JP2000280433A - Inorganic decorative board - Google Patents

Abstract

(57) [Abstract] PROBLEM TO BE SOLVED: To provide an inorganic decorative board used for building interior materials such as walls and ceilings, and to form a curved surface without performing a complicated process such as wetting with water. It is to provide. SOLUTION: An adhesive layer, on one surface of an inorganic base material,
In the laminate in which the decorative sheet layer and the surface protective layer are sequentially laminated, the decorative sheet layer is made of a paper-based sheet having a picture printing layer, and the inorganic base material contains reinforcing fibers, and is mainly made of gypsum. An inorganic decorative board which is a gypsum board comprising a core material and a coating material laminated on both front and back surfaces of the core material.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic decorative panel used for building interior materials such as wall surfaces and ceilings, and more particularly to an inorganic decorative panel capable of forming a curved surface by processing a curved surface.

[0002]

2. Description of the Related Art Conventionally, as an inorganic decorative board, a printed pattern is printed on an inorganic base material such as an asbestos slate board, a cement slate board or a calcium silicate board by, for example, (1) direct printing on the inorganic base material. After forming, a transparent resin paint is applied on the printed pattern to form a top coat layer, (2)
A decorative sheet on which a printed pattern is formed is laminated on an inorganic base material, and a transparent resin paint is applied thereon to form a top coat layer. (3) A pattern is formed on the inorganic base material surface using transfer paper. It has been known that a pattern is provided by a method of transferring a pattern or the like, and then a transparent resin paint is applied on the pattern layer to form a top coat layer.

[0003] In recent years, however, the number of parts constituted by curved surfaces has increased in both buildings, regardless of the interior and exterior. The above-mentioned asbestos slate plate, cement slate plate, and calcium silicate plate are shown below. For reasons
It was unsuitable for use. That is, asbestos slate board,
Cement slate boards are excellent in strength, but they are not suitable for bending at all.In addition, calcium silicate boards are soaked in water to give flexibility, and these boards should be attached to curved base frames. While pressing along the curved surface of
It is possible to form a curved surface by fixing with screws or the like, but if a decorative sheet, particularly a paper-based sheet on which a pattern print layer is formed, is adhered to the surface, It was impossible to perform the processing, and eventually it could not be used.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above problems, and an object of the present invention is to provide an inorganic decorative plate used for building interior materials such as walls and ceilings. In particular, an object of the present invention is to provide an inorganic decorative board capable of forming a curved surface without performing a complicated process such as wetting with water.

[0005]

Means for Solving the Problems To achieve the above object, a solution of the present invention is a laminating method in which an adhesive layer, a decorative sheet layer, and a surface protective layer are sequentially laminated on one surface of an inorganic base material. In the body, the decorative sheet layer is made of a paper-based sheet having a pattern printing layer, and the inorganic base material contains reinforcing fibers, and is mainly laminated on both front and back surfaces of a gypsum core material and the core material. The purpose is to provide an inorganic decorative board which is a gypsum board made of a covering material. With this configuration, a fine pattern printing layer can be formed at a low cost on the upper surface of the inorganic base material, and a small curved surface can be formed as it is without using water. A possible inorganic decorative board.

[0006] Further, since the coating material is a glass fiber nonwoven fabric, it is possible to freely perform curved surfaces while maintaining toughness, and also to impart nonflammability.

Further, since the adhesive layer is made of a reactive hot-melt type adhesive and does not contain a solvent, a step of drying the adhesive is not required, and the working environment is deteriorated because no solvent is released. Without this, space can be saved and the equipment can be made compact, and continuous production at high speed is possible, so that productivity is improved.

