JPH11268186A - Manufacture of decorative plate - Google Patents
Manufacture of decorative plateInfo
- Publication number
- JPH11268186A JPH11268186A JP10072104A JP7210498A JPH11268186A JP H11268186 A JPH11268186 A JP H11268186A JP 10072104 A JP10072104 A JP 10072104A JP 7210498 A JP7210498 A JP 7210498A JP H11268186 A JPH11268186 A JP H11268186A
- Authority
- JP
- Japan
- Prior art keywords
- sheet material
- sheet
- decorative
- layer
- thermosetting resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Landscapes
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【0001】[0001]
【発明の属する技術分野】本発明は、主に内装材として
様々な用途に使用される耐燃性に優れた化粧板に関する
ものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board excellent in flame resistance which is mainly used as an interior material for various uses.
【0002】[0002]
【従来の技術】内装材として使用される化粧板は、市場
において不燃及び準不燃化粧板の需要が高まっており、
それに用いられる化粧板には、珪酸カルシウム板等の不
燃性基材の表面に化粧層を施したものが以前から用いら
れ、ガラス不織布やガラス織布を基材として水酸化アル
ミニウム等の無機充填材と樹脂を含有する配合物を含浸
させたものを積層して加熱加圧成形したものが近年検討
されている(特開平1−56539号公報、特開平1−
56540号公報など)。珪カル板等の不燃性基材の表
面に化粧層を施したものは軽量で且つ安価であるが脆
く、ガラス不織布やガラス織布を基材として水酸化アル
ミニウム等の無機充填材と樹脂を含有する配合物を含浸
させたものを積層して加熱加圧成形したものはガラス不
織布やガラス織布基材への配合物の含浸処理率に限界が
あり、化粧板中ガラス基材比率が高くなるため高強度で
はあるがコスト的に高いものとなってしまう。2. Description of the Related Art The demand for non-combustible and semi-non-combustible decorative panels in the market for decorative panels used as interior materials is increasing.
The decorative board used for this purpose has been made of a non-combustible base material such as a calcium silicate plate with a decorative layer applied to the surface. It has been used for a long time. In recent years, a laminate obtained by laminating a mixture impregnated with a resin-containing compound and subjecting the mixture to heat and pressure molding has been studied (JP-A-1-56539 and JP-A-1-56539).
No. 56540). A non-combustible substrate such as a silica plate with a decorative layer on the surface is lightweight and inexpensive but brittle, and contains an inorganic filler such as aluminum hydroxide and a resin based on a glass nonwoven fabric or glass woven fabric What is impregnated with the compound to be laminated and heat-press molded is limited in the impregnation rate of the compound to the glass nonwoven fabric or glass woven fabric substrate, and the glass substrate ratio in the decorative plate increases Therefore, it has high strength but is expensive.
【0003】[0003]
【発明が解決しようとする課題】本発明は、ガラス不織
布やガラス織布を基材とし、これに水酸化アルミニウム
等の無機充填材と樹脂を含有する配合物を塗工する工程
において、従来の方式では困難であった膜厚の厚い塗工
を実現することにより、従来と同等以上の耐燃性を有す
る安価な耐燃性化粧板を提供するものである。SUMMARY OF THE INVENTION The present invention relates to a process for applying a compound containing an inorganic filler such as aluminum hydroxide and a resin to a glass nonwoven fabric or a glass woven fabric as a base material. The present invention provides an inexpensive fire-resistant decorative board having a fire resistance equal to or higher than that of a conventional one by realizing a thick coating that was difficult in the method.
