide paper. As the thermosetting resin, phenol resin, diallyl phthalate resin, unsaturated polyester resin, amino-formaldehyde resin, or a mixture thereof can be applied, and among them, phenol resin excellent in heat resistance is preferable.

  Phenol resins are obtained by reacting phenols and aldehydes at a ratio of 1 to 3 moles of aldehydes with 1 mole of phenolic hydroxyl group under a basic catalyst or an acidic catalyst. Phenol, cresol, xylenol, octylphenol, phenylphenol, bisphenol A, bisphenol S, bisphenol F and the like. Examples of aldehydes include formaldehyde, paraformaldehyde, glyoxal, trioxal and the like.

In addition, those modified with a modifying agent that promotes plasticization such as paratoluene sulfonamide, tung oil, phosphoric esters, glycols, etc. can be applied as necessary, and basic catalysts include alkali metals such as sodium and potassium, And oxides and hydroxides of alkaline earth metals such as magnesium and calcium, amines such as triethylamine and triethanolamine, and ammonia. Examples of acidic catalysts include paratoluenesulfonic acid and hydrochloric acid.
Moreover, as a fiber base material of this reinforcing layer, kraft paper having a basis weight of about 150 to 300 g / m ² is used, and a resin liquid containing the above resin as a main component by a calculation method represented by Equation 1 is 30 to 80%. It is obtained by impregnating at an impregnation rate and drying.

  Examples of the metal foil material include iron, copper, aluminum, and stainless steel. Examples of the adhesive applied to both surfaces include phenol butyral resin, nylon resin, polyolefin resin, epoxy resin, and epoxy-phenol resin. Can be mentioned. Of these, copper foil and aluminum foil are preferred, and the thickness is preferably 30 to 100 μm in consideration of bending workability at room temperature. Moreover, since it will melt | dissolve and nonflammability will fall if thickness is thin also from a nonflammable surface, 30 micrometers or more are preferable. By using the metal foil, a thermal diffusion effect and a gas barrier effect are exhibited.

On the metal foil, a thermosetting resin-impregnated decorative paper is laminated as a surface decorative layer. The thermosetting resin-impregnated decorative paper is obtained by applying a resin liquid composed of a thermosetting resin such as an amino-formaldehyde resin, a diallyl phthalate resin, and an unsaturated polyester resin to a decorative paper for decorative board of 60 to 180 g / m < ² >. The impregnation rate shown is impregnated so as to be 30 to 200% and dried. In particular, it is preferable to use a melamine-formaldehyde resin in terms of hardness and stain resistance.

  Amino-formaldehyde resins include initial condensates obtained by reacting amino compounds such as melamine, urea, benzoguanamine, and acetoguanamine with formaldehyde, etherification with lower alcohols such as methyl alcohol and butyl alcohol, and paratoluene. Those modified with a reactive modifier that promotes plasticization such as sulfonamide can be applied, and among them, a melamine-formaldehyde resin excellent in durability is preferable.

A resin-impregnated surface paper may be used to improve the wear resistance of the decorative layer and protect the color and pattern. The resin-impregnated surface paper is obtained by impregnating a surface paper having a basis weight of 20 to 40 g / m ² with a resin liquid containing a thermosetting resin composition as a main component, similarly to decorative paper, and drying.

  EXAMPLES Hereinafter, although an Example is given and demonstrated in detail, this invention is shown more concretely and is not specifically limited.

Example 1
Soft flame retardant core layer A slurry in which 88 parts of aluminum hydroxide is blended with 12 parts of acrylic resin having a Tg of −50 ° C. in a polyester fiber nonwoven fabric of 70 g / m ² has a slurry solid content fixing ratio shown in Formula 1. A prepreg (a) was obtained by impregnation so as to be 900%.

Thermosetting resin-impregnated decorative paper A decorative paper for decorative plates having a basis weight of 80 g / m ² was impregnated with a resin solution comprising a melamine-formaldehyde resin to obtain a thermosetting resin-impregnated decorative paper.

Surface protective layer A surface paper having a basis weight of 20 g / m ² was impregnated with a resin solution composed of melamine-formaldehyde resin as a surface protective layer to obtain a thermosetting resin-impregnated surface paper.

Metal foil reinforced paper A curable kraft paper having a basis weight of 200 g / m ² was impregnated with a resin solution containing a phenol resin as a main component so that the impregnation ratio shown in Formula 1 was 50% to obtain a thermosetting resin-impregnated paper.

