JP2001040852A - Veneer-attached inorganic decorative board and method for producing the same - Google Patents

Abstract

(57) [Problem] To provide a veneer-attached inorganic decorative board excellent in durability and fire resistance, lightweight and excellent in workability without being contaminated by an alkali component, and a method for producing the same. SOLUTION: A core layer containing an inorganic foam and an organic binder as essential components is laminated and integrated between a front and back layer containing mineral fibers, an inorganic powder and an organic binder as essential components. An inorganic substrate of 6 to 0.9 is obtained. Then, a veneer was attached to at least the surface of the inorganic substrate, and a decorative groove was provided.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a veneer-attached inorganic decorative board used as, for example, an eave ceiling material, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as an eave ceiling material, a veneer such as a plywood with a veneer attached thereto is used. However, since the eave ceiling material is directly exposed to the wind and rain, the wooden substrate has a large swelling and shrinkage due to water absorption and drying. For this reason, cracks and the like easily occur on the surface,
The durability was low. Further, since the eave ceiling material uses a wooden substrate, there is a problem that it cannot be used in a fire prevention regulated area.

On the other hand, in order to solve the above problems, it is conceivable to use an inorganic substrate containing an alkali component such as a calcium silicate plate or a cement plate instead of a wooden substrate. However, since the inorganic substrate contains an alkali component, the veneer may be contaminated by the alkali component, and it is necessary to perform a sufficient sealer treatment. In particular, when used for exterior parts such as eave ceilings, rainwater etc. seeps into the inorganic substrate,
Since the alkali component is easily eluted, alkali contamination tends to be more remarkable. Further, since the inorganic substrate is heavy, if the construction is insufficient, there is a risk of falling or the like, and the inorganic substrate cannot be made thick. In particular, when a decorative groove is provided, the bending strength is significantly reduced, and the groove is easily broken.

Further, the inorganic substrate is hard, and it is difficult to cut with a blade for a wooden substrate, and chipping or fuzzing is liable to occur even when cutting. For this reason, a method of attaching a veneer after cutting the groove is also conceivable. However, in this method, the veneer plate easily protrudes from the groove, resulting in a problem that not only the finishing accuracy is low, but also labor is required and productivity is low.

SUMMARY OF THE INVENTION In view of the above problems, an object of the present invention is to provide a veneer-bonded inorganic decorative board excellent in durability and fire resistance, lightweight and excellent in workability without being contaminated by an alkali component, and a method for producing the same. It is in.

[0006]

The veneer-coated inorganic decorative board according to the present invention comprises an inorganic foam and an organic binder between a front and back layer containing mineral fibers, an inorganic powder and an organic binder as essential components. And a decorative groove provided on at least the surface of an inorganic substrate having a specific gravity of 0.6 to 0.9, obtained by laminating and integrating a core layer containing as an essential component.

Further, the method for producing a veneer-attached inorganic decorative board comprises an inorganic foam and an organic binder as essential components between a front and back layer containing mineral fibers, an inorganic powder and an organic binder as essential components. After attaching a veneer to at least the surface of the inorganic substrate having a specific gravity of 0.6 to 0.9 obtained by laminating and integrating the core layer, the decorative groove and the real part are so formed that a part of the inorganic substrate is exposed from the surface. Forming and then painting the decorative groove and the real part.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment according to the present invention will be described with reference to FIG. The veneer-attached inorganic decorative board according to the present embodiment includes a veneer 5 on the front and back surfaces of the inorganic substrate 1.
6 is bonded and integrated with an adhesive.

The inorganic substrate 1 is specifically referred to as a volcanic glassy multilayer plate, and has a three-layer structure in which a core layer 4 is laminated and integrated between front and back layers 2 and 3. Things.

The front and back layers 2 and 3 are used to develop strength, and are mainly composed of mineral fibers, inorganic powders, and organic binders. As the mineral fiber, rock wool, slag wool, glass wool, or the like can be used, and the added amount thereof is preferably 20 to 80% by weight. If it is less than 20% by weight, the flexural strength will be low. If it exceeds 80% by weight, the proportion of the inorganic powder or the organic binder will be relatively low, and the surface hardness and the strength of the decorative board will be low. Because it becomes.

The inorganic powder is used to increase the surface hardness and smoothness.
Examples thereof include calcium carbonate, silica sand, slag, and microsilica, and the added amount is 10 to 65% by weight. If the content is less than 10% by weight, desired surface hardness and smoothness cannot be obtained. If the content is more than 65% by weight, the ratio of mineral fibers and organic binders becomes relatively low, so that desired strength is obtained. Is not obtained.

The organic binder is for binding and integrating the mineral fiber and the inorganic powdery material.
Starch, polyvinyl alcohol, or a phenol resin, an acrylic resin, or the like can be used to increase the water resistance, and the addition amount is preferably 5% by weight to 30% by weight. If the amount is less than 5% by weight, the desired strength cannot be obtained. If the amount exceeds 30% by weight, the fire resistance cannot be satisfied.