【0004】[0004]
【問題を解決するための手段】本発明は、ガラス不織布
の片面側から水酸化アルミニウムを主成分とする無機充
填材を含有する熱硬化性樹脂を塗工し、加熱乾燥して芯
材層用シート材料を作製する工程、ガラス織布に熱硬化
性樹脂を含浸乾燥して補強層用シート材料を作製する工
程、化粧シートにメラミン樹脂を含浸乾燥して化粧層用
シート材料を作製する工程、及び2枚以上の芯材層用シ
ート材料の間に補強層用シート材料を挿入し、表面に化
粧層用シート材料を重ね合わせ加熱加圧成形する工程を
有することを特徴とする耐燃性化粧板の製造方法、であ
り、製造工程が簡単であり、かつ連続生産が可能であ
り、性能上も従来の化粧板と同等以上のものを得ること
ができる。Means for Solving the Problems The present invention relates to a method for applying a thermosetting resin containing an inorganic filler containing aluminum hydroxide as a main component from one side of a glass nonwoven fabric, drying by heating and drying. A step of producing a sheet material, a step of impregnating and drying a glass woven fabric with a thermosetting resin to produce a sheet material for a reinforcing layer, a step of impregnating and drying a decorative sheet with a melamine resin to produce a sheet material for a decorative layer, And a step of inserting a sheet material for a reinforcing layer between two or more sheet materials for a core layer, superimposing the sheet material for a decorative layer on the surface thereof, and subjecting the material to heat and pressure molding. The production process is simple, the production process is simple, continuous production is possible, and the performance can be improved to a level equivalent to or higher than that of the conventional decorative board.
【0005】本発明において、ガラス不織布として長尺
のガラス不織布を使用し、このガラス不織布へ無機充填
材と熱硬化性樹脂からなる配合物を塗工する工程の一例
(概略断面図)を図1に示す。巻き出し装置(1)から
巻き出された長尺のガラス不織布(2)は、搬送ローラ
ー(3)により移送されながら、その上面に無機充填材
と熱硬化性樹脂との配合物である粘度の高いペースト状
物(4)をコーター(5)により所定の膜厚になるよう
に塗布する。塗工する厚みは、成形の際のシート材料の
積層枚数を少なくするために0.3〜2.0mm程度に
厚くすることが望ましい。In the present invention, an example (schematic sectional view) of a process of using a long glass nonwoven fabric as a glass nonwoven fabric and applying a compound comprising an inorganic filler and a thermosetting resin to the glass nonwoven fabric is shown in FIG. Shown in The long glass nonwoven fabric (2) unwound from the unwinding device (1) is transported by the transport roller (3), and has a viscosity of a compound of an inorganic filler and a thermosetting resin on the upper surface thereof while being transferred. A high paste (4) is applied by a coater (5) to a predetermined thickness. The thickness of the coating is desirably as large as about 0.3 to 2.0 mm in order to reduce the number of sheets of the sheet material to be laminated at the time of molding.
【0006】コーター(5)としては、コンマロールコ
ーター、ナイフコーター、ダイスコーター、リバースコ
ーター等があるが、塗工厚みが厚いので配合物粘度を高
くする必要がある。このため高粘度配合物の塗工に適し
た方式、例えばコンマロールコーター、ナイフコーター
等が好ましい。As the coater (5), there are a comma roll coater, a knife coater, a die coater, a reverse coater and the like. However, since the coating thickness is large, it is necessary to increase the viscosity of the composition. For this reason, a method suitable for coating a high-viscosity compound, such as a comma roll coater or a knife coater, is preferred.
【0007】長尺のガラス不織布に無機充填材を配合し
た熱硬化性樹脂を塗工した後、乾燥装置(6)を通過さ
せて水分や溶剤を蒸発させ、芯材層用シート材料(プリ
フレグ)(8)を得る。加熱乾燥条件は配合物の樹脂
量、揮発成分の種類や量、塗工厚みによって異なるが、
通常100〜160℃で5〜15分間程度である。乾燥
後、この長尺のプリフレグ(8)はカッター(7)によ
り所定長さに切断される。或いは切断しないで連続成形
に供することも可能である。このようにして、本発明の
化粧板の製造に使用される芯材層用シート材料が得られ
る。[0007] A long glass nonwoven fabric is coated with a thermosetting resin containing an inorganic filler, and then passed through a drying device (6) to evaporate moisture and a solvent, thereby forming a core material sheet material (pre-fleg). (8) is obtained. The heating and drying conditions vary depending on the amount of resin in the compound, the type and amount of volatile components, and the coating thickness.
