Building materials

Abstract

To provide a decorative sheet satisfying the texture of wood and a nonflammable building material using the same.SOLUTION: There is provided a decorative sheet 11 of the present invention has a polishing mark 12 by sanding on the surface. It is preferable that the decorative sheet 11 has a thickness of 0.3 mm or less, has a polishing mark 12 due to sanding, has a wood texture in appearance, and is composed of a flame retardant resin and a flame retardant. The flame retardant is magnesium hydroxide, a phosphorus-nitrogen compound, a zinc molybdate / magnesium silicate compound, or the like, and it is preferable to add 15 to 100 parts by mass when the resin is 100 parts by mass. In the building material of the present invention, the decorative sheet 11 is attached to the surface of the base material.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] Bracket, decorative sheet To Regarding the building materials used. [Background technology]

[0002] The use of wood grain decorative sheets in building materials has been known for some time, and there is still a high demand for building materials that have a wood-like texture. In wallpapers and synthetic wood with a wood-like texture, the wood-like texture is achieved by mixing wood powder with resin, and this technology is widely used. Patent Document 1 proposes creating synthetic wood with a wood-like pattern by extruding a resin composition and sanding the surface. Patent Document 2 proposes creating a flame-retardant wood grain decorative sheet by incorporating a flame retardant into paper or nonwoven fabric, adhesive layer, transparent adhesive layer, and transparent polyvinyl chloride resin layer. [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2000-141326 [Patent Document 2] Japanese Patent Publication No. 2001-205744 [Overview of the project] [Problems that the invention aims to solve]

[0004] Indoor building materials are required to have fire-retardant properties, but the extruded synthetic wood described in Patent Document 1 has many combustible parts, making it difficult to achieve fire-retardant properties. Even when the surface resin layer is made thin to reduce heat release due to combustion in an integrally extruded product with a metal base material, it is difficult to achieve fire-retardant properties. In the aforementioned prior art, no decorative sheets with a sanded surface existed. Conventional sheets did not have a sanded surface, which limited the expression of surface texture. Furthermore, it was difficult to create a wood-like texture with the above-mentioned sheets while also meeting the requirements for non-combustibility as a building material. In the case of building materials with a wood-like texture using wood powder, it was difficult to make them non-combustible.

[0005] To solve the aforementioned conventional problems, the present invention provides a decorative sheet that satisfies the texture of wood. To Non-combustible materials used of We provide building materials. [Means for solving the problem]

[0006] This invention building materials It is a flame-retardant resin and a flame retardant / modifier. and coloring agents Includes, It does not contain wood powder, Decorative sheets with a thickness of 0.3 mm or less (excluding 0.3 mm). Building materials with a surface layer And, The surface of the decorative sheet has sanding marks formed on it, giving it a wood-like texture. The aforementioned building material is characterized in that the decorative sheet is laminated onto a metal substrate which is a non-combustible material as defined in Article 2, Item 9 of the Building Standards Act, and satisfies the following criteria in a heat generation test in accordance with ISO 5660-1. (1) The total heat output for the first 20 minutes after the start of heating is 8 MJ / m². 2 The following applies: (2) For 20 minutes after the start of heating, there are no cracks or holes that penetrate to the back surface and are harmful from a fire safety perspective. (3) For the first 20 minutes after the start of heating, the heating rate remains at 200 kW / m² for at least 10 seconds. 2 It does not exceed that. [Effects of the Invention]

[0008] This invention The building material is a decorative sheet. A decorative sheet that has sanding marks on its surface to give it a wood-like appearance. of The present invention provides a non-combustible building material. Specifically, the surface of the decorative sheet is polished by sanding, resulting in polishing marks, a high-quality appearance on the sheet surface, and a natural touch. Further thinning of the resin layer reduces the flammable portion, allowing for both a wood-like texture and the non-combustibility of the building material using it to be achieved simultaneously. Used Decorative sheets can be applied to various building materials, regardless of their shape or size, or, in the case of wallpaper, to the surface of walls, giving them a wide range of applications.

Brief Description of the Drawings

[0009] [Figure 1] FIG. 1 is a schematic perspective view of a sanded decorative sheet according to an embodiment of the present invention. [Figure 2] FIG. 2 is a surface photograph (40 times magnification) of the decorative sheet. [Figure 3] FIG. 3A is a schematic perspective view of the building material, and FIG. 3B is a cross-sectional view thereof. [Figure 4] FIG. 4 is a graph of the fireproof performance test by a cone calorimeter in Example 1 of the present invention.

