Decorative board

Abstract

To provide a decorative board which has quasi-noncombustibility and is excellent in designability.SOLUTION: A decorative board includes a base material board 2, and a decorative sheet 4 stuck to one surface 2a side of the base material board 2. The base material board 2 is composed of a noncombustible material according to Construction Ministry's notification No. 1400 in 2000 or a quasi-noncombustible material according to Construction Ministry's notification No. 1401 in 2000, and the decorative sheet 4 is composed of a quasi-noncombustible according to Construction Ministry's notification No. 1401 in 2000. An organic mass contained in the decorative sheet 4 is 260 g / m2 or less. An adhesive 3 used in sticking is an adhesive so that a ratio of a starch paste to a synthetic resin emulsion is 100:0 to 80:20.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This invention relates to decorative boards. [Background technology]

[0002] Conventionally, decorative boards have been proposed that consist of a sheet of resin composition laminated onto gypsum board (see, for example, Patent Document 1). Such decorative boards include those that are fire-resistant and semi-noncombustible, which can be used in special buildings such as apartment buildings, hotels, and hospitals (Articles 6, 27, 28, 35-35-3, and 90-3 of the Building Standards Act). [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Publication number 6-6916 [Overview of the project] [Problems that the invention aims to solve]

[0004] However, such decorative boards lack aesthetic appeal and are used in areas that are usually hidden, such as the interior walls of closets, but are rarely used on the walls or ceilings of living rooms, corridors, or entrances. This invention focuses on the points mentioned above and aims to provide a decorative board that is semi-non-combustible and has excellent design. [Means for solving the problem]

[0005] To solve the above problems, one aspect of the present invention comprises (a) a base board, (b) a decorative sheet attached to one side of the base board and having a foamed resin layer and a patterned layer formed on the side of the foamed resin layer opposite to the base board, (c) the base board is a non-combustible material as defined in Ministry of Construction Notification No. 1400 of 2000, or a semi-non-combustible material as defined in Ministry of Construction Notification No. 1401 of 2000, (d) the decorative sheet is a semi-non-combustible material as defined in Ministry of Construction Notification No. 1401 of 2000, and (e) the organic mass contained in the foamed resin layer is 260 g / m². 2 The following conditions apply: (f) The adhesive used for bonding is composed of starch paste and synthetic resin emulsion in a ratio of 100:0 to 80:20; (g) The amount of adhesive applied is 60 g / m² in terms of solid content. 2 The main point is that it is a decorative board as described below. [Effects of the Invention]

[0006] According to one aspect of the present invention, the base board has non-combustible properties, the organic mass of the decorative sheet is limited to an appropriate range, and the mixing ratio and application amount of the adhesive are adjusted to an appropriate range, thereby providing semi-non-combustible properties that can be used in special buildings such as condominiums and hotels. Furthermore, since a decorative sheet is attached, the aesthetic appeal can be improved. Therefore, it is possible to provide a decorative board that is both semi-non-combustible and aesthetically pleasing. [Brief explanation of the drawing]

[0007] [Figure 1] This is a cross-sectional view showing a decorative board according to an embodiment of the present invention. [Modes for carrying out the invention]

[0008] Next, embodiments of the present invention will be described with reference to the drawings. Here, the drawings are schematic, and the relationship between thickness and planar dimensions, the ratio of the thickness of each layer, etc. are different from the actual ones. Further, the embodiments shown below illustrate configurations for embodying the technical idea of the present invention, and the technical idea of the present invention is not specified to the following in terms of the material, shape, structure, etc. of the components. The technical idea of the present invention can be variously modified within the technical scope defined by the claims described in the claims.

[0009] (Decorative board) As shown in FIG. 1, the decorative board 1 of the present embodiment is formed by attaching a decorative sheet 4 via an adhesive 3 to one surface 2a side of a base board 2. The decorative board 1 of the present embodiment complies with ISO5660-1 and in a heating test based on the provisions of Article 1, Paragraph 5 (quasi-non-combustible material) of the Construction Standard Law Construction Example (Cabinet Order No. 338 of 1950), (1) the total heat release amount within 10 minutes after the start of heating is 8 MJ / m 2 as follows, (2) there are no cracks and holes penetrating to the fire-hazardous back surface within 10 minutes after the start of heating, and (3) the maximum heat release rate does not exceed 200 kW / m continuously for 10 seconds or more within 10 minutes after the start of heating. 2 It has quasi-non-combustibility satisfying the conditions.

