Non-flammable decorative panels

Abstract

To provide a non-combustible decorative board which can be manufactured at low cost, can prevent cracks from occurring as much as possible, and has further improved non-combustibility by suppressing combustion calories. [Solution] A non-flammable decorative board X has a non-flammable base material 1 made of calcium silicate board, a metal foil 7 laminated on one surface side thereof with an alkali penetration inhibiting layer 2 interposed therebetween, and surface decorative layers 10, 11 provided on the surface of the metal foil opposite the non-flammable base material, wherein the alkali penetration inhibiting layer has an alkali sealer layer 3 formed by applying an alkali sealer, and an undercoat layer 6 containing a water-resistant resin, the alkali sealer layer being provided on the non-flammable base material side and the undercoat layer being provided on the metal foil side, and the alkali sealer layer and undercoat layer being joined together via an adhesive layer 5 to form the alkali penetration inhibiting layer.

Description

[Technical Field]

[0001] This invention relates to a non-combustible decorative board, and more specifically to a non-combustible decorative board in which a metal foil is laminated on a non-combustible base material made of calcium silicate board, and a surface decorative layer is provided on this metal foil. [Background technology]

[0002] Calcium silicate boards are lightweight, non-flammable, water-resistant, and have minimal dimensional changes or warping. Furthermore, they are relatively inexpensive, making them widely used.

[0003] Examples include interior materials such as building walls, ceilings, and partitions, plumbing facilities such as kitchens, toilets, and bathrooms, commercial facilities such as offices, stores, hospitals, and schools, and industrial facilities such as food factories, hospitals, medical facilities, pharmaceutical warehouses, and laboratories, and the list goes on and on.

[0004] On the other hand, calcium silicate boards have drawbacks such as being weak in impact resistance, making them prone to cracking, and causing parts of the surface to peel off or crumble, generating dust.

[0005] Therefore, for example, an inorganic glassy layer is formed on the surface of a calcium silicate board, and then a surface layer having a thickness of 10 to 40 μm containing a vinyl organic compound and silicate is provided on top of that, thereby increasing the surface pencil hardness to 6H or more and suppressing the occurrence of cracks (see Patent Document 1).

[0006] However, even if an inorganic glassy layer is formed on the surface of a calcium silicate board, as in Patent Document 1, and a surface layer made of a mixture of resin and silicate is further provided on top of that, it does not sufficiently suppress the occurrence of cracks when the calcium silicate board is subjected to impact.

[0007] On the other hand, a non-flammable decorative board is known which has a resin film 3 such as a PET (polyethylene terephthalate) film bonded to the surface of a calcium silicate board 1a via a first adhesive layer 2, an aluminum foil 5 bonded on top of that via a second adhesive layer 4, and a surface decorative layer 7 made of reinforced paper or the like printed with a wood-grain pattern or the like, bonded on top of that via a third adhesive layer 6 (see Patent Document 2).

[0008] Similarly, a calcium silicate board 1a is known in which a moisture-impermeable layer 3 made of a resin film is provided on the surface thereof via a first adhesive layer 2, a metal layer 5 such as aluminum foil is attached on top of that via a second adhesive layer 4, a surface decorative layer 7 is provided on top of that via a third adhesive layer 6, and a coating layer containing aggregate such as sand or gravel and a hydraulic binder is further provided on top of that (see Patent Document 3).

[0009] In the cases of the materials described in Patent Documents 2 and 3, when the calcium silicate board receives an impact, the conformability of the aluminum foil or resin film is said to be able to suppress the occurrence of cracks.

[0010] In Patent Documents 2 and 3, metal foil such as aluminum foil is used, but alkaline components are easily generated from the calcium silicate board. Therefore, in order to prevent the metal foil from being corroded by the alkali generated from the calcium silicate board, a resin film is provided between the calcium silicate board and the metal foil to block the migration of alkaline components to the metal foil side.

[0011] However, although the PET film used in Patent Document 2 has a combustion calorie content that is about half (about 5,500 kcal / kg) of that of olefin-based resin films such as polyethylene (PE) and polypropylene (PP), there is still room for improvement in terms of ensuring non-combustibility as an interior material.

