Base material for interior wall material and method of manufacturing the same

Abstract

To provide an underlying base material for interior wall material which does not need formation or cure of a sealer layer, which does not need to form a sealer layer at a butt end for wrapping and adhering the butt end, which does not have a risk of occurrence of warpage caused by single-sided coating, and which can save the time and labor for re-adhering of a decorative film, and to provide a manufacturing method of the same.SOLUTION: An underlying base material for interior wall is a single layer structure in which main components are a silicious raw material, a calcareous raw material and a reinforcement fiber, and which includes an aqueous sealer component together with these main components. The content of the aqueous sealer component is within a range of 30-50 pts.mass with respect to 100 pts.mass of the main components.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a base substrate for interior wall materials and a manufacturing method thereof, and more particularly to a base substrate for manufacturing non-flammable interior wall materials by attaching any decorative film to the surface thereof, and a manufacturing method thereof. [Background technology]

[0002] Conventionally, known interior wall materials include those in which the surface of an inorganic substrate such as gypsum board or calcium silicate board is UV-coated, and those in which a decorative layer is provided using a decorative film such as a vinyl chloride sheet or diallyl phthalate-impregnated paper. These interior wall materials have a non-flammable inorganic substrate as their core material, and therefore have superior fire resistance compared to interior wall materials with a wood-based substrate as their core material. Therefore, they are widely used for the walls of commercial facilities, public facilities, etc., and the interior decoration of homes.

[0003] The inorganic substrates, such as the above-mentioned gypsum boards and calcium silicate boards, have rough surfaces, making it difficult to directly adhere a decorative film having an adhesive layer on the back surface thereto, and therefore cannot be used as a base substrate for interior wall materials as is. Therefore, in order to enable the attachment of a decorative film, it was necessary to form a sealer layer on the surface of the inorganic substrate to smooth it (Patent Document 1). Then, after forming a sealer layer on the surface of the inorganic substrate and smoothing it, the product was supplied to the market with a decorative film attached thereon.

[0004] Thus, conventional interior wall materials with an inorganic base material such as calcium silicate board as a core material have been manufactured with a decorative film attached to the core material and supplied to the market in this state, but while this is not a major problem if the same product is to be mass-produced, it is not economically feasible to meet the demand for small lots of a wide variety of products. In other words, manufacturing and stocking a large number of interior wall materials with decorative films attached in different patterns in advance, for each pattern, is not profitable as there is a possibility of a lot of waste, and there is also the problem of the space required for storage.

[0005] To solve these problems, the applicant of the present application has previously proposed a base material used in the manufacture of non-combustible interior wall materials that can meet the demand for small lots and a wide variety of products (Patent Document 2). This base material comprises a calcium silicate board with a sealer layer formed on the surface with an aqueous sealer for adhering a resin decorative film, and is distributed as a common material for interior wall materials in a state before the decorative film is adhered. According to this invention, the base material, which is a common material for each interior wall material, is distributed as an independent product, enabling interior wall material manufacturers to use it to manufacture interior wall materials with desired patterns and colors, thereby meeting the demand for a wide variety of non-combustible interior wall materials in small lots. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-83269 [Patent Document 2] Japanese Patent Publication No. 2022-20550 Summary of the Invention [Problem to be solved by the invention]

[0007] The base substrate described in Patent Document 2 can meet the demand for supplying a wide variety of small lots of non-flammable interior wall materials, but it has been found that if a decorative film is attached immediately after forming a sealer layer on the surface of the inorganic base material, sufficient peel strength may not be obtained, and it is necessary to cure the base substrate after forming the sealer layer.As a result, a new problem has arisen in that the decorative film attachment process cannot be started for a long time (several days to several weeks) after the sealer layer formation process, and it is necessary to secure time for curing and a storage space during that time.

[0008] Generally, decorative films are applied to the edges (end grain) of the base material to improve its appearance, but applying a uniform sealer layer to the edges (end grain) of an inorganic substrate is not always easy and is a time-consuming task. In addition, because the sealer layer is formed on only one side of the base material, there is a concern that the base material may warp.

