Interior building materials

Abstract

We provide interior building materials that can shorten the construction process for interior finishes. [Solution] The interior building material 1 comprises an insulating material 10 and a gypsum board 40 bonded to the insulating material. Furthermore, the interior building material has a design portion 80 on the side of the gypsum board opposite to the side bonded to the insulating material. The design portion may include a plurality of recesses and / or protrusions formed on the surface of the gypsum board. Because the interior building material of this invention has a design portion 80, there is no need to apply finishing materials such as wallpaper or paint to the gypsum board at the construction site. Therefore, the construction period required for interior work can be shortened, and consequently, the construction period required for building construction can be shortened.

Description

[Technical Field]

[0001] This technology relates to interior building materials. [Background technology]

[0002] Previously, interior building materials used in the interior of buildings were required to have functionalities such as heat resistance, water resistance, chemical resistance, impact resistance, sound insulation, dustproof properties, and adhesive properties, in addition to thermal insulation, which is intended to block the transfer of heat. For example, Patent Document 1 discloses a building board having a gypsum board, a radiant layer made of a sheet material such as paper and aluminum foil, and a polyisocyanurate foam layer provided between the gypsum board and the radiant layer. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Publication No. 55-117514 [Overview of the project] [Problems that the invention aims to solve]

[0004] Incidentally, conventional methods for interior finishing involve two steps: installing base materials such as insulation, and then applying finishing materials such as wallpaper or decorative panels to these base materials. These steps are performed at the construction site. The inventor of this invention realized that if the insulation installation step could be shortened at the construction site, the interior finishing process could be shortened, and thus the construction period for the building could be reduced.

[0005] Therefore, the main objective of this technology is to provide interior building materials that can shorten the construction process for interior finishes. [Means for solving the problem]

[0006] In this technology, first, an insulating material and, The insulation layer has a gypsum board bonded to it, The present invention provides an interior building material having a decorative portion on the side of the gypsum board opposite to the side that is adhered to the thermal insulation material. Furthermore, with respect to the interior building material relating to this technology, the design portion includes a plurality of recesses and / or protrusions formed on the surface of the gypsum board. Furthermore, with respect to the interior building materials relating to this technology, the surface of the gypsum board facing the insulation material is greater than or equal to the surface of the insulation material facing the gypsum board. Furthermore, the interior building materials related to this technology are used for ceiling interiors. Furthermore, with respect to the interior building materials relating to this technology, the thermal insulation material includes a foam formed from at least one selected from the group consisting of rigid polyurethane foam, polyisocyanurate foam, polystyrene foam, polyolefin ethylene foam, and phenolic foam. Furthermore, regarding the interior building materials related to this technology, the foam is the polyisocyanurate foam which is a reaction product of 60% by mass or more of polyisocyanate, 0.1% by mass or more of polyether-based polyol, and 5% by mass or more of polyester-based polyol. Furthermore, with respect to the interior building materials relating to this technology, the design portion further includes a painted layer. [Brief explanation of the drawing]

[0007] [Figure 1] Perspective view of interior building materials related to this technology [Figure 2] Side cross-sectional view of interior building materials related to this technology [Figure 3] Side cross-sectional view of interior building material related to this technology and enlarged view of the gypsum board surface layer. [Figure 4] Floor plan of interior building materials related to this technology [Figure 5] Side view showing the installed state of interior building materials related to this technology. [Modes for carrying out the invention]

[0008] Hereinafter, preferred embodiments for implementing the present technology will be described. The embodiments described below show examples of typical embodiments of the present technology, and any of the embodiments can be combined. Also, the scope of the present technology is not construed narrowly by these.

[0009] As shown in FIG. 1, the interior building material 1 according to the present technology has a heat insulating material 10 and a gypsum board 40 adhered to the heat insulating material 10.