[0010] (Base board) As the base board 2, a non-combustible material defined in the Ministry of Construction Notification No. 1400 of 2000 or a quasi-non-combustible material defined in the Ministry of Construction Notification No. 1401 of 2000 is used. For example, a gypsum board, a glass fiber mixed cement board, a fiber mixed calcium silicate board, a rock wool board, or a glass wool board can be adopted. Further, the base board 2 may be provided with various functions such as sound absorption performance, moisture absorption and desorption performance, formaldehyde absorption and decomposition performance, etc. Further, as the thickness of the base board 2, for example, 9 mm to 15 mm can be adopted.

[0011] (Adhesive) As the adhesive 3, a simple starch paste or a mixture of starch paste and synthetic resin emulsion is used. As the synthetic resin emulsion, for example, vinyl acetate resin emulsion, ethylene vinyl acetate resin, or acrylic resin emulsion can be adopted. From the perspective of non-combustion performance, the ratio of starch paste to synthetic resin emulsion is set to 100:0 to 80:20. When the ratio of the synthetic resin emulsion is larger than 80:20, the organic mass increases and the non-combustion performance decreases. Note that 100:0 represents the case of using only starch paste. Also, considering adhesion, the ratio of starch paste to synthetic resin emulsion is preferably 95:5 to 80:20. When the ratio of the synthetic resin emulsion is smaller than 95:5, the adhesion between the base board 2 and the decorative sheet 4 decreases, causing the ends of the decorative sheet 4 to lift.

[0012] In addition, from the perspective of non-combustion performance, the application amount of the adhesive 3 is 60 g / m 2 or less in terms of solid content. When it is larger than 60 g / m 2 , the organic mass increases and the non-combustion performance decreases. Also, considering adhesion, the application amount of the adhesive 3 is preferably 20 g / m 2 or more and 60 g / m 2 or less. When it is less than 20 g / m 2 , the adhesion between the base board 2 and the decorative sheet 4 decreases, causing the ends of the decorative sheet 4 to lift. Also, as the adhesive 3, it is preferable to use a product that meets the quality standards of JIS A 6922(1), has a JIS mark, or has equivalent quality, has received ministerial approval for non-regulated formaldehyde emission, and has been registered with the Japan Wallcovering Association after confirmation of non-exothermic properties (2).

[0013] (Decorative Sheet) As the decorative sheet 4, a semi-noncombustible material as specified in Ministry of Construction Notification No. 1401 of 2000 is used. As the decorative sheet 4, for example, a foamed wallpaper can be used which comprises a foamed resin layer 6 and a patterned layer 7 formed on the side 6a of the foamed resin layer 6 opposite to the base board 2. The foamed resin layer 6 is formed by foaming a layer made of a resin composition containing a resin and a foaming agent (for example, a pyrolysis-type foaming agent, a microencapsulated foaming agent). As the resin constituting the foamed resin layer 6, for example, a vinyl chloride resin or an olefin resin can be used. The total mass of the foamed resin layer 6 is 400 g / m². 2 The following applies. Furthermore, the organic mass of the foamed resin layer 6 is 260 g / m². 2 The following applies: 260g / m² 2 If the value is greater, the fire-resistant performance will decrease.

[0014] The pattern layer 7 is formed by printing a pattern using printing ink. As the printing ink, one or more of the following can be used as a vehicle: chlorinated polyethylene, chlorinated polyolefins such as chlorinated polypropylene, polyester, polyurethane made from isocyanate and polyol, acrylic, vinyl acetate, vinyl chloride / vinyl acetate copolymer, cellulose resin, polyamide resin, etc., to which pigments, solvents, various auxiliary agents can be added to make the ink. Examples of patterns include wood grain, stone pattern, fabric pattern, leather pattern, geometric figures, letters, symbols, or solid colors.

[0015] A backing material 5 may be formed between the base board 2 and the foamed resin layer 6. As the backing material 5, for example, a nonwoven fabric containing papermaking material such as flame-retardant paper, Japanese paper, or glass fiber nonwoven fabric can be used. In addition, a topcoat layer 8 may be formed on the side 7a of the patterned layer 7 opposite to the foamed resin layer 6. Lamination with EVAL film may also be performed. Furthermore, there are no particular restrictions on the thickness of the decorative sheet 4, but considering crushing during product storage, it is preferable to have a thickness of less than 450 μm.