[0012] For example, the Ministry of Land, Infrastructure, Transport and Tourism has established a work manual for testing non-combustible materials, one of which is a heat generation test. The criterion for this test is a total heat generation of 8MJ / m for 20 minutes after the start of heating. 2 (For example, see Tsuneto Dobashi et al., Comparison of Non-flammability Tests and Heat Release Tests for Interior Materials, General Building Research Corporation of Japan, GBRC, 115 (2004) 1, pp. 19-23) However, within the interior materials industry, the standard is set at 7.2 MJ / m, which is 10% lower than this standard. 2 The following are the management indicators: [Prior art documents] [Patent documents]

[0013] [Patent Document 1] Japanese Patent Application Publication No. 5-238852 [Patent Document 2] Japanese Patent Application Laid-Open No. 2018-51899 [Patent Document 3] Utility Model Registration No. 3223162 Summary of the Invention [Problem to be solved by the invention]

[0014] As mentioned above, decorative panels made of calcium silicate boards are required to be able to reliably prevent cracks from occurring due to impacts and to be fully non-flammable. Moreover, it is extremely important to achieve these requirements while keeping costs as low as possible.

[0015] Therefore, the inventors conducted extensive research into the above-mentioned problems and discovered that in a non-flammable decorative board in which a metal foil is laminated on one surface side of a non-flammable base material made of calcium silicate board via an alkali penetration prevention layer, and a surface decorative layer is provided on the metal foil side, by constructing the alkali penetration prevention layer from an alkali sealer layer, an adhesive layer, and a primer layer, it is possible to prevent cracks from occurring due to impact as much as possible, and to reduce combustion calories and achieve a board that is even more non-flammable than previous decorative boards at low cost, thereby completing the present invention.

[0016] Therefore, the object of the present invention is to provide a non-combustible decorative panel that can be manufactured at low cost, can prevent cracks from occurring as much as possible, and has reduced combustion calories to further improve non-combustibility. [Means for solving the problem]

[0017] In other words, the non-flammable decorative board of the present invention has metal foil laminated on one surface side of a non-flammable base material made of calcium silicate board via an alkali penetration inhibitor layer, and a surface decorative layer on the surface side of the metal foil opposite the non-flammable base material, and the alkali penetration inhibitor layer has an alkali sealer layer formed by applying an alkali sealer, and a primer layer containing a water-resistant resin, the alkali sealer layer being provided on the non-flammable base material side and the primer layer being provided on the metal foil side, and the alkali sealer layer and primer layer being joined together via an adhesive layer made of an adhesive to form the alkali penetration inhibitor layer.

[0018] The alkali penetration prevention layer is intended to prevent the migration of alkali generated from the calcium silicate board toward the metal foil. As mentioned above, calcium silicate, the main component of calcium silicate board, is alkaline, and therefore may corrode the metal foil. Therefore, in this invention, an alkali penetration prevention layer is provided by joining the alkali sealer layer and the primer layer via an adhesive layer.

[0019] Here, the alkali sealer layer is formed by applying an alkali sealer. As such an alkali sealer, one containing a thermosetting resin or a resin having an isocyanate group can be used. Alternatively, one containing a silicate can be used. Among these, the former thermosetting resin or resin having an isocyanate group can include urethane resin, polyester resin, epoxy resin, phenolic resin, etc., as well as urethane resin. Furthermore, the latter one containing a silicate can include sodium silicate such as water glass, or potassium silicate. Of these, one containing a urethane resin or one containing a silicate is preferred.

[0020] The alkaline sealer layer is provided on the side of the non-combustible substrate made of calcium silicate board. When providing the alkaline sealer layer, the amount of alkaline sealer to be applied is not particularly limited, but as a guideline, the amount of alkaline sealer to be applied is 10 to 100 g / m2 in terms of solids. 2 It is best to have that level.