[0010] <Heat insulating material 10> As shown in FIG. 2, the heat insulating material 10 has at least a heat insulating layer 12. Further, if necessary, a heat insulating material skin layer 14 provided on the surface of the heat insulating layer 12 (the surface of the heat insulating layer 12 that is adhered to the gypsum board 40), a heat insulating material back layer 16 provided on the back surface of the heat insulating layer 12 (the surface opposite to the surface of the heat insulating layer 12 (opposite)) etc. may be provided.

[0011] The material constituting the heat insulating layer 12 is not limited as long as it is a material that exhibits a heat insulating effect, as long as it does not impair the functions and effects of the present technology. For example, a foam can be used. The type of foam used for the heat insulating layer 12 is also not limited as long as it does not impair the functions and effects of the present technology. For example, foams formed from at least one selected from the group consisting of rigid urethane foam, polyisocyanurate foam, polystyrene foam, polyolefin foam, and phenolic foam can be mentioned. Among these, in the present technology, it is preferable to use polyisocyanurate foam as the foam used for the heat insulating layer 12. The polyisocyanurate foam that can be used in the present technology can be manufactured by a general method. For example, a polyisocyanurate foam production composition containing polyisocyanate (for example, 60% by mass or more); polyols such as polyether polyol (for example, 0.1% by mass or more), polyester polyol (for example, 5% by mass or more); blowing agent; catalyst; foam stabilizer; flame retardant; other additives, etc. can be used to manufacture the foam used for the heat insulating layer 12.

[0012] The lower limit of the isocyanate index of the polyisocyanurate foam can be freely set as long as it does not impair the function and effects of this technology, but for example it may be 200 or more, preferably 250 or more, more preferably 300 or more, even more preferably 350 or more, and even more preferably 400 or more. The upper limit of the isocyanate index of the polyisocyanurate foam can also be freely set as long as it does not impair the function and effects of this technology, but for example it may be 1,000 or less, preferably 900 or less, more preferably 800 or less, even more preferably 700 or less, even more preferably 600 or less, and even more preferably 500 or less. In this technology, for example, a polyisocyanurate foam with an isocyanate index of 400 to 500 can be used for the heat insulating layer 12. In this technology, the isocyanate index is a value calculated as [(amount of isocyanate in the composition for manufacturing polyisocyanurate foam / amount of active hydrogen in the composition for manufacturing polyisocyanurate foam) × 100].

[0013] The lower limit of the thickness of the insulation layer 12 can be freely set as long as it does not impair the purpose and effect of this technology, but for example it may be 14.0 mm or more, preferably 15.0 mm or more, and more preferably 16.0 mm or more. The upper limit of the thickness of the insulation layer 12 can also be freely set as long as it does not impair the purpose and effect of this technology, but for example it may be 100 mm or less, preferably 80.0 mm or less, and more preferably 60.0 mm or less.

[0014] The lower limit of the basis weight of the insulation layer 12 can be freely set as long as it does not impair the purpose or effect of this technology, but for example, 0.35 kg / m 2 Preferably 0.40 kg / m 2 More preferably 0.45 kg / m 2 The above is sufficient. Furthermore, the upper limit of the basis weight of the insulation layer 12 can be freely set as long as it does not impair the purpose or effect of this technology, for example, 1.30 kg / m 2 Preferably, 1.25 kg / m 2 More preferably, 1.20 kg / m 2It may be as follows.

[0015] The lower limit value of the density of the heat insulation layer 12 can be freely set as long as the object and effect of the present technology are not impaired. For example, it can be 26 kg / m 3 or more, preferably 28 kg / m 3 or more, more preferably 30 kg / m 3 or more. Also, the upper limit value of the basis weight of the heat insulation layer 12 can be freely set as long as the object and effect of the present technology are not impaired. For example, it can be 46 kg / m 3 or less, preferably 44 kg / m 3 or less, more preferably 42 kg / m 3 [[ID=1​​​​​​​​​​​​​​​​​​​​​The gypsum board core layer 42 is not particularly limited as long as it is a commonly used material, and may be manufactured using, for example, gypsum, an adhesion enhancer, a dispersant, a foaming agent, and gypsum containing glass fibers.