Modes for Carrying Out the Invention

[0010] The present invention is a decorative sheet Building materials that use The surface of the decorative sheet is sanded and has a wood-like pattern in appearance. It is sanded (polished) with polishing marks, and the surface is rough, but it has high appearance quality, a natural touch, and a woody form. The polishing marks are fine irregularities.

[0011] The thickness of the decorative sheet is preferably 0.3 mm or less, more preferably 0.2 mm or less. Thereby, the building material using this has more preferable incombustibility.

[0012] The sanding of the decorative sheet is preferably one-way sanding. Thereby, more preferable appearance quality, a natural touch, and a straight-grained woody texture can be obtained.

[0013] The decorative sheet preferably has a composition containing a flame-retardant resin and a flame retardant. Any flame-retardant thermoplastic resin can be used as the flame-retardant resin. Examples of flame-retardant resins include polyvinyl chloride, polyvinyl fluoride, polyvinylidene fluoride, polychlorotrifluoroethylene, polytetrafluoroethylene, ethylene-tetrafluoroethylene copolymer, and tetrafluoroethylene-hexafluoropropylene copolymer. A vinyl chloride resin containing polyvinyl chloride is more preferable as the flame-retardant resin. A vinyl chloride resin is a polymer having repeating units derived from vinyl chloride. The vinyl chloride resin may be a homopolymer of vinyl chloride, or a copolymer of vinyl chloride and a monomer copolymerizable with said vinyl chloride. Examples of copolymers include ethylene-vinyl chloride copolymer, vinyl acetate-vinyl chloride copolymer, vinyl chloride-halogenated olefin copolymer, and other copolymers mainly composed of vinyl chloride. Vinyl chloride resins have high flame retardancy due to the bonding of chlorine (Cl), and when combined with a flame retardant, the flame retardancy is synergistically increased, resulting in flame retardancy applicable to non-combustible materials.

[0014] Examples of the aforementioned flame retardants include hydrated metal compounds, antimony compounds, molybdenum compounds, zinc compounds, phosphate esters, halogenated phosphate esters, phosphorus-nitrogen compounds, red phosphorus, reactive phosphorus-based flame retardants, halogen-based flame retardants, and the like. These flame retardants may be used in combination as needed. The aforementioned flame retardant is preferably at least one selected from magnesium hydroxide, phosphorus-nitrogen compounds, and zinc molybdate / magnesium silicate compounds. More preferably, magnesium hydroxide, phosphorus-nitrogen compounds, and zinc molybdate / magnesium silicate compounds are added.

[0015] The aforementioned flame retardant also acts as a sanding modifier. This provides both flame retardancy and sanding modifier properties. Here, sanding modifier refers to good abrasive properties. An inorganic filler can be used as the sanding modifier, preferably magnesium hydroxide. It is preferable not to add flammable substances such as fibers or wood powder. Adding flammable substances makes it difficult to obtain non-flammability.

[0016] When the flame-retardant resin is 100 parts by mass, it is preferable to add 15 to 100 parts by mass of the flame retardant, more preferably 20 to 90 parts by mass, and even more preferably 35 to 75 parts by mass. As a result, building materials using this material will have more desirable non-combustibility.

[0017] The decorative sheet is preferably used as a base material that is a non-combustible material as defined in Article 2, Item 9 of the Building Standards Act. The decorative sheet can be laminated to the base material and used as a building material. The non-combustible performance test of the building material is performed as an exothermic test in accordance with ISO 5660-1. In order for the building material to be certified as non-combustible, the results of the test must satisfy the following criteria. (1) The total heat output for the first 20 minutes after the start of heating is 8 MJ / m². 2 The following conditions must be met: (2) For 20 minutes after the start of heating, there should be no cracks or holes that penetrate to the back surface, which would be harmful from a fire safety standpoint. (3) For the first 20 minutes after the start of heating, the heating rate remains at 200 kW / m² for at least 10 seconds. 2 Do not exceed this limit. Furthermore, if the above criteria are met for 5 minutes after the start of heating, the material is classified as flame-retardant, and if the criteria are met for 10 minutes, it is classified as semi-noncombustible. In other words, noncombustible materials also meet the criteria for flame-retardant and semi-noncombustible materials.