Further, since the surface protective layer is made of an ionizing radiation-curable resin, it is possible to obtain flexible physical properties, and an inorganic decorative plate excellent in stain resistance, scratch resistance, solvent resistance, etc. And can be.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a laminated sectional view showing an embodiment of an inorganic decorative board of the present invention, wherein 10 is an inorganic decorative board, 1 is a plaster board, 2 is a core material, 3 is a coating material, 4 is an adhesive layer, 5 Denotes a decorative sheet layer, 6 denotes a paper-based sheet, 7 denotes a pattern printing layer, 7a denotes a solid ink layer, 7b denotes a pattern ink layer, and 8 denotes a surface protective layer.

The structure of the inorganic decorative board 10 of the present invention is shown in FIG.
As shown in FIG. 1, a gypsum board 1 comprising a core material 2 mainly composed of gypsum and containing coating materials 3 laminated on both upper and lower surfaces thereof, containing reinforcing fibers
A decorative sheet layer 5 made of a paper-based sheet 6 on which an upper surface is provided with a solid ink layer 7a and a pattern printing layer 7 composed of a pattern ink layer 7b via an adhesive layer 4, and a further upper surface of the pattern printing layer 7 The surface protection layer 8 is laminated on the base material, and the inorganic base material is a decorative sheet layer made of a paper-based sheet using a core material mainly composed of gypsum containing reinforcing fibers and containing a reinforcing fiber. Thus, an inorganic decorative plate capable of forming a curved surface can be obtained.

The gypsum constituting the core material 2 used in the gypsum board 1 of the present invention may be any of natural gypsum, phosphogypsum, hydrofluoric gypsum and the like. Of calcined gypsum obtained by baking gypsum and a setting accelerator represented by potassium sulfate, foam for reducing weight, adhesion of starch and the like for promoting adhesion between the core material and base paper for gypsum board It is obtained by kneading and hardening an additive, water, an additive such as vermiculite, which improves the fire resistance, aluminum hydroxide, a water reducing material, preferably an appropriately selected additive such as a relatively long fiber, and water. Further, a gypsum plate obtained by adding a water repellent to these raw materials can also be provided with water resistance.

The gypsum board 1 of the present invention includes a core 2
By incorporating the reinforcing fiber therein, the brittleness of the gypsum plate lacking in toughness is reduced, and the flexibility and flexibility of the gypsum plate are improved, and the bending strength is increased. Here, examples of the reinforcing fibers to be contained in the core material include waste paper such as newspapers and virgin pulp, glass fibers which are inorganic fibers, rock wool, wallestonite, sepiolite, and the like.The core material may be used alone or as a mixture. In an amount of 0.5 to 5 parts by weight of the weight of the gypsum. In addition, the shape of these reinforcing fibers has a diameter of 5 to 13 μm, considering that the plaster plate can be formed into a curved surface.
And those of 10 to 20 mm are suitable for use.

In order to disperse these reinforcing fibers in a gypsum board in a good condition, the fibers are mixed with calcined gypsum before mixing the calcined gypsum with the fibers and water to form a slurry. It is preferable that the surface of the fiber is coated with calcined gypsum, or that the fiber is given a sizing property and surface-treated with polyethylene oxide or the like that exhibits dispersibility in contact with water before use. By coating the surface of the fiber with plaster of paris or a dispersing agent in this way, the fiber is easily and uniformly dispersed in the slurry of plaster of Paris, and finally mixed in a state of being uniformly dispersed in the gypsum plate. Thus, the fibers function as a link between the cured bodies. Therefore, a gypsum board with sufficiently improved strength can be obtained. In particular, it is preferable to use glass fiber as the inorganic fiber because the reinforcing effect is high when the glass fiber is contained in the gypsum plate.