[0021] The lower and upper limits of the thickness of the gypsum board core layer 42 can be freely set as long as they do not impair the purpose or effect of this technology. The lower limit of the thickness of the gypsum board core layer 42 may be, for example, 4.5 mm or more, preferably 5.0 mm or more, and more preferably 5.5 mm or more. The upper limit of the thickness of the gypsum board core layer 42 may be, for example, 15.5 mm or less, preferably 15.0 mm or less, and more preferably 14.5 mm or less.

[0022] As shown in Figure 3, the structure of the gypsum board surface layer 44 is not particularly limited as long as it does not impair the function and effect of this technology, and may consist of a single layer or multiple layers. In this technology, it is preferable that the gypsum board surface layer 44 consists of multiple layers. An example of the structure of the gypsum board surface layer 44 is that it may have a coating layer 52 that covers the surface of the gypsum board core material layer 42 and a coating layer 54 painted on the coating layer 52. The stacking order of these layers is not limited.

[0023] The coating layer 52 is not particularly limited as long as it does not impair the function and effects of this technology, but examples include non-combustible paper such as glass paper and aluminum hydroxide-containing paper, ceramic sheets, and mixed paper of glass fibers and pulp. In this embodiment, the coating layer 52 is aluminum hydroxide-containing paper.

[0024] The lower and upper limits of the thickness of the coating layer 52 can be freely set as long as they do not impair the purpose or effect of this technology. The lower limit of the thickness of the coating layer 52 may be, for example, 0.04 mm or more, preferably 0.06 mm or more, and more preferably 0.08 mm or more. The upper limit of the thickness of the coating layer 52 may be, for example, 0.45 mm or less, preferably 0.40 mm or less, and more preferably 0.35 mm or less.

[0025] The coating layer 54 is not particularly limited as long as it does not impair the function or effect of this technology, but examples include acrylic resin paints and vinyl acetate resin paints.

[0026] The lower and upper limits of the coating layer 54 can be freely set as long as they do not impair the purpose or effect of this technology. If the coating layer 54 is an acrylic resin paint, the lower limit of the coating layer 54 can be, for example, 40 g / m² (as solid content). 2 Preferably 50 g / m² 2 More than 60g / m 2 The above is sufficient. Furthermore, the upper limit of the coating amount of the coating layer 54 can be freely set as long as it does not impair the purpose or effect of this technology, for example, 115 g / m² (as solid content). 2 The following is preferably 105 g / m² 2 More preferably 95 g / m 2 The following is acceptable:

[0027] If the coating layer 54 is a vinyl acetate resin paint, the lower limit of the coating layer 54 application amount is, for example, 50 g / m² (as solid content). 2 Preferably 60 g / m² 2 Above, a comfortable 70g / m 2 The above is sufficient. Furthermore, the upper limit of the coating layer 54 can be freely set as long as it does not impair the purpose or effect of this technology, for example, 140 g / m² (as solid content). 2 Preferably 130 g / m² 2 More preferably 125 g / m² 2 The following is acceptable:

[0028] The lower limit of the thickness of the gypsum board 40 can be freely set as long as it does not impair the purpose and effect of this technology, but for example it may be 5.0 mm or more, preferably 5.5 mm or more, and more preferably 6.0 mm or more. The upper limit of the thickness of the gypsum board 40 can also be freely set as long as it does not impair the purpose and effect of this technology, but for example it may be 16.0 mm or less, preferably 15.5 mm or less, and more preferably 15.0 mm or less.

[0029] The insulation material 10 and the gypsum board 40 are bonded to each other. The method for bonding the gypsum board 40 and the insulation material 10 is not particularly limited as long as it is a commonly used method, for example, a bonding method using adhesive or a heat-fusion method. In this embodiment, the insulation material 10 and the gypsum board 40 are bonded to each other with adhesive. That is, an adhesive layer 62 is provided between the gypsum board 40 and the insulation material 10.