[0021] The undercoat layer contains a water-resistant resin and is provided on the metal foil side. Examples of water-resistant resins that form the undercoat layer include polyester resins, urethane resins, and epoxy resins, with polyester resins and urethane resins being preferred. When forming this undercoat layer, inorganic additives such as silica may be added. There are no particular restrictions on the amount of coating when forming the undercoat layer, but a rough guideline is a solid amount of 3 to 50 g / m. 2 It is best to have that level.

[0022] Furthermore, the adhesive layer that bonds the alkali sealer layer and the primer layer can be any known adhesive, but it is preferable to use a reactive hot melt adhesive. Examples of reactive hot melt adhesives include PUR-HM (Poly Urethane Reactive Hot Melt). When forming this adhesive layer, inorganic additives such as silica may be added. There are no particular restrictions on the amount of reactive hot melt adhesive to be applied, but a rough guideline is a solid amount of 20 to 150 g / m. 2 It is best to have that level.

[0023] In this way, the alkali sealer layer neutralizes or inhibits the alkaline components of the calcium silicate board, and the adhesive layer and primer layer on top of it inhibit moisture penetration, reliably preventing corrosion of the metal foil. Moreover, the alkali penetration suppression layer formed by these layers can reduce combustion calories compared to when a resin film is used, which is advantageous in ensuring non-flammability.

[0024] In addition, in the present invention, known calcium silicate boards can be used as non-combustible substrates made of calcium silicate boards. Calcium silicate boards (commonly known as calcium silicate boards) generally contain siliceous materials, calcareous materials, reinforcing fibers, etc., and in some cases, pulp or other materials are mixed in to form plate-shaped building materials. Commercially available products with thicknesses of 3 mm and 6 mm are widely available. While such known calcium silicate boards can be used in the present invention, it is preferable to use those that are certified as non-combustible materials.

[0025] Furthermore, for non-combustible substrates made of calcium silicate boards, an alkali sealer may be applied to the back side opposite the alkali penetration prevention layer to provide a back alkali sealer layer in order to more reliably prevent alkali generation. As with the previously mentioned alkali sealers, those containing urethane resins or silicates such as sodium silicate can be used. The amount of alkali sealer to be applied is approximately 5 to 50 g / m2 in solids. 2 It is best to have that level.

[0026] The metal foil used in the present invention may be, for example, aluminum foil or copper foil, but aluminum foil is preferred in terms of cost. There is no particular limitation on the thickness, but it may be, for example, about 5 to 30 μm.

[0027] In this invention, a surface decorative layer is provided on the surface opposite the non-combustible base material of the metal foil. This surface decorative layer can be appropriately set depending on the application and environment of the non-combustible decorative board, but it is preferable to have, for example, a colored layer with a pattern printed on reinforced paper and a top coating layer covering the colored layer.

[0028] Of these, commercially available reinforced paper can be used, and although there are no particular restrictions on its thickness, paper of approximately 20 to 100 μm can be used. The colored layer can be formed to a thickness of approximately 5 to 30 μm by, for example, gravure printing using an acrylic resin-based ink. In this case, inorganic additives such as titanium oxide may also be included. Furthermore, from the perspective of stain resistance and surface protection, the top coating layer can be formed to a thickness of approximately 2 to 20 μm by, for example, gravure printing using a urethane resin-based paint.

[0029] In addition, in the present invention, the metal foil and the reinforced paper are preferably joined via a heat-sealed layer formed by heat-sealing a thermoplastic resin. Such a heat-sealed layer is preferably made of a heat-sealable material such as polypropylene (PP), polyethylene (PE), or high-density polyethylene (HDPE). Furthermore, by providing the heat-sealed layer with a thickness of, for example, about 10 to 30 μm, it is possible to impart moisture-proof properties.