[0009] Furthermore, in recent years, there has been an increasing demand for re-applying decorative films to interior wall materials that are already in use. However, in the case of interior wall materials that use a base substrate on which a conventional sealer layer has been formed, the decorative film is first peeled off and then polished to remove any irregularities. However, this treatment damages the sealer layer of the base substrate, so a new sealer layer must be formed and then time must be spent on curing, making the re-applying process complicated and time-consuming, and resulting in problems of increased costs.

[0010] The present invention has been made in view of the problems with the conventional technology, and aims to provide a base substrate for interior wall materials that does not require the formation or curing of a sealer layer, does not require the formation of a sealer layer on the end grain for enveloping and adhering the end grain, does not have the risk of warping due to one-sided application, and does not require the effort of re-application of decorative film, and a method for manufacturing the same. [Means for solving the problem]

[0011] The inventors investigated the reason why sufficient peel strength is not obtained when a decorative film is applied immediately after forming a sealer layer on the surface of an inorganic substrate, and as a result, they concluded that in order to obtain sufficient peel strength, the sealer components must sufficiently fill the voids in the inorganic material, such as calcium silicate board, and become entangled in the structure, and that for this purpose, it is necessary to allow it to cure for a certain period of time, and thus completed the present invention.

[0012] That is, the invention described in claim 1 for solving the above problem is a base substrate for an interior wall material of a single layer structure without a sealer layer on the surface, which contains a siliceous raw material, a calcareous raw material, and reinforcing fibers as main components, and also contains an aqueous sealer component together with the main components. So, The content of the aqueous sealer component is in the range of 30 to 50 parts by mass relative to 100 parts by mass of the main component, and the aqueous sealer component is an aqueous inorganic sealer whose solid content is 100% by mass of silicate. The present invention relates to a base substrate for an interior wall material, characterized in that:

[0013] The invention described in claim 2 for solving the above problem is a base substrate for an interior wall material having a single-layer structure without a sealer layer on the surface, the base substrate containing a siliceous raw material, a calcareous raw material, and reinforcing fibers as main components, and containing an aqueous sealer component together with the main components, The content of the aqueous sealer component is in the range of 30 to 50 parts by mass relative to 100 parts by mass of the main component, and the aqueous sealer component has a solid content of The base material for interior wall materials is characterized by being a water-based acrylic resin paint containing 40 to 60% by mass of acrylic resin and 60 to 40% by mass of silicate.

[0014] In addition, the claims for solving the above problems are 3 The invention described in is a method for manufacturing a base substrate for interior wall materials, characterized in that a dispersion of a main component containing a siliceous raw material, a calcareous raw material, and reinforcing fibers is dispersed in water, and an aqueous sealer component is mixed and kneaded to form a raw material slurry, which is then molded into a desired shape and dried to form a single-layer structure without a sealer layer on the surface.

[0015] In one embodiment, the aqueous sealer component comprises: The amount of the main component is 30 to 50 parts by mass per 100 parts by mass of the main component. The aqueous sealer component is an aqueous inorganic sealer whose solid content is 100% by mass of silicate. Let's say In one embodiment, the aqueous sealer component comprises: The amount of the main component is 30 to 50 parts by mass per 100 parts by mass of the main component. The water-based sealer component is a water-based acrylic resin paint having a solid content of 40 to 60% by mass of acrylic resin and 60 to 40% by mass of silicate. Let's say . [Effects of the Invention]

[0016] The base substrate of the present invention is as described above, and the sealer layer components that help the decorative film adhere well are pre-kneaded into the base substrate during its manufacture and are firmly held in the base substrate in an appropriate amount exposed across the entire surface, eliminating the need for a separate process to form a sealer layer on the base substrate or curing it. A contractor who acquires the base substrate can immediately apply a decorative film with sufficient peel strength, and it is possible to manufacture an interior wall material that is non-flammable. Furthermore, because the sealer components are present almost uniformly throughout the base substrate, there is no risk of the base substrate warping, and the application of a decorative film that wraps around the edge (end grain) of the base substrate can be easily performed without the need to form a sealer layer or curing it. Furthermore, there is the effect of making it possible to easily and inexpensively reapply the decorative film.