Flexible non-combustible decorative board prepreg (a) six, one metal foil reinforced paper, phenolic both sides of an aluminum foil having a thickness of 40 [mu] m - butyral resin adhesive coated foils double coated each side 7 g / m ² ( 1) One sheet and one sheet of thermosetting resin-impregnated decorative paper were laminated and hot-press molded under the conditions of 130 ° C., 70 kg / cm ² , 90 minutes to obtain a flexible noncombustible decorative board of Example 1 .

Example 2
In Example 1, it implemented similarly except having used the slurry which mix | blended 90 parts of aluminum hydroxide with respect to 10 parts of acrylic resins.

Example 3
In Example 1, it implemented similarly except having used the slurry which mix | blended 80 parts of aluminum hydroxide with respect to 20 parts of acrylic resins.

Example 4
The same procedure as in Example 1 was carried out except that impregnation was performed so that the slurry solid content fixing ratio shown in Formula 1 was 1100%.

Example 5
The same operation was carried out except that the surface protective layer was not used in Example 1.

Example 6
In Example 1, it implemented similarly except having used 40-micrometer-thick copper foil instead of aluminum foil.

Example 7
The same procedure as in Example 1 was performed except that the metal foil reinforced paper was not used.

Example 8
In Example 1, it implemented similarly except having replaced with the phenol butyral resin and using polyolefin resin.

Comparative Example 1
In Example 1, it carried out similarly except not using adhesive coat foil (1) foil.

Comparative Example 2
In Example 1, it implemented similarly except having used the 10-micrometer-thick aluminum foil instead of the 40-micrometer-thick aluminum foil.

Comparative example 3 (when there are few inorganic fillers with respect to the resin component)
In Example 1, it carried out similarly except having used the slurry which mix | blended 20 parts of aluminum hydroxide with respect to 10 parts of acrylic resins, However, Acrylic resin flowed out at the time of hot press molding, and the decorative sheet was not obtained.

Comparative example 4 (when there are many inorganic fillers with respect to the resin component)
In Example 1, it carried out similarly except having used the slurry which mix | blended 150 parts of aluminum hydroxide with respect to 10 parts of acrylic resins, but adhesiveness was bad and the decorative sheet was not obtained.

Comparative Example 5 (when the impregnation rate of the slurry is less than the lower limit)
In Example 1, the same procedure was carried out except that the slurry solid content impregnation rate was 500%, but the adhesion was slightly inferior, and the resulting 1.2 mm thick decorative sheet was delaminated with a cutter knife.

Comparative Example 6 (when the impregnation rate of the slurry exceeds the upper limit)
In Example 1, the same procedure was carried out except that the slurry solid content impregnation rate was 1500%, but the acrylic resin flowed out during hot press molding, and a decorative sheet was not obtained.

Comparative Example 7 (when Tg of thermoplastic resin exceeds 0 ° C.)
In Example 1, the same operation was carried out except that an acrylic resin having a Tg of 20 ° C. obtained by copolymerizing 35 g of BA (butyl acrylate), 5 g of 2-HEMA (2-hydroxyethyl methacrylate) and 50 g of MMA (methyl methacrylate) was used. And the decorative sheet of Comparative Example 5 having a thickness of 1.2 mm was obtained, but the bendability was poor.

  The evaluation results are shown in Table 1.

The test method was as follows.

Nonflammability: The total calorific value (MJ / m ² ) was measured in the exothermic test / evaluation method of a 20-minute test using a cone calorimeter based on ISO 5660.

  Flexibility: A test specimen having a size of 300 × 300 (mm) was wound around 350R, 500R, and 600R concrete round pillars, respectively.

1 is a cross-sectional configuration diagram of a flexible non-combustible decorative board of Example 1. FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Surface protective layer 2 Melamine resin impregnated decorative paper 3 Adhesive coat foil 4 Phenolic resin impregnated paper for metal foil reinforcement 6 Prepreg 9 Flexible incombustible decorative board

Claims (3)

A flexible non-combustible decorative board comprising a soft flame-retardant core layer, a metal foil coated with an adhesive on both sides, and a surface decorative layer, which are sequentially laminated and integrally molded. The flexible incombustible decorative board according to claim 1, wherein a reinforcing layer is interposed between the soft flame-retardant core layer and the metal foil. 3. The flexible non-combustible decorative board according to claim 1, wherein the soft flame-retardant core layer comprises a resin-impregnated prepreg in which a fiber base material is impregnated with a slurry made of a thermoplastic resin and an inorganic filler. .

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