[0016] As described above, the decorative board 1 according to this embodiment comprises a base board 2 and a decorative sheet 4 attached to one side 2a of the base board 2, having a foamed resin layer 6 and a patterned layer 7 formed on the side 6a of the foamed resin layer 6 opposite to the base board 2. The base board 2 is made of a non-combustible material as defined in Ministry of Construction Notification No. 1400 of 2000 or a semi-non-combustible material as defined in Ministry of Construction Notification No. 1401 of 2000, and the decorative sheet 4 is made of a semi-non-combustible material as defined in Ministry of Construction Notification No. 1401 of 2000. Furthermore, the organic mass contained in the decorative sheet 4 is 260 g / m². 2 The following was determined. Furthermore, the adhesive 3 used for bonding was an adhesive composed of starch paste and synthetic resin emulsion in a ratio of 100:0 to 80:20.

[0017] Therefore, since the base board 2 has non-combustible properties, the organic mass of the decorative sheet 4 is limited to an appropriate range, and the mixing ratio and application amount of the adhesive 3 are adjusted to an appropriate range, it is possible to provide semi-non-combustible properties that can be used in special buildings such as condominiums and hotels. In addition, the decorative sheet is attached, which improves the aesthetic appearance. Therefore, it is possible to provide a decorative board 1 that is both semi-non-combustible and aesthetically pleasing. Furthermore, unlike general interior walls which require many steps and time, such as gypsum board installation, puttying, drying, wall surface installation, and drying, interior walls using such a decorative board 1 can be expected to be less labor-intensive as it only requires direct installation to the lightweight steel frame or wall material, eliminating the need for subsequent steps. In addition, since wall surface installation is completed by installing the base board 2, it is possible to prevent unevenness of the substrate, and cracking and tearing of the decorative sheet 4 due to earthquakes or aging.

[0018] Furthermore, in the decorative board 1 according to this embodiment, in a heating test based on ISO 5660-1 and Article 1, Item 5 (semi-noncombustible materials) of the Building Standards Act Enforcement Example (Cabinet Order No. 338 of 1950), (1) the total heat output for 10 minutes after the start of heating was 8 MJ / m². 2 (2) For the first 10 minutes after heating begins, there are no cracks or holes penetrating to the back surface which would be harmful from a fire safety perspective, and (3) for the first 10 minutes after heating begins, the maximum heating rate remains at 200 kW / m² for at least 10 seconds. 2It has been made to have semi-non-combustible properties that do not exceed certain conditions. Therefore, it can be used in special buildings such as condominiums and hotels. Furthermore, in the decorative board 1 according to this embodiment, the adhesive 3 used for bonding contains starch paste and synthetic resin emulsion in a ratio of 95:5 to 80:20, and the amount of adhesive 3 applied is 20 g / m² in terms of solid content. 2 More than 60g / m 2 The following measures can be taken to improve adhesion.

[0019] (Examples) Examples and comparative examples of decorative board 1 according to the embodiment of the present invention are described below. However, the present invention is not limited to the following examples.

[0020] (Example 1) First, as backing material 5, the basis weight is 65g / m². 2 Plain paper (manufactured by Nippon Paper Industries Co., Ltd.: "NI65AT") was prepared. Next, a paste was applied to the surface of the backing material 5 by coating method, consisting of 100 parts by mass of EVA resin (manufactured by Sumika Chemtex: "S-7400(HQ)"), 12.2 parts by mass of a heat-expandable microcapsule foaming agent (Matsumoto Oil & Fat Pharmaceutical Co., Ltd.: "FT-16"), and 90 parts by mass of the inorganic powder calcium carbonate (manufactured by Asahi Mining & Spray Co., Ltd.: "MC-100"). The organic mass of the foamed resin layer 6 was 200 g / m². 2 Next, a pattern was printed onto the surface of the foamed resin layer 6 using gravure printing with an acrylic resin-based ink to form a patterned print layer. The basis weight of the patterned print layer was 2 g / m². 2 Next, an acrylic topcoat was applied to the surface of the printed image layer using the gravure coating method to form topcoat layer 8. The basis weight of the topcoat layer was 5 g / m². 2 Next, the foaming agent was heated and foamed, an embossed pattern was applied to the surface protective layer side by applying pressure with an embossing roll, and the whole was cooled and dried to form a decorative sheet 4 (semi-noncombustible material) with semi-noncombustible and noncombustible properties.

[0021] Next, adhesive 3, a mixture of starch paste and synthetic resin emulsion, was applied to the backing material 5 of the formed decorative sheet 4 using a lip coater, and then dried with 55°C hot air for 60 seconds. Ethylene vinyl acetate resin was used as the synthetic resin emulsion. The amount of adhesive 3 applied was 40 g / m² in terms of solid content. 2 Next, the decorative sheet 4 was attached to the base board 2 via the coated adhesive 3. As the base board 2, a gypsum board (Tiger Board GB-R9) with a thickness of 9.5 mm and square edges, which has the fire-retardant properties of a semi-noncombustible material (QM-9828), was used. Subsequently, the surface of the decorative sheet 4 was laminated with EVAL film using a hot roll. This produced the decorative sheet 4 of Example 1.