[0030] The non-combustible decorative board of the present invention has the structure described above, which can prevent cracks from occurring on the surface of the decorative board as much as possible. Moreover, the non-combustible decorative board of the present invention can further improve its non-combustibility by reducing the combustion calories. Specifically, in a heat generation test using a cone calorimeter, the total heat generation rate for 20 minutes after the start of heating was 8MJ / m. 2 It can be less than or equal to 7.2 MJ / m 2 Less than or equal to 5MJ / m 2 It can be as follows:

[0031] In addition to the above-mentioned properties, the non-flammable decorative panels of the present invention can be manufactured at relatively low cost, and their applications are not particularly limited. For example, they can be used in interior materials (non-flammable decorative panels for interior use) such as building walls, ceilings, and partitions, as well as in plumbing facilities such as kitchens, toilets, and bathrooms, commercial facilities such as offices, stores, hospitals, and schools, and industrial facilities such as food factories, hospitals, medical facilities, pharmaceutical warehouses, and laboratories. In particular, they are highly suitable for the construction of various clean rooms, as they can minimize the generation of dust due to cracks. [Effects of the Invention]

[0032] According to this invention, it is possible to prevent cracks from occurring due to impact as much as possible, and it is also possible to reduce the combustion calories and obtain decorative panels that are even more non-flammable than conventional panels at low cost. [Brief explanation of the drawings]

[0033] [Figure 1] FIG. 1 is a schematic diagram illustrating the non-flammable decorative board according to the present invention. [Figure 2] FIG. 2 is an explanatory diagram showing three types of test plates (a) to (c) prepared for the crack test. [Figure 3] FIG. 3 is a schematic diagram for explaining the crack test using a test plate, where FIG. 3(1) is a plan view and FIG. 3(2) is a side view. DETAILED DESCRIPTION OF THE INVENTION

[0034] The present invention will be explained in detail with reference to the drawings.

[0035] 1 is an explanatory diagram showing an example of a non-combustible decorative board X according to the present invention, and is shown schematically to allow understanding of its layer structure. Specifically, the non-combustible decorative board X according to this embodiment has a non-combustible substrate 1 made of calcium silicate board (manufactured by DIC Decor, product name: DIC Funen Solid Color S80). This non-combustible substrate 1 is made of calcium silicate board with a thickness of 6 mm, and contains, in addition to calcareous raw materials such as lime, siliceous raw materials such as silica stone, inorganic additives such as calcium carbonate, and organic fibers such as pulp, and is a non-combustible material certified by the Minister of Land, Infrastructure, Transport and Tourism (NM-2773).

[0036] An alkali sealer layer (surface alkali sealer layer) 3 formed by applying an alkali sealer is provided on one surface of the non-combustible substrate 1. This alkali sealer layer 3 is formed by applying an alkali sealer containing a urethane resin and has a thickness of 20 μm. Furthermore, on the opposite back surface of the non-combustible substrate 1, a back alkali sealer layer 4 is provided which is also formed by applying an alkali sealer containing a urethane resin and has a thickness of 10 μm.

[0037] An adhesive layer 5 made of a reactive hot melt adhesive is provided on the surface side of the alkaline sealer layer 3. This adhesive layer 5 is formed using a PUR-HM adhesive, and the reactive groups react with moisture in the air to develop strong adhesiveness, and in the non-flammable decorative board X according to this embodiment, the adhesive layer 5 has a thickness of 35 μm.

[0038] Furthermore, a primer layer 6 containing a water-resistant resin is formed on the surface side of the adhesive layer 5. This primer layer 6 is made of a surface treatment agent containing a polyester-based resin, and is formed to a thickness of 2 μm by applying it to an aluminum foil described below. Furthermore, an aluminum foil 7 having a thickness of 9 μm is provided on the surface side of the primer layer 6.

[0039] Furthermore, a reinforced paper 9 having a thickness of 30 μm and a basis weight of 30 g is attached to the surface side of the aluminum foil 7 via a heat-sealed layer 8 having a thickness of 15 μm and formed by heat-sealing a polyethylene (PE) sheet.

[0040] In addition, this reinforced paper 9 is provided with a 10 μm thick colored layer 10 with a wood grain pattern printed with acrylic resin ink, and on top of that is provided a 6 μm thick top coating layer 11 formed using urethane resin paint.