[0013] As the binder, cement, gypsum,
Inorganic binders such as water glass also exist, but they may elute the alkaline component, which is not preferred as a veneer base material. In the present invention, an organic binder containing no alkaline component is used.

Further, in order to increase the strength, organic fibers such as pulp and polypropylene may be added in an amount of 2 to 15% by weight.

The core layer 4 is for reducing the weight of the decorative board, and is mainly composed of an inorganic foam and a binder. Examples of the inorganic foam include pearlite, shirasu foam, glass foam and the like, and the added amount is 40 to 80% by weight. 40% by weight
If it is less than 8, sufficient weight reduction cannot be performed.
If the amount exceeds 0% by weight, the proportion of the binder or the fiber decreases, and the strength cannot be improved.

The binder binds and integrates the above-mentioned inorganic foam, and the same binder as the binder for the front and back layers 2 and 3 can be used. The addition amount is preferably 5% by weight to 30% by weight. . If the amount is less than 5% by weight, the desired strength cannot be obtained, and if it exceeds 30% by weight, the fire resistance cannot be satisfied.

Further, in order to increase the strength, organic fibers such as pulp and polypropylene may be added in an amount of 4 to 30% by weight. If necessary, an inorganic powder such as aluminum hydroxide, calcium carbonate, silica sand or the like may be added. However, in order to maintain weight reduction, the content needs to be 50% by weight or less.

It is appropriate that the specific gravity of the front and back layers 2 and 3 is 0.8 to 1.2, the specific gravity of the core layer 4 is 0.2 to 0.7, and the total specific gravity is 0.2 to 0.7. If the specific gravity of the front and back layers 2 and 3 is less than 0.8, a desired strength cannot be obtained. If the specific gravity exceeds 1.2, the front and back layers become hard and workability deteriorates. If the specific gravity of the core layer 4 is less than 0.2, the strength as the core layer cannot be maintained, and if it exceeds 0.7, the weight cannot be reduced sufficiently.

The veneers 5 and 6 are adhered to enhance the decorativeness. For example, a natural wood veneer, an artificial wood veneer or the like may be bonded to at least the surface of the inorganic substrate 1 with an adhesive (melamine, urea melamine). Etc.). In the case where the thickness of the inorganic substrate is small, it is preferable to attach a projecting plate to the front and back surfaces of the inorganic substrate 1 in order to prevent the occurrence of warpage, but this is not essential.

Next, the manufacturing method of this embodiment will be described. A mineral fiber, an organic binder, an inorganic powder, an organic fiber, and the like are put into water and stirred to obtain a slurry. The slurry is formed into a wet mat to be the front and back layers 2 and 3. On the other hand, an inorganic foam, an organic binder, an inorganic powder, an organic fiber and the like were mixed under water spray to obtain a mixture. And
After the mixture is sprayed and deposited on the wet mat to be the surface layer 2, the wet mat to be the back layer 3 is overlaid. Then, after heating and pressing with a hot press, the substrate is dried with a drier to obtain an inorganic substrate 1 having an overall specific gravity of 0.6 to 0.9.

After sticking the protruding plates 5 and 6 on the front and back surfaces of the inorganic substrate 1, a decorative groove 7 is formed on the surface with an existing wood substrate blade such as plywood. Further, actual processing is also performed on the side end of the inorganic substrate 1 with a processing machine used for a wooden substrate to form male seeds 8 and female seeds 9. The decorative groove 7 and the real parts 8, 9
Then, a paint made of urethane resin, acrylic silicone resin, fluororesin or the like is applied by spraying or the like. At this time, the paint that has protruded from the veneers 5 and 6 is wiped off with a roll. further,
If necessary, the surface is top-coated with a urethane resin or the like.

[0022]

EXAMPLES (Example) Thickness 12.5 mm, width 165 m
m, a length of 1818 mm and a specific gravity of 0.7 as a whole, a melamine adhesive is applied to the front and back surfaces of a volcanic glassy multilayer plate (trade name: Dylite) at a ratio of 15 g / scale ² . Then, on its surface, a 0.35 mm thick natural laminated slice veneer (grain type:
Ayuse) and the back side has a thickness of 0.2
mm natural wood veneers are bonded together and pressed together with a hot press.

A decorative groove having a depth of 3.4 mm is cut on the surface of the veneer attached to the inorganic substrate with a wooden substrate knife. Then, the end of the inorganic substrate is actually processed by an existing processing machine to form a male fruit and a female fruit. Then, a urethane resin paint is applied to the decorative groove and the real part at a rate of 10 g / size ² and the paint that has protruded from the veneer is wiped off with a roll or the like. Finally, a urethane resin paint was applied to the whole at a rate of 10 g / size ² to form a top coat.