[0022] (Example 2) In Example 2, a vinyl-based wallpaper having a foamed resin layer 6 was used as the decorative sheet 4. This layer was prepared by applying a paste containing 100 parts by mass of vinyl chloride resin (Tosoh Corporation: "T-70A"), 165 parts by mass of filler (Bihoku Funka Kogyo Co., Ltd.: "BF-200S"), and 2.5 parts by mass of foaming agent (Unicel Co., Ltd.: "OH-300N"). The decorative board 1 of Example 2 was prepared in the same manner as in Example 1. (Example 3) In Example 3, the organic mass of the foamed resin layer 6 was 260 g / m². 2 The decorative board 1 of Example 2 was manufactured in the same manner as in Example 1.

[0023] (Example 4) In Example 4, the organic mass of the foamed resin layer 6 was 260 g / m². 2 The decorative board 1 of Example 4 was manufactured in the same manner as in Example 2. (Example 5) In Example 5, the amount of adhesive 3 applied was 10 g / m² in terms of solid content. 2 The decorative board 1 of Example 5 was manufactured in the same manner as in Example 3. (Example 6) In Example 6, the amount of adhesive 3 applied was 20 g / m² in terms of solid content. 2The decorative board 1 of Example 6 was manufactured in the same manner as in Example 3.

[0024] (Example 7) In Example 7, the amount of adhesive 3 applied was 60 g / m² in terms of solid content. 2 The decorative board 1 of Example 7 was manufactured in the same manner as in Example 3. (Example 8) In Example 8, the mixing ratio of the starch paste and synthetic resin emulsion in adhesive 3 was set to 100:0. Otherwise, the decorative board 1 of Example 8 was prepared in the same manner as in Example 3. (Example 9) In Example 9, the mixing ratio of the starch paste and synthetic resin emulsion in adhesive 3 was set to 85:15. Otherwise, the decorative board 1 of Example 9 was prepared in the same manner as in Example 1.

[0025] (Comparative Example 1) In Comparative Example 1, the organic mass of the foamed resin layer 6 was 300 g / m². 2 The decorative board 1 of Comparative Example 1 was prepared in the same manner as in Example 1. (Comparative Example 2) In Comparative Example 2, the organic mass of the foamed resin layer 6 was 300 g / m². 2 The decorative board 1 of Comparative Example 2 was prepared in the same manner as in Example 2.

[0026] (Comparative Example 3) In Comparative Example 3, the amount of adhesive 3 applied was 80 g / m² in terms of solid content. 2 The decorative board 1 of Comparative Example 3 was prepared in the same manner as in Example 3. (Comparative Example 4) In Comparative Example 4, the mixing ratio of the starch paste and synthetic resin emulsion in adhesive 3 was set to 75:25. Otherwise, the decorative board 1 of Comparative Example 4 was prepared in the same manner as in Example 3.

[0027] (Performance evaluation) The following performance evaluations were performed on decorative board 1 of Examples 1-9 and Comparative Examples 1-4. (Nonflammable performance) In the evaluation of semi-noncombustibility, in accordance with ISO 5660-1, a heating test was conducted based on the provisions of Article 1, Item 5 (Semi-noncombustible materials) of the Building Standards Act Enforcement Regulations (Cabinet Order No. 338 of 1950) to determine whether all of the following criteria (1), (2), and (3) were satisfied. If the criteria were found to be satisfied, it was marked as a pass "○", and if they were found not to be satisfied, it was marked as a fail "×". (1) Total heat output for the first 10 minutes after the start of heating is 8 MJ / m² 2 below (2) For 10 minutes after the start of heating, there are no cracks or holes that penetrate to the back surface which would be harmful from a fire safety standpoint. (3) For the first 10 minutes after heating begins, the maximum heating rate remains at 200 kW / m² for at least 10 seconds. 2 Do not exceed

[0028] (Adhesion) In the adhesion evaluation, immediately after attaching (wrapping) the decorative sheet 4 to the base board 2, we checked for any lifting (rebounding) at the edges of the decorative sheet 4. If no lifting was detected, it was marked as a pass ("○"), and if lifting was detected, it was marked as a fail ("×"). (Evaluation results) The evaluation results are shown in Table 1. In addition to the evaluation results for "non-combustible performance" and "adhesion," Table 1 also shows the "overall evaluation" results based on these evaluations. In the "overall evaluation," "○" and "△" are considered passing grades, and "×" is considered a failing grade.