Next, a coating material 3 made of a glass fiber nonwoven fabric is laminated on the upper and lower surfaces of a core material 2 mainly made of gypsum, containing the above-mentioned reinforcing fibers, thereby reducing the incombustibility. It has a gypsum board that has both functions of flexibility and rigidity and also has excellent surface water repellency. Here, the glass fiber nonwoven fabric is manufactured by a wet method of dispersing glass fibers in water and making the same with a paper machine, and includes an acrylic resin, a vinyl acetate resin,
The fibers are bound together using a binder such as an epoxy resin. As the coating material 3 of the core material 2, besides the glass fiber nonwoven fabric, a non-combustible base paper mixed with walastenite, which is a mineral fiber, or a non-combustible base paper using aluminum hydroxide instead of wollastenite Non-combustible base paper such as the above can also be used. In addition, on the side of the covering material 3 to which the decorative sheet 5 is adhered, a seal for preventing impregnation into the inside, improvement of the surface (interlayer) strength of the covering material itself, and elution of alkali components from the inorganic base material are provided. Prevention, a sealer layer may be formed if necessary, for example,
Vinyl acetate resin, urethane resin, epoxy resin, acrylic resin and the like can be used.

The adhesive layer 4 is a layer for bonding a decorative sheet 5 composed of a paper-based sheet 6 provided with a picture print layer 7 to the gypsum board 1, and is made of a general adhesive, for example, a vinyl acetate resin. Emulsion adhesives such as ethylene / vinyl acetate resin, urea resin, urethane resin, etc., one-component curable urethane resin, two-component curable urethane resin,
A reactive resin-based adhesive such as a liquid-mixed epoxy resin can also be used, but compared to them, it has excellent heat resistance and solvent resistance, and has a high initial adhesive strength and completes bonding in a short time. Reactive hot melt adhesives, which are also advantageous in processing speed and line length, are the most suitable for use.

A moisture-curable heat-sensitive adhesive, which is a kind of reactive hot-melt adhesive, is a composition containing a prepolymer having an isocyanate group at a molecular terminal as an essential component. The prepolymer is usually a polyisocyanate prepolymer having one or more isocyanate groups at both molecular terminals, and is a solid thermoplastic resin at room temperature. The isocyanate groups react with each other due to the moisture in the air to cause a chain extension reaction. As a result, a reactant having a urea bond in the molecular chain is generated, and the isocyanate group at the molecular end further reacts with the urea bond, It causes biuret bond to branch and cause a cross-linking reaction. Although the skeleton structure of the molecular chain of the prepolymer having an isocyanate group at the molecular terminal is arbitrary, specifically, a polyurethane skeleton having a urethane bond, a polyester skeleton having an ester bond, a polyether skeleton having an ether bond, polyethylene, It is a polyolefin skeleton having an olefin bond such as polypropylene, and the physical properties of the adhesive can be adjusted by appropriately employing one or more of these skeleton structures.

In particular, when the inorganic base material is exposed to an atmosphere such as moisture or moisture, the base material becomes strongly alkaline due to the alkali component eluted from the inorganic base material. And the like, as a result of hydrolysis of the resin and the like, resulting in poor adhesion.Therefore, a strong alkali-resistant resin is required. Polyolefin-based reactive hot-melt adhesives to which groups have been added are preferred.

Various types of papers can be used as the paper-based sheet 5 for forming the pattern printing layer 7 on the inorganic decorative board 10, such as thin paper, bleached or unbleached kraft paper, fine paper, pure white paper, and the like. A paper-reinforced paper, a mixed paper in which a synthetic resin is mixed to enhance the interlayer strength, a titanium paper, or the like is used, and in consideration of the workability and adhesion of the sheet, the basis weight is 20 to 75.
An inter-sheet reinforced paper in which the inter-sheet strength is increased by using acrylamide, epoxy amide, or the like on thin paper of g / m ² is preferable.

As the pattern printing layer 7, a solid ink layer 7a of solid printing and a pattern ink layer 7b for expressing, for example, stones, cloths, surface patterns of natural leather, abstract patterns, etc. are provided. As the vehicle of the ink to be provided, a known vehicle can be used.For example, an acrylic type, a vinyl chloride type, a vinyl chloride-vinyl acetate copolymer, a chlorinated polyolefin, nitrocellulose, a simple substance or a mixture composed of a resin such as urethane, If necessary, a colorant such as a pigment or a dye, an extender, a solvent and the like can be appropriately mixed. It is also possible to include a glittering pigment together with the coloring pigment in the solid ink layer. Further, the solid ink layer includes only the coloring pigment and is configured without the glittering pigment, and the glittering pigment is included in the picture ink layer. May be included.