[0018] The aforementioned An example of a manufacturing method for decorative sheets includes the following steps: (1) A process of mixing a flame-retardant resin with a component containing a flame retardant, and then molding it into a sheet. (2) The process of sanding the sheet. As the sheet forming method described in (1) above, methods for creating sheets and films can be employed. For example, sheet forming methods include extrusion molding and calendering. A specific example of calendering includes a mixing (formulation) step including a ribbon blender, a kneading step including a Banbury mixer and mixing rolls, a filtering step including a strainer, a rolling step including calendering rolls, a cooling step including cooling rolls, and a winding step including a winding machine. In particular, it is preferable to knead the formulation using a Banbury mixer in the kneading step, and then roll it into a sheet with a thickness of 0.3 mm or less, preferably 0.2 mm or less, using calendering rolls in the rolling step. In the sanding process described in (2) above, it is preferable to sand (polish) the surface of the sheet in one direction. Sanding is performed using sandpaper. The sandpaper is preferably of a grit of 20 to 100. More preferably of a grit of 24 to 80.

[0019] The building material of the present invention has the decorative sheet laminated to the surface of a base material. The material of the base material can be selected from non-combustible materials according to the intended use. If strength is required, it is preferable to use a metal as the base material. Examples of metals include aluminum, iron, stainless steel, copper, and various alloys. Any shape can be used, such as a plate or a hollow body. Materials used in residential building materials, furniture, shelves, warehouse walls, etc., can be applied. The base material is preferably aluminum, especially a hollow aluminum body with a thickness of about 1 to 5 mm. This is because it is superior in terms of strength, precision, and weight. Aluminum base materials are lightweight and do not rust, making them suitable as building materials. It is preferable to interpose an adhesive layer between the base material and the decorative sheet when laminating them. In this invention, "made of aluminum" includes "made of aluminum alloy," and the same applies to other metals.

[0020] The aforementioned building materials are preferably those that meet the requirements for obtaining non-combustible certification in a heat generation test in accordance with ISO 5660-1. For this purpose, it is preferable to use non-combustible materials as defined in Ministry of Land, Infrastructure, Transport and Tourism Notification No. 1178, such as steel or aluminum, as the base material.

[0021] The building material of the present invention involves laminating the decorative sheet to the surface of a substrate via an adhesive layer using a laminator. The adhesive contained in the adhesive layer may be solvent-based or hot-melt type. For example, a urethane-based resin can be used as the adhesive.

[0022] In the process of forming the sheet, additives such as plasticizers, colorants, various stabilizers, and fillers may be added. Any type of plasticizer can be used. Any color can be used as the coloring agent. Examples of the coloring agent include pigments, coloring masterbatches, dry colors, paste colors, liquid masterbatches, and the like. By changing the color of the coloring agent, sheets of any desired color can be obtained. The coloring agent content is preferably 3 to 10% by weight relative to the resin. Examples of stabilizers include heat stabilizers, antioxidants, light stabilizers (UV absorbers), and surfactants. Other additives and fillers may also be used as appropriate.

[0023] The following explanation will be given using drawings. In the following, the same reference numerals indicate the same object. Figure 1 is a schematic perspective view of the decorative sheet 11 obtained by sanding. This decorative sheet 11 has sanding marks 12 in one direction, creating a wood grain pattern. Figure 2 is a surface photograph (40x magnification) of the decorative sheet. The surface of the decorative sheet has been sanded in one direction and has a straight-grained wood texture.

[0024] Figure 3A is a schematic perspective view of the building material, and Figure 3B is a cross-sectional view thereof. This building material 13 has a decorative sheet 16 attached to the surface of a base material 14 with an adhesive layer 15 in between. The base material 14 is preferably hollow aluminum. [Examples]

[0025] The present invention will be specifically described using the following examples. However, the present invention is not limited to the following examples.

[0026] (Example 1) (1) Main material As a thermoplastic resin, 100 parts by mass of vinyl chloride resin was prepared, along with 40 parts by mass of phthalate-based plasticizer, 3 parts by mass of stabilizer, and 6 parts by mass of pigment. (2) Filling material 35 parts by mass of magnesium hydroxide and 36 parts by mass of other fillers were prepared as the main flame retardant and modifier. The fillers included a phosphorus-nitrogen compound and a zinc molybdate / magnesium silicate compound as auxiliary flame retardants. In this case, when the polyvinyl chloride resin is 100 parts by mass, the flame retardant is 71 parts by mass. The proportions of the above materials are summarized in Table 1.