[0041] In this non-combustible decorative board X, the alkali components contained in the calcium silicate board are neutralized or inhibited by a front alkali sealer layer 3 and a back alkali sealer layer 4 applied to the non-combustible substrate 1. In addition, an adhesive layer 5 made of a reactive hot melt adhesive and an undercoat layer 6 made of a polyester resin can prevent water penetration. Therefore, the front alkali sealer layer 3, adhesive layer 5, and undercoat layer 6 provided between the non-combustible substrate 1 and the aluminum foil 7 function as an alkali penetration suppression layer 2, which can reliably block the migration of alkali from the calcium silicate board, which is the non-combustible substrate 1, to the aluminum foil 7.

[0042] Furthermore, in this non-combustible decorative board X, the rigidity is strengthened by the aluminum foil 7, and cracks are suppressed, thereby preventing the generation of dust, etc. Furthermore, the combustion calories of the non-combustible decorative board X are reduced by the above-mentioned configuration, and in addition, the presence of the aluminum foil 7 improves gas barrier performance, and the heat dispersion effect of aluminum further enhances non-combustibility.

[0043] The method for producing such a non-combustible decorative board X is not particularly limited, and it can be obtained by various methods, but for example, the following method can be preferably adopted.

[0044] First, aluminum foil 9 is bonded to the backside of the above-mentioned reinforced paper 9 via a heat-sealed layer 8 formed by heat-sealing a polyethylene (PE) sheet. The heat-sealing temperature is about 270 to 350°C. Next, a surface treatment agent containing a polyester resin is applied to the backside of the aluminum foil 9 to form an undercoat layer 6, resulting in an intermediate work-in-progress.

[0045] Next, the surface of the reinforced paper 9 of the intermediate work-in-progress obtained above is printed with an acrylic resin ink using a gravure printing machine to form a colored layer 10. Next, a urethane resin paint is applied to the surface of the colored layer 10, and then heated to promote curing, thereby forming a top coating layer 11.

[0046] On the other hand, the front and back surfaces of the calcium silicate board, which is the non-flammable substrate 1, are polished with a sanding device, and then an alkaline sealer containing a urethane resin is applied to each surface to form a front alkaline sealer layer 3 and a back alkaline sealer layer 4.

[0047] Next, a PUR-HM adhesive is applied to the surface alkaline sealer layer 3 formed on the surface of the non-combustible substrate 1, and the intermediate work-in-progress provided with the colored layer 10 and top coating layer 11 described above is joined. After that, the edges are trimmed, etc., to obtain the non-combustible decorative board X. [Example]

[0048] The non-combustible decorative board X obtained above was subjected to the following evaluation tests.

[0049] [Pyrogenicity test] The non-combustible decorative board X obtained above was cut into a size of 100 mm length x 100 mm width, and a heat generation test was carried out according to a method in accordance with ISO5660-1. That is, the non-combustible decorative board X cut to the above size was heated with a cone heater, the generated gas was ignited with a spark igniter, and burned, and the oxygen concentration of the combustion gas was measured. Then, a test to determine the total heat generation amount in a 20-minute heat generation test was carried out three times, and the first test was 3.3 MJ / m 2 , and the second time was 4.3MJ / m 2 , and the third time was 2.6MJ / m 2 and the average is 3.4MJ / m 2 Therefore, the total calorific value of the non-combustible decorative panel X obtained above in the heat generation test using a cone calorimeter is 5MJ / m on average. 2 The following was confirmed:

[0050] [Crack test] For the non-combustible decorative panel X obtained above, as shown in Figure 2, test panel x (a) was cut out from a 450 mm x 450 mm square into a 100 mm wide L-shape, test panel x (b) was cut out from the same into a 200 mm wide L-shape, and test panel x (c) was cut out from the same into a 300 mm wide L-shape.