The resin for forming the surface protective layer 8 may be a curable resin for a conventionally known decorative plate such as an ionizing radiation curable resin or a thermosetting resin (including a room temperature curable resin and a two-component reactive resin). The resin used can be used.

Examples of the thermosetting resin include unsaturated polyester resins, epoxy resins, and polyurethane resins. Among them, a polyol component having an OH group such as an acrylic polyol, a polyester polyol, a polyether polyol, or an epoxy polyol is mainly used. A two-part curable urethane-based resin obtained by adding an isocyanate compound such as tolylene diisocyanate, hexamethylene diisocyanate, or meta-xylene diisocyanate as a curing agent is preferred.

As the ionizing radiation-curable resin, specifically, a polyfunctional compound having two or more polymerizable unsaturated bonds such as acryloyl group, methacryloyl group, acryloyloxy group, epoxy group and thiol group in the molecule. A composition curable by ionizing radiation, which is obtained by appropriately mixing a prepolymer, oligomer and / or monomer of the above, is used. Here, the ionizing radiation means an electromagnetic wave or a charged particle beam having an energy quantum capable of polymerizing or cross-linking a molecule, usually an ultraviolet ray or an electron beam is used, and the curing speed is high and workability is good. It is preferable because it is easy to adjust the physical properties of the resin such as flexibility and hardness and is excellent in stain resistance, scratch resistance, solvent resistance and the like.

Examples of the above prepolymers and oligomers include unsaturated polyesters such as condensates of unsaturated dicarboxylic acids and polyhydric alcohols, and methacrylates such as polyester methacrylate, polyether methacrylate, polyol methacrylate, silicon methacrylate, and melamine methacrylate; Examples include acrylates such as polyester acrylate, epoxy acrylate, urethane acrylate, polyether acrylate, polyol acrylate, silicon acrylate, and melamine acrylate, and cationic polymerization type epoxy compounds.

Examples of the above monomers include styrene, α
Styrene monomers such as methylstyrene, acrylates such as methyl acrylate, 2-ethylhexyl acrylate, methoxyethyl acrylate, butoxyethyl acrylate, butyl acrylate, methoxybutyl acrylate, phenyl acrylate, and methacrylic acid Methacrylates such as methyl, ethyl methacrylate, propyl methacrylate, methoxyethyl methacrylate, ethoxymethyl methacrylate, phenyl methacrylate, lauryl methacrylate, 2- (N, N-diethylamino) ethyl acrylate, methacrylic acid Substituted amino of unsaturated acid such as -2- (N, N-dimethylamino) ethyl, 2- (N, N-dibenzylamino) methyl acrylate, 2- (N, N-diethylamino) propyl acrylate Alcohol esters, Unsaturated carboxylic acid amides such as acrylamide and methacrylamide, compounds such as ethylene glycol diacrylate, propylene glycol diacrylate, neopentyl glycol diacrylate, 1,6 hexanediol diacrylate, and triethylene glycol diacrylate, dipropylene glycol diacrylate A polyfunctional compound such as ethylene glycol dimethacrylate, propylene glycol dimethacrylate, diethylene glycol dimethacrylate, and / or
Polythiol compounds having two or more thiol groups in the molecule, such as trimethylolpropanetrithioglycolate, trimethylolpropanetrithiopropylate,
Pentaerythritol tetrathioglycol and the like.

As a coating method, a known coating means such as a curtain flow coater, a roll coater, a spray coat or the like can be used.
g / m ² is preferred.