[0030] The adhesive layer 62 is not particularly limited as long as it does not impair the function and effects of this technology, but examples include styrene-butadiene rubber adhesives. Styrene-butadiene rubber adhesives that can be used in this technology can be manufactured by general methods. For example, a styrene-butadiene rubber adhesive used in the adhesive layer 62 can be manufactured using a composition containing styrene-butadiene rubber resin (e.g., 25% to 60% by mass); a crosslinking agent (e.g., 20% or more by mass); and an inorganic filler (e.g., 20% to 50% by mass). The crosslinking agent is not particularly limited as long as it does not impair the function and effects of this technology, but examples include diphenylmethane diisocyanate (MDI). The inorganic filler is not particularly limited as long as it does not impair the function and effects of this technology, but examples include calcium carbonate.

[0031] The amount of adhesive layer 62 applied can be freely set as long as it does not impair the purpose or effect of this technology. For example, the amount of adhesive layer 62 applied may be 80 g / m² (as solid content). 2 The following amounts are acceptable, but are not limited to these application amounts. Furthermore, the application amount of the adhesive layer 62 may be, for example, 45 g / m² (as organic mass). 2 The following amounts are acceptable, but are not limited to these application amounts.

[0032] As shown in Figure 4, the side of the gypsum board 40 facing the insulation layer 12 is larger than or equal to the side of the insulation material 10 facing the gypsum board 40. Specifically, the front and back surfaces of the gypsum board 40 are larger than or equal to the front and back surfaces of the insulation material 10. More specifically, in a plan view, the periphery of the gypsum board 40 overlaps with the periphery of the insulation material 10, or extends outward beyond the periphery of the insulation material 10. That is, each side surface of the gypsum board 40 (the surface perpendicular to the front and back surfaces of the gypsum board 40) is on the same plane as the corresponding side surface of the insulation material 10 (the surface perpendicular to the front and back surfaces of the insulation material 10), or is located outside the corresponding side surface of the insulation material 10. In this embodiment, the side of the gypsum board 40 facing the insulation layer 12 is larger than the side of the insulation material 10 facing the gypsum board 40, that is, each side surface of the gypsum board 40 is located outside the corresponding side surface of the insulation material 10.

[0033] <Design section 80> As shown in Figures 1 and 3, the interior building material 1 according to this technology includes a design portion 80 provided on the side of the gypsum board 40 opposite to the side that is adhered to the insulation material 10. The design portion 80 is a visible part of the interior building material 1 according to this technology to which a pattern, color, or a combination thereof has been applied. For example, the design portion 80 may be a part that is involved in forming the pattern of the interior building material 1 according to this technology. Examples of patterns include embossed patterns and travertine patterns.

[0034] The design portion 80 according to this technology should reflect the shape of the surface portion of the gypsum board 40. That is, in the design portion 80 according to this technology, it is preferable that a plurality of recesses and / or protrusions formed on the surface of the gypsum board core material layer 42 directly and / or indirectly reflect the pattern. Direct and / or indirect involvement means that the recesses and / or protrusions that form the pattern as the design portion 80 may include exposed recesses and / or protrusions formed on the surface of the gypsum board core material layer 42, or may include recesses and / or protrusions of the gypsum board core material layer 42 reflected via another member.

[0035] As shown in Figure 3, in this embodiment, the design portion 80 includes a plurality of recesses 48 formed on the surface of the gypsum board core material layer 42 to form a travertine pattern, and a gypsum board surface layer 44 (painted layer 54) that reflects these recesses 48.

[0036] Multiple recesses 48 formed on the surface of the gypsum board core material layer extend irregularly in the direction of the surface of the gypsum board core material layer 42, and their depth, length, and width may also be irregular.

[0037] The shape of the gypsum board surface layer 44 is not particularly limited, as long as it reflects the recesses 48 of the gypsum board core layer 42. In this embodiment, the coating layer 52 of the gypsum board surface layer 44 has recesses 58 formed therein that correspond to the multiple recesses 48 formed on the surface of the gypsum board core layer 42. The coating layer 54 of the gypsum board surface layer 44 includes painted portions at the bottom and sides of each recess 58 of the coating layer 52.