Of the volcanic glassy multi-layer plate used as the inorganic substrate used in the present embodiment, the front and back layers are 65% by weight of rock wool as mineral fiber, 20% by weight of aluminum hydroxide as inorganic powder, and 20% by weight of organic powder. Pulp 5% by weight as fiber
It contains 5% by weight of starch as an organic binder and 5% by weight of powdered phenol as a water-resistant binder. On the other hand, the core layer is composed of 65% by weight of pearlite as an inorganic foam, 20% by weight of aluminum hydroxide as an inorganic powder, 5% by weight of pulp as an organic fiber, 5% by weight of starch as an organic binder, and 5% by weight as a water-resistant binder. It contains 5% by weight of powdered phenol.

(Comparative Example 1) A sample processed in the same manner as in the above-mentioned Example except that a commercially available plywood having the same dimensions was used instead of the above-mentioned inorganic substrate was used as a sample.

(Comparative Example 2) A sample was prepared in the same manner as in the above-mentioned Example except that a commercially available calcium silicate plate having the same dimensions was used instead of the above-mentioned inorganic substrate.

Next, the bending strength and the breaking load in the longitudinal direction of the samples according to the example and comparative examples 1 and 2 were measured. The measurement results are shown below. Flexural strength (N / mm ² ) Flexural breaking load (N) Example 25.2 1352 Comparative Example 1 26.5 1430 Comparative Example 2 17.6 392

As is clear from the above measurement results, the embodiment using the inorganic substrate has almost the same mechanical strength as Comparative Example 1 using plywood, while Comparative Example 2 using a calcium silicate plate. It was also found that these had excellent mechanical strength.

On the other hand, in the case of Comparative Example 1, since the swelling at the time of absorbing water and the shrinking at the time of drying were large, cracks occurred in the veneer attached to the surface. In addition, the base material cannot be used in a fire control area because of plywood. In the case of Comparative Example 2, fine fuzzing occurred in the groove. In addition, when stored in a high-humidity state, stains occurred due to the eluted alkali.

[0030]

According to the first aspect of the present invention, since an inorganic substrate is used instead of a wooden substrate, swelling and shrinkage due to water absorption and drying are small, and durability is improved.
Can also be used in fire-regulated areas. In addition, since an inorganic substrate having a specific gravity of 0.6 to 0.9, which is close to the specific gravity of the wooden substrate, is used, not only is it lightweight, but its cutting workability is similar to that of the wooden substrate, and chipping and fuzzing are unlikely to occur. . In particular, since the front and back layers of the inorganic substrate contain mineral fibers, even a different material such as a veneer is unlikely to peel off due to the anchoring effect of the adhesive.

Further, since the inorganic substrate is used instead of the calcium silicate plate or the cement plate, there is no possibility that the veneer is contaminated with an alkali component, and there is no need to perform a sealer treatment. And by using for eaves ceiling,
Even if rainwater or the like soaks into the inorganic substrate, there is an effect that alkali components are not eluted and alkali contamination does not occur.

According to the second aspect, after the veneer is attached to at least the surface of the inorganic substrate, a decorative groove is formed. Therefore, unlike the conventional example, the projecting plate does not protrude into the groove, so that the finishing accuracy is high, the labor is reduced, and the productivity is improved.

[Brief description of the drawings]

FIG. 1 shows a veneer-attached inorganic decorative plate according to the present invention, wherein FIG. 1 (a) is a plan view and FIG. 1 (b) is an enlarged cross-sectional view taken along line AA of FIG. 1 (a).

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Inorganic substrate, 2 ... Surface layer, 3 ... Back layer, 4 ... Core layer, 5,
6 ... veneer, 7 ... decorative groove, 8 ... male, 9 ... female.

Continued on the front page F-term (reference) 2E110 AA02 AA26 AA27 AA46 AA65 BA05 BA12 BA22 BB03 BD23 DA03 DA23 DC08 EA09 GA24Z GA33W GA33X GA42Z GB12Z GB32Z GB33Z GB62W GB62X 2E162 CA25 CA26 CA27 CC02 4F100 AA00AA00AA00A00AA00AA00AA00A0000 AP01D AS00A AS00B AS00C BA03 BA04 BA05 BA06 BA07 BA10A BA10C BA10D BA10E BA13 CB00 CC00E DC21D DE01A DE01C DG01A DG01C DJ01B GB08 HB00D JJ07 JK06 JL03 JL04 JL06

Claims (2)

[Claims] 1. A core layer comprising an inorganic foam and an organic binder as essential components between a mineral fiber, an inorganic powder and a front and back layer comprising an organic binder as essential components was obtained by laminating and integrating. A veneer-attached inorganic decorative plate, characterized in that a veneer is attached to at least a surface of an inorganic substrate having a specific gravity of 0.6 to 0.9 and a decorative groove is provided. 2. A core layer comprising an inorganic foam and an organic binder as essential components is laminated and integrated between a front and back layer comprising mineral fibers, an inorganic powder and an organic binder as essential components. After attaching a veneer to at least the surface of the inorganic substrate having a specific gravity of 0.6 to 0.9, a decorative groove and a real part are formed so that a part of the inorganic substrate is exposed from the surface, and then the decorative groove and the real part are formed. A method for producing a veneer-attached inorganic decorative board, characterized in that a part has been painted.