[0017] Furthermore, the method for manufacturing the base substrate according to the present invention does not require the formation of a sealer layer or curing treatment, and allows for good adhesion of decorative films and the like, and makes it possible to manufacture interior wall materials that are non-flammable.It is also easy to apply decorative films that wrap around the edge faces (end grain) of the base substrate, and further has the effect of easily manufacturing a base substrate that allows for the decorative films to be easily and inexpensively re-applied. DETAILED DESCRIPTION OF THE INVENTION

[0018] [Base material] The base substrate for interior wall materials according to the present invention has a single-layer structure whose main components are a siliceous raw material, a calcareous raw material, and reinforcing fibers, and which contains an aqueous sealer component in the main components, the content of the aqueous sealer component being in the range of 30 to 50 parts by mass per 100 parts by mass of the main components. Such a base substrate for interior wall materials does not require the formation or curing of a sealer layer, and decorative films and the like can be directly attached. Furthermore, it is possible to manufacture interior wall materials that are non-flammable, and it is also possible to attach decorative films so that they wrap around the end faces (end grain) of the base substrate, and further, the decorative films can be easily reattached.

[0019] The siliceous raw material constituting the base substrate of the present invention can be one or a combination of silica stone powder, silica sand, silica gel, white carbon, diatomaceous earth, etc. The calcareous raw material constituting the base substrate of the present invention can be one or a combination of quicklime, slaked lime, Portland cement, etc. The calcareous raw material and the above siliceous raw material can be such that the CaO / SiO2 (molar ratio) is in the range of 0.5 to 1.2.

[0020] The reinforcing fibers constituting the substrate of the present invention can be one or a combination of glass fibers, carbon fibers, etc. The average fiber length of the reinforcing fibers can be in the range of 20 mm or less. m If the content exceeds this range, it becomes difficult to disperse the reinforcing fibers uniformly, which is undesirable. Such reinforcing fibers can be present in the range of 0.5 to 8 mass % in the main component.

[0021] The base material of the present invention can contain the main components consisting of the above-mentioned siliceous raw material, calcareous raw material, and reinforcing fiber in the range of 67 to 77 mass %.

[0022] The aqueous sealer components constituting the base substrate of the present invention can be one or a combination of several types, such as an aqueous inorganic sealer with a solid content of 100% by mass of silicate, or an aqueous acrylic resin paint with a solid content of 40 to 60% by mass of acrylic resin and 60 to 40% by mass of silicate.

[0023] Such aqueous sealer components are contained in a range of 30 to 50 parts by mass per 100 parts by mass of the main component. If the content of the aqueous sealer components per 100 parts by mass of the main component exceeds 50 parts by mass, the strength of the base substrate may be insufficient, and if it is less than 30 parts by mass, the surface of the base substrate may become rough, which may reduce the adhesion of decorative films and the like to the base substrate.

[0024] The thickness of the base substrate of the present invention can be set depending on the use of the interior wall material obtained by attaching a decorative film or the like to the base substrate, and can be appropriately set, for example, in the range of 3 to 21 mm. The shape of the base substrate may be any of a sheet, plate, elongated body, etc., and the thickness, length, surface shape, etc. can be appropriately set.

[0025] In addition to the main components of the siliceous raw material, the calcareous raw material, and the reinforcing fiber, and the aqueous sealer component, the base substrate of the present invention may contain one or more other components within a range that does not impair the effects of the present invention.

[0026] The base substrate of the present invention can be used as an interior wall material by attaching a desired decorative film selected from a wide variety of decorative resin films to the surface.

[0027] The decorative film to be attached to the base substrate of the present invention is printed with a wood grain pattern or a variety of other patterns and color patterns, and is, for example, a vinyl chloride resin film with a thickness of 0.17 mm or less that can be gravure printed. The decorative film is manufactured separately from the base substrate, and has an adhesive layer on its back surface, with a release paper covering the adhesive layer. When in use, the release paper can be peeled off and the film can be attached to the base substrate for interior wall materials.