[0038] In other embodiments, the coating layer 52 of the gypsum board surface layer 44 may have through holes to expose the multiple recesses 48 formed on the surface of the gypsum board core layer 42. In other embodiments, the coating layer 54 of the gypsum board surface layer 44 may include painted portions on the bottom and sides of each recess 48 of the gypsum board core layer 42.

[0039] <Manufacturing of interior building material 1 related to this technology> The manufacturing method for the interior building material 1 related to this technology includes a step of manufacturing an insulating material 10 and a step of manufacturing a gypsum board 40.

[0040] The process for manufacturing the thermal insulation material 10 is not limited as long as it does not impair the function or effect of this technology, and may be a general method. For example, first, a foam to be used for the thermal insulation layer 12 may be manufactured using a polyisocyanurate foam manufacturing composition containing polyols such as polyisocyanate (e.g., 60% by mass or more), polyether-based polyols (e.g., 0.1% by mass or more), polyester-based polyols (e.g., 5% by mass or more), a blowing agent, a catalyst, a foam stabilizer, a flame retardant, and other additives. If necessary, the thermal insulation material 10 is manufactured by providing a thermal insulation surface layer 14 and a thermal insulation back layer 16 on the thermal insulation layer 12.

[0041] In the process of manufacturing the gypsum board 40, at least the design portion 80 is formed. The process of manufacturing the gypsum board 40 is not limited as long as it does not impair the function and effect of the present technology, but in this embodiment, first, a gypsum slurry, which is a mixture of gypsum and water, is poured into a mold. Next, the coating layer 52 of the gypsum board surface layer 44 is placed on the area that may become the surface of the gypsum board core material layer 42. Next, a mold having a plurality of protrusions is pressed onto the area that may become the surface of the gypsum board core material layer 42. Next, the gypsum slurry is hardened. Next, the mold having a plurality of protrusions is removed. Next, the coating layer 54 is applied to the surface of the gypsum board core material layer 42.

[0042] In other embodiments, the coating layer 52 of the gypsum board surface layer 44 does not need to be placed on the surface of the gypsum board core layer 42. In this case, the coating layer 52 may be provided on the surface of the gypsum board core layer 42 after a plurality of recesses 48 corresponding to a plurality of protrusions have been formed on the surface of the gypsum board core layer 42. If necessary, the coating layer 52 may have recesses 58 or through holes that reflect the recesses 48 of the gypsum board core layer 42.

[0043] The manufacturing method of the interior building material 1 according to this technology includes a step of bonding the insulation material 10 and the gypsum board 40. The step of bonding the insulation material 10 and the gypsum board 40 is not limited as long as it does not impair the function or effect of this technology, and may be a general method. For example, after applying an adhesive layer 62 to the back surface of the gypsum board 40, the surface of the insulation material 10 may be brought into contact with the back surface of the gypsum board 40 via the adhesive layer 62. This bonds the insulation material 10 and the gypsum board 40 to each other.

[0044] In other embodiments, the step of bonding the insulation material 10 and the gypsum board 40 may be included in the step of manufacturing the insulation material 10. For example, an adhesive layer 62 may be applied to the back surface of the gypsum board 40 in advance, and an insulation material surface layer 14 may be prepared as needed. Then, the foam used for the insulation layer 12 may be foamed, thereby bonding the insulation material 10 and the gypsum board 40 together with the formation of the foam.

[0045] As described above, in the manufacturing method of the interior building material 1, particularly in the process of manufacturing the gypsum board 40, a plurality of recesses 48 corresponding to a plurality of protrusions are formed on the surface of the gypsum board core layer 42, and a plurality of recesses 58 corresponding to the plurality of recesses 48 formed on the surface of the gypsum board surface layer 44 are formed in the coating layer 52. In other words, the design portion 80 is formed in the process of manufacturing the gypsum board 40. Therefore, the design portion 80 is not formed at the construction site.