[0027] [Table 1]

[0028] (3) Preparation of compound and sheet The main material and filler were mixed, and the resulting mixture was formed into a sheet by calendering. Specifically, each material was mixed in a ribbon blender, kneaded in a Banbury mixer (resin temperature at discharge 170°C) and mixing rolls, then rolled through a strainer and calendered with a calender roll (set temperature 180°C). The thickness of the resulting sheet was approximately 0.20 mm. (4) Sanding The surface of the sheet was sanded in one direction using a wide belt sander designed for thin materials. The grit of the sandpaper and the sanding method are as follows: • Sandpaper grit: #80 • Sandpaper speed: 5m / min • Sheet feed speed: 10m / min As a result of the above, a decorative sheet resembling a wood grain pattern was obtained. The surface of the obtained decorative sheet is shown in Figure 2 (surface photograph, magnification 40x). (5) Creation of building materials The cosmetic sheet was pasted using a profile laminator. Aluminum with a thickness of 1.1 mm was used as the base material. The adhesive may be a solvent-based or hot-melt type depending on the situation. In this example, a polyurethane-based hot-melt adhesive was used. The obtained building material had a wood grain pattern and a woody texture. The results of the heat generation test of the obtained building material using a cone calorimeter are shown in Table 2 below and the graph in Figure 4.

[0029] The test method in Table 2 is "Grade of the Certification Test (Building Standards Law): Non-combustible" and complies with ISO5660-1. The common conditions are as follows. · Sample direction: Horizontal (with holder cover, without wire grid) · Sample area: 0.008840 m 2 · Radiation amount: 50.0 kW / m 2 (Heater temperature 710.5 °C) · Exhaust flow rate: 0.024 m 3 / sec (Exhaust temperature 20.9 °C, Exhaust pressure 130.021 Pa) · Sample distance: 25 mm · Test time: 1200 sec · Calibration factor: 0.04272136 · Conversion factor: 13.100 MJ / kg

[0030]

Table 2

[0031] As is clear from Table 2 and Figure 4, the building material of Example 1 satisfied the following and met the requirements for obtaining a non-combustible certification. (1) The total heat release amount within 20 minutes after the start of heating is 8 MJ / m 2 or less. (2) There are no cracks and holes that penetrate to the back surface, which is harmful in terms of fire prevention, within 20 minutes after the start of heating. (3) The heat release rate does not exceed 200 kW / m continuously for 10 seconds or more within 20 minutes after the start of heating. 2

Industrial Applicability

[0032] This invention Used Decorative sheets are useful for building materials, furniture, shelves, warehouse walls, vehicle interior walls, concrete walls, and interior wallpaper. Non-combustible building materials with decorative sheets attached to their surface are useful as building components such as decorative building materials, building handrails, security grilles, decking materials, and balcony louvers, as well as components for furniture, fixtures, and lighting equipment. [Explanation of symbols]

[0033] 11,16 Decorative sheet 12 Polishing marks 13 Building materials 14 Base material 15 Adhesive layer

Claims

1. A building material containing flame-retardant resin, a flame retardant / modifier, and a coloring agent, without wood powder, and having a decorative sheet surface layer with a thickness of 0.3 mm or less (except for 0.3 mm). The surface of the decorative sheet has sanding marks formed on it, giving it a wood-like texture. The aforementioned building material is characterized in that the decorative sheet is laminated onto a metal substrate which is a non-combustible material as defined in Article 2, Item 9 of the Building Standards Act, and satisfies the following criteria in a heat generation test in accordance with ISO 5660-1. (1) The total heat output during the first 20 minutes after the start of heating is 8 MJ / m² or less. (2) For 20 minutes after the start of heating, there are no cracks or holes that penetrate to the back surface and are harmful from a fire safety standpoint. (3) For the first 20 minutes after the start of heating, the heating rate shall not exceed 200 kW / m² for more than 10 seconds.

2. The building material according to claim 1, wherein the flame retardant and modifier is at least one selected from magnesium hydroxide, a phosphorus-nitrogen compound, and a zinc molybdate / magnesium silicate compound.

3. The building material according to claim 1 or 2, wherein when the resin is 100 parts by mass, the flame retardant and modifier is 15 to 100 parts by mass.

4. The building material is the building material according to any one of claims 1 to 3, wherein the base material is made of aluminum.

5. The building material according to any one of claims 1 to 4, wherein an adhesive layer exists between the base material and the decorative sheet.

Images