[0028] Conventional interior wall substrates have a rough surface, requiring the formation of a sealer layer on the substrate before applying a decorative film. However, the interior wall substrate of the present invention has a sealer component exposed on its entire surface, allowing the decorative film to be applied directly without forming a sealer layer, and it is also possible to apply the decorative film by wrapping around the end face (end grain). Furthermore, the interior wall substrate of the present invention has the sealer component distributed almost evenly throughout the entire interior, eliminating the risk of warping due to one-sided application. Furthermore, if a decorative film needs to be reapplied to an interior wall material using this substrate, the decorative film can be removed and the surface polished to a thickness of several millimeters to reveal a new sealer layer, allowing the desired decorative film to be immediately applied without the need for a separate sealer layer.

[0029] Furthermore, by attaching a decorative film to the base substrate of the present invention, it is possible to manufacture an interior wall material that has non-combustibility. The base substrate of the present invention is certified as non-combustible in the following non-combustibility evaluation according to the non-combustibility test of ISO-5660-1, using an interior wall material in which a decorative film is directly attached to the base substrate as a test specimen. <Non-flammable evaluation> To be certified as non-flammable, the test must be carried out for 20 minutes. Total calorific value (MJ / m 2 ) Total calorific value is 8MJ / m 2 Is less than or equal to Maximum heat release rate (kw / m 2 at) The final heat generation rate is 200kw / m for 10 seconds or more. 2 Not to exceed Appearance condition No penetration, cracks or holes that would be harmful to fire safety must be allowed to the back surface. It is necessary to meet the following conditions.

[0030] Furthermore, the base substrate of the present invention provides high adhesive strength to the decorative film in an interior wall material produced by directly adhering the decorative film, making it difficult for the decorative film to fall off. For example, when the adhesive strength test is a 180-degree peeling test at a speed of 200 mm / min, the maximum adhesive strength (N) is 10 N or more, preferably in the range of 10 to 22 N.

[0031] [Method of manufacturing base material] The method for manufacturing a base substrate for interior wall materials according to the present invention is characterized in that a dispersion of a main component containing a siliceous raw material, a calcareous raw material, and reinforcing fibers is dispersed in water, and an aqueous sealer component is mixed with the dispersion in an amount of 30 to 50 parts by mass per 100 parts by mass of the main component, and kneaded to form a raw material slurry, which is then formed into a desired shape and dried.

[0032] Examples of the siliceous raw material that can be used include silica powder, silica sand, silica gel, white carbon, and diatomaceous earth, and these siliceous raw materials can be used alone or in combination of two or more.

[0033] Examples of calcareous raw materials that can be used include quicklime, slaked lime, Portland cement, etc., and these calcareous raw materials can be used alone or in combination of two or more.

[0034] Such a calcareous raw material and the above siliceous raw material can be blended so that the CaO / SiO2 (molar ratio) is in the range of 0.5 to 1.2.

[0035] Examples of the reinforcing fibers used include glass fibers and carbon fibers, and these reinforcing fibers can be used alone or in combination of two or more. The average fiber length of the reinforcing fibers can be set to 20 mm or less. If the average fiber length of the reinforcing fibers exceeds 20 mm, it becomes difficult to uniformly disperse the reinforcing fibers, which is not preferable.

[0036] Such reinforcing fibers can be blended in the range of 0.5 to 8 mass % in the main component.

[0037] In the method for producing a base material of the present invention, the main components consisting of the above-mentioned siliceous raw material, calcareous raw material and reinforcing fibers are dispersed in water to prepare a dispersion.

[0038] Next, the aqueous sealer components are added to the dispersion as described above, and the mixture is kneaded to prepare a raw material slurry.

[0039] Examples of the aqueous sealer component to be used include an aqueous inorganic sealer with a solid content of 100% by mass of silicate, or an aqueous acrylic resin paint with a solid content of 40 to 60% by mass of acrylic resin and 60 to 40% by mass of silicate.

[0040] The amount of the aqueous sealer component added to the dispersion is set to 30 to 50 parts by mass per 100 parts by mass of the main component. If the amount of the aqueous sealer component added to 100 parts by mass of the main component exceeds 50 parts by mass, the strength of the base substrate produced may be insufficient, while if it is less than 30 parts by mass, the surface of the base substrate produced may become rough, reducing the adhesion of a decorative film or the like to the base substrate.