[0026]

EXAMPLES Example 1 50 g / m ² paper-reinforced paper (Tenma Special Paper Co., Ltd., OP
A-50) The surface of gravure printing is provided with a concealed solid printing layer with an acrylic ink and a woodgrain pattern printing layer with a nitrified cotton-based ink to prepare a decorative sheet, and then a woodgrain pattern of the decorative sheet. A urethane acrylate-based electron beam curing type (E) having 1 part by weight of silicon acrylate and 6 parts by weight of tris (β-chlorotyl phosphate) added on the upper surface of the printing layer.
B) A surface protective layer was formed by a roll coating method so that the resin was 100 g / m ^2, and a sheet was prepared. Next, a 6 mm-thick glass fiber nonwoven fabric is laminated on both sides, and a fiber reinforced gypsum board (Yoshino Gypsum Co., Ltd., Tiger Gloss Rock) containing 2 parts by weight of glass fiber as a core material is urethane-coated with a sponge roll coater. System sealer (China Paint Co., Ltd., 7X sealer) is applied at 60 g / m ² and 150 ° C.
For 1 minute to produce a sealer-treated inorganic substrate. Next, using a hot melt applicator, a polyolefin-based reactive hot melt adhesive is applied to the unprinted surface of the sheet so as to have a thickness of 60 g / m ^2, and then the sealer of the inorganic substrate is applied. The adhesive decorative sheet was placed on the layer face so that the adhesive layer face was opposed to the mirror face decorative sheet, and bonded at a pressure roll temperature of 80 ° C. and a bonding speed of 3 m / min to produce an inorganic decorative board.

[0027]

As described above, the present invention relates to a laminate in which an adhesive layer, a decorative sheet layer, and a surface protective layer are sequentially laminated on one surface of an inorganic base material, wherein the decorative sheet layer has a pattern. It consists of a paper-based sheet with a print layer,
Since the inorganic base material contains a reinforcing fiber, a gypsum board made of a core material mainly composed of gypsum and a coating material laminated on both front and back surfaces of the core material, the inorganic base material is used. It is possible to form a decorative plate capable of forming a curved surface, in which a fine pattern printing layer can be formed on the upper surface at a low cost and a small curved surface can be formed as it is without using water. Furthermore, by making the covering material a glass fiber non-woven fabric, it has toughness,
It is possible to perform the curved surface more freely, and it is possible to impart nonflammability.

In addition, since the adhesive layer is made of a reactive hot-melt adhesive, no solvent is contained, so that the step of drying the adhesive is not required, and the working environment is deteriorated because the solvent is not released. Without the need for space saving, the equipment is also space-saving and compact, and high-speed continuous production is possible, thus improving productivity. In addition, the surface protective layer is made of an ionizing radiation-curable resin, so that it has flexibility. It is also possible to obtain physical properties, and an inorganic decorative board excellent in stain resistance, scratch resistance, solvent resistance and the like can be obtained.

[Brief description of the drawings]

FIG. 1 is a laminated sectional view showing an embodiment of an inorganic decorative board of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Inorganic base material 2 Core material 3 Coating material 4 Adhesive layer 5 Decorative sheet layer 6 Paper quality sheet 7 Picture printing layer 7a Solid ink layer 7b Picture ink layer 8 Surface protective layer 10 Inorganic decorative board

Claims (4)

[Claims] An adhesive layer is provided on one side of an inorganic base material.
In the laminate in which the decorative sheet layer and the surface protective layer are sequentially laminated, the decorative sheet layer is made of a paper-based sheet having a picture printing layer, and the inorganic base material contains reinforcing fibers, and is mainly made of gypsum. An inorganic decorative board comprising a gypsum board comprising a core material and a coating material laminated on both front and back surfaces of the core material. 2. The inorganic decorative board according to claim 1, wherein the coating material is a glass fiber nonwoven fabric. 3. The inorganic decorative board according to claim 1, wherein the adhesive layer is made of a reactive hot melt adhesive. 4. The inorganic decorative board according to claim 1, wherein the surface protective layer is made of an ionizing radiation-curable resin.