[0046] Furthermore, by ensuring that the side of the gypsum board 40 facing the insulation layer 12 is greater than or equal to the side of the insulation material 10 facing the gypsum board 40, the difference in right-angle accuracy between the insulation material 10 and the gypsum board 40 can be eliminated. In addition, the misalignment that occurs between the insulation material 10 and the gypsum board 40 during the bonding process can be eliminated.

[0047] <Applications of interior building material 1 related to this technology> The interior building material 1 according to this technology is used for the interior of a ceiling. Specifically, the interior of a ceiling is constructed by arranging multiple interior building materials 1 in the vertical and horizontal directions. That is, the interior building materials 1 are arranged so that the surface of the gypsum board 40 faces downward. As shown in Figure 5, the arrangement of the interior building materials 1 is not particularly limited as long as it does not impair the purpose and effect of this technology, but in this embodiment, the interior building materials 1 are arranged so that there are no gaps between the gypsum board 40 of adjacent interior building materials 1. The structure of a ceiling using the interior building material 1 according to this technology is not particularly limited as long as it does not impair the purpose and effect of this technology, but for example, it has multiple furring strips (not shown) provided on the ceiling and multiple interior building materials 1 fixed to these furring strips.

[0048] In this case, since each side of the gypsum board 40 is on the outside of the corresponding side of the insulation material 10, a gap is formed between the insulation materials 10 of adjacent interior building materials 1. This reduces the causes of problems during on-site installation work. For example, each insulation material 10 does not receive external force from other insulation materials 10 adjacent to it. Therefore, the interior building materials 1 can be placed without placing an excessive load on the insulation material 10. Furthermore, if each side of the gypsum board 40 is on the same plane as the corresponding side of the insulation material 10, each insulation material 10 may come into contact with other insulation materials 10 adjacent to it, but it is unlikely to receive an excessive external force (reaction force) due to contact. Therefore, even if each side of the gypsum board 40 is on the same plane as the corresponding side of the periphery of the insulation material 10, the interior building materials 1 can be placed without placing an excessive load on the insulation material 10.

[0049] As described above, since the interior building material 1 according to this technology has a design portion 80, there is no need to apply finishing materials such as wallpaper or paint to the gypsum board 40 at the construction site. Therefore, the construction period required for interior work can be shortened, and consequently, the construction period required for the building can be shortened. In addition, the cost of finishing materials can be reduced. Furthermore, since the insulation material 10 of the interior building material 1 according to this technology functions as a so-called base material and is bonded to the gypsum board 40, the process of separately installing the insulation material 10 at the construction site can be shortened. Therefore, the construction period required for interior work can be shortened even further, and consequently, the construction period required for the building can be shortened even further. [Explanation of Symbols]

[0050] 1: Interior building materials 10: Insulation 40: Gypsum board 48: Recess 54: Paint layer 80: Design Department

Claims

1. Insulation material, The insulation material has a gypsum board bonded to it, An interior building material comprising a decorative portion on the side of the gypsum board opposite to the side that is adhered to the insulation material.

2. The interior building material according to claim 1, wherein the design portion includes a plurality of recesses and / or protrusions formed on the surface of the gypsum board.

3. The interior building material according to claim 1, wherein the surface of the gypsum board facing the insulation material is greater than or equal to the surface of the insulation material facing the gypsum board.

4. An interior building material according to claim 1, used for interior ceiling finishes.

5. The interior building material according to claim 1, wherein the thermal insulation material includes a foam formed from at least one selected from the group consisting of rigid polyurethane foam, polyisocyanurate foam, polystyrene foam, polyolefin ethylene foam, and phenolic foam.

6. The interior building material according to claim 5, wherein the foam is a polyisocyanurate foam which is a reaction product of 60% by mass or more of polyisocyanate, 0.1% by mass or more of polyether-based polyol, and 5% by mass or more of polyester-based polyol.

7. The interior building material according to any one of claims 1 to 6, wherein the design portion further comprises a painted layer.

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