[0041] In the method for manufacturing a base substrate of the present invention, the raw material slurry is then formed into a desired shape and dried to obtain a base substrate for an interior wall material. The shape of the base substrate may be a sheet, a plate, a long body, or the like, and the thickness, length, surface shape, etc. can be set appropriately.

[0042] The area and shape of the sheet body and the length of the elongated body can be set as appropriate. In forming a base material of a desired shape, for example, a method can be used in which the raw material slurry is formed into a sheet of a desired thickness using a papermaking machine, cured with high-temperature, high-pressure steam to harden, and then dried, or a method can be used in which the raw material slurry is poured into a desired mold, cured with high-temperature, high-pressure steam to harden, and then dried, or a method can be used in which the raw material slurry is cured with high-temperature, high-pressure steam while being stirred, and then dehydration press molding and drying.

[0043] The base material produced as described above has a single-layer structure containing a siliceous raw material, a calcareous raw material, and reinforcing fibers as its main components, and an aqueous sealer component as well. The base material produced by this method can be directly attached with a decorative film without forming a sealer layer or curing, and can produce a non-flammable interior wall material. It can also be attached with a decorative film so that it wraps around the end face (end grain) of the base material, and the decorative film can be easily re-applied.

[0044] In the method for manufacturing a base substrate of the present invention, the raw material slurry may contain, in addition to the main components of the siliceous raw material, the calcareous raw material, and the reinforcing fiber, and the aqueous sealer component, one or more other components within a range that does not impair the effects of the present invention. [Industrial Applicability]

[0045] The base substrate of the present invention is as described above, and the sealer layer components that help the decorative film adhere well are kneaded into the base substrate in advance during its manufacture and are firmly held in the base substrate with an appropriate amount exposed on the surface. This eliminates the need for a separate process to form a sealer layer on the base substrate or to cure it. Any contractor who obtains the base substrate can immediately apply a decorative film with sufficient peel strength, and this has the effect of enabling the production of interior wall materials that are non-flammable. Because the sealer components are distributed almost uniformly throughout the base substrate, there is no need to worry about warping of the base substrate. Furthermore, the application of the decorative film by wrapping around the edge (end grain) of the base substrate can be easily carried out without the need to form a sealer layer or cure it. Furthermore, the decorative film can be easily and inexpensively re-applied. Therefore, the present invention has great industrial applicability.

Claims

1. A base substrate for an interior wall material having a single-layer structure without a sealer layer on the surface, the base substrate containing a siliceous raw material, a calcareous raw material, and reinforcing fibers as main components, and containing an aqueous sealer component together with the main components, The content of the aqueous sealer component is in the range of 30 to 50 parts by mass per 100 parts by mass of the main component, and the aqueous sealer component is an aqueous inorganic sealer whose solid content is 100% by mass of silicate.

2. A base substrate for interior wall materials having a single-layer structure without a sealer layer on the surface, the base substrate containing a silicate material, a calcareous material, and reinforcing fibers as main components, and containing an aqueous sealer component together with the main components, The content of the aqueous sealer component is in the range of 30 to 50 parts by mass per 100 parts by mass of the main component, and the aqueous sealer component is an aqueous acrylic resin paint having a solid content of 40 to 60% by mass of acrylic resin and 60 to 40% by mass of silicate.

3. A method for manufacturing a base substrate for interior wall materials, characterized in that a dispersion of a main component containing a siliceous raw material, a calcareous raw material, and reinforcing fibers is dispersed in water, and an aqueous sealer component is mixed and kneaded to form a raw material slurry, which is then molded into a desired shape and dried to form a single-layer structure without a sealer layer on the surface.

4. A method for manufacturing a base substrate for interior wall materials as described in claim 3, wherein the aqueous sealer component is blended in a range of 30 to 50 parts by mass per 100 parts by mass of the main component, and the aqueous sealer component is an aqueous inorganic sealer whose solid content is 100% by mass of silicate.

5. 4. The method for manufacturing a base substrate for an interior wall material according to claim 3, wherein the aqueous sealer component is blended in a range of 30 to 50 parts by mass with respect to 100 parts by mass of the main component, and the aqueous sealer component is an aqueous acrylic resin paint having a solid content of 40 to 60% by mass of acrylic resin and 60 to 40% by mass of silicate.