[0051] Next, for each of the test plates x (a) to (c) prepared above, as shown in Figure 3, a predetermined number of PVC spacers measuring 50 mm in length, 20 mm in width, and 1 mm in thickness were stacked on top of each other with the top coating layer 11 facing up, and the test plate x was placed on the floor with the spacers at a 45° angle in the 90° L-shaped notch of each test plate x (so that the spacers were sandwiched between the test plate x and the floor). A 3 kg weight was then placed on each L-shaped portion of the test plate x. The height between the floor and the test plate x was changed from h = 1 mm to h = 11 mm by stacking the spacers one by one, and a 3 kg load was applied to each L-shaped portion of the test plate x. It was visually confirmed whether cracks occurred in the L-shaped notch of the test plate x. In this test, the number of spacers was adjusted for each test panel x (a) through (c), increasing the height h between the floor and the test panel x from lowest to highest. A 'good' indicates no cracks at the L-shaped notch, and an 'x' indicates cracks. The test examined how far the height h could be increased. For comparison, similar tests were also conducted on conventional decorative calcium silicate boards (conventional products), using test panels (a) through (c) prepared in the same manner as above. The results are summarized in Table 1. The conventional decorative calcium silicate boards (conventional products) were the same calcium silicate boards used to prepare non-combustible decorative board X, but with a backside alkali sealer layer 4 formed on the backside in the same manner as above. The opposite surface of the boards was coated with a polyester UV-curable resin filler layer approximately 100 μm thick, and an acrylic urethane enamel resin layer approximately 20–30 μm thick was then applied to the surface.

[0052] [Table 1]

[0053] In the above crack test, for the calcium silicate board used for comparison, cracks occurred on test board (a) when the spacer height was h = 1 mm. Similarly, cracks occurred on test board (b) when the spacer height was h = 2 mm, and on test board (c) when the spacer height was h = 3 mm. However, while Table 1 indicates that cracks occurred at a height of h = 3 mm, even at a height of h = 2 mm, what appeared to be a faint crack was observed in the notch of test board (c). In contrast, for non-combustible decorative board X, cracks occurred on test board (a) when the spacer height was h = 10 mm, but no cracks were observed on test boards (b) and (c) even when the spacer height was h = 11 mm. [Explanation of symbols]

[0054] 1: Non-flammable substrate, 2: Alkali penetration prevention layer, 3: Surface alkali sealer layer, 4: Back alkali sealer layer, 5: Adhesive layer, 6: Primer layer, 7: Aluminum foil, 8: Heat-sealed layer, 9: Reinforced paper, 10: Colored layer, 11: Top coating layer, X: Non-flammable decorative board, x: Test board.

Claims

1. A non-combustible decorative board comprising a non-combustible base material made of calcium silicate board, a metal foil laminated on one surface side thereof via an alkali penetration suppression layer, and a surface decorative layer provided on the surface side of the metal foil opposite to the non-combustible base material, the alkali penetration suppression layer has an alkali sealer layer formed by applying an alkali sealer and an undercoat layer containing a water-resistant resin, A non-flammable decorative board characterized in that the alkali sealer layer is provided on the non-flammable substrate side and the primer layer is provided on the metal foil side, and the alkali sealer layer and the primer layer are joined via an adhesive layer to form the alkali penetration suppression layer.

2. 2. The non-flammable decorative board according to claim 1, wherein the alkali sealer contains a urethane resin or a silicate.

3. 2. The non-combustible decorative board according to claim 1, wherein the undercoat layer is made of a polyester resin.

4. 2. The non-flammable decorative board according to claim 1, wherein the adhesive layer is made of a reactive hot melt adhesive.

5. 2. The non-combustible decorative board according to claim 1, wherein the surface decorative layer comprises a colored layer printed on a reinforced paper and a top coating layer covering the colored layer.

6. The non-combustible decorative board according to claim 5, wherein the metal foil and the reinforcing paper are joined via a heat-sealed layer formed by heat-sealing a thermoplastic resin.

7. 2. The non-combustible decorative board according to claim 1, wherein the metal foil is made of aluminum foil.

8. The total calorific value of the heat generation test using a cone calorimeter is 8MJ / m ２ The non-flammable decorative board according to claim 1, wherein:

9. 2. The non-combustible decorative board according to claim 1, which is a non-combustible decorative board for interior use.

Images