[0029] [Table 1]

[0030] As shown in Table 1 above, in the decorative board 1 of Examples 1 to 9, the evaluation result for "non-combustible performance" was a pass ("○"), and the "overall evaluation" was a pass ("○") or a "△" ("△"). Specifically, in Examples 1 to 4, 6, 7, and 9, "non-combustible performance" and "adhesion" were both pass ("○"), and the "overall evaluation" was a pass ("○"). In Example 4, "non-combustible performance" was a pass ("○"), but the amount of adhesive 3 applied was 10g / m² in terms of solid content. 2Because the amount was reduced, the "adhesion" was a failure ("×"), and the overall evaluation was a passing grade ("△"). In addition, in Example 8, the "non-flammability" was a passing grade ("○"), but because the mixing ratio of starch paste and synthetic resin emulsion in adhesive 3 was set to 100:0 (more starch paste), the "adhesion" was a failure ("×"), and the overall evaluation was a passing grade ("△").

[0031] On the other hand, in the decorative board 1 of Comparative Examples 1 and 2, the organic mass of the foamed resin layer 6 was 300 g / m². 2 Because the amount was increased, the "non-combustible performance" was marked as a failure ("×"), and the "overall evaluation" was also marked as a failure ("×"). In addition, in Comparative Example 3, for decorative board 1, the amount of adhesive 3 applied was 80 g / m² in terms of solid content. 2 Because the amount was increased, the "non-combustible performance" was rejected ("×") and the "overall evaluation" was rejected ("×"). In addition, in the decorative board 1 of comparative example 4, the mixing ratio of the starch paste and synthetic resin emulsion in adhesive 3 was set to 75:25 (the amount of synthetic resin emulsion was increased), so the "non-combustibility" was rejected ("×") and the "overall evaluation" was rejected ("×").

[0032] Therefore, it was confirmed that the decorative boards 1 of Examples 1 to 9, unlike the decorative boards 1 of Comparative Examples 1 to 4, possess semi-noncombustible properties. Furthermore, it was confirmed that the decorative boards 1 of Examples 1 to 9 have improved aesthetic appeal because they are covered with decorative sheets 4. Thus, it was confirmed that it is possible to provide decorative boards 1 that are both semi-noncombustible and have excellent aesthetic appeal. In addition, it was confirmed that the decorative boards 1 of Examples 1 to 4, 6, 7, and 9, unlike the decorative boards 1 of Examples 5 and 8, have excellent adhesion between the base board 2 and the decorative sheet 4. [Explanation of symbols]

[0033] 1... Decorative board, 2... Base board, 3... Adhesive, 4... Decorative sheet, 5... Backing material, 6... Resin layer

Claims

1. Base board and The backing material, foamed resin layer, pattern layer, and topcoat layer are laminated in this order to form the structure. A decorative sheet is provided, in which the backing material is attached to the base board via an adhesive, The aforementioned base board is a non-combustible material as defined in Ministry of Construction Notification No. 1400 of 2000, or a semi-non-combustible material as defined in Ministry of Construction Notification No. 1401 of 2000. The aforementioned decorative sheet is a semi-noncombustible material as defined in Ministry of Construction Notification No. 1401 of 2000. The basis weight of the aforementioned backing material is 65 g / m². 2 And, The organic mass contained in the foamed resin layer is 260 g / m2. The basis weight of the patterned layer is 2 g / m². 2 And, The basis weight of the top coat layer is 5 g / m². 2 And, The aforementioned adhesive is composed of starch paste and synthetic resin emulsion in a ratio of 95:5 to 80:

20. The amount of adhesive applied is 20 g / m² in terms of solid content. 2 60g / m or more 2 A decorative board characterized by the following:

2. In accordance with ISO 5660-1, and based on the provisions of Article 1, Item 5 (Semi-noncombustible materials) of the Building Standards Act Enforcement Order (Cabinet Order No. 338 of 1950), in a heating test, (1) the total heat output for the first 10 minutes after the start of heating was 8 MJ / m³. 2 The following conditions must be met: (2) For 10 minutes after the start of heating, there must be no cracks or holes penetrating to the back surface which would be harmful from a fire safety perspective; and (3) For 10 minutes after the start of heating, the maximum heating rate must be 200 kW / m² for at least 10 seconds. 2 The decorative board according to claim 1, characterized in that it has semi-noncombustible properties that satisfy the condition not exceeding the limit.

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