Usually, it is about 5 to 15 minutes at 100 to 160 ° C. After drying, the long pre-flag (8) is cut into a predetermined length by a cutter (7). Alternatively, it is also possible to perform continuous molding without cutting. In this way, a sheet material for a core material layer used for manufacturing the decorative board of the present invention is obtained.
【0008】得られた芯材層用シート材料(11)は、
化粧板(14)の板厚に応じて、複数枚使用し、表面化
粧用シート材料(12)及び補強層用シート材料(1
3)と組み合わされて加熱加圧成形される。化粧層用シ
ート材料(12)は、通常のメラミン樹脂化粧板に用い
るものと同様であり、化粧紙等の化粧シートにメラミン
樹脂を含浸乾燥したものである。補強層用シート材料
(13)はガラス繊維織布にメラミン樹脂、フェノール
樹脂等の熱硬化性樹脂を含浸したプリフレグであるが、
耐燃性をより大きくするためには熱硬化性樹脂はメラミ
ン樹脂が好ましい。The obtained core material layer sheet material (11)
According to the thickness of the decorative board (14), a plurality of sheets are used, and the surface decorative sheet material (12) and the reinforcing layer sheet material (1) are used.
It is heated and pressed in combination with 3). The decorative layer sheet material (12) is the same as that used for a normal melamine resin decorative plate, and is obtained by impregnating and drying a decorative sheet such as decorative paper with a melamine resin. The sheet material (13) for the reinforcing layer is a pre-flag obtained by impregnating a thermosetting resin such as a melamine resin or a phenol resin into a glass fiber woven fabric.
In order to further increase the flame resistance, the thermosetting resin is preferably a melamine resin.
【0009】これらのシート材料は、補強層用シート材
料(13)を中央に、その両側に芯材層用シート材料
(11)を重ね合わせ、片側又は両側の表面に化粧層用
シート材料を重ね合わせる。芯材層用シート材料(1
1)は、樹脂配合物の塗工面を中央の補強層用シート材
料側にし補強層用シート材料の両側で同一枚数とするの
が、化粧板の反り・変形の防止のために好ましい。化粧
層用シート材料は、同様に化粧板の反り・変形の防止の
ために、両表面に配置するのが好ましい。成形条件は、
主として得られた芯材層用シート材料中の樹脂配合物の
流動性によるが、通常温度120〜150℃、圧力60
〜110kg/cm2 、時間50〜120分間が適当で
ある。In these sheet materials, a sheet material for a core material layer (11) is laminated on both sides of a sheet material for a reinforcing layer (13) in the center, and a sheet material for a decorative layer is laminated on one or both surfaces. Match. Sheet material for core layer (1
In 1), it is preferable to make the coated surface of the resin composition the center side of the sheet material for the reinforcing layer and to set the same number of sheets on both sides of the sheet material for the reinforcing layer in order to prevent warpage and deformation of the decorative board. Similarly, the decorative layer sheet material is preferably disposed on both surfaces in order to prevent warpage and deformation of the decorative plate. The molding conditions are
Although it depends mainly on the fluidity of the resin composition in the obtained core material layer sheet material, the temperature is usually 120 to 150 ° C. and the pressure is 60.
110110 kg / cm 2 and a time of 50 to 120 minutes are appropriate.
【0010】[0010]
【実施例】以下、実施例及び比較例により具体的に説明
する。The present invention will be specifically described below with reference to examples and comparative examples.
【0011】《実施例1》坪量75g/m2 のガラス不
織布を巻き出し、続いてこれに次の配合からなる熱硬化
性樹脂配合物Aをコンマロールコーターにより厚さ1.
2mm(乾燥後)になるように塗工した。 (配合物A配合) フェノール樹脂(不揮発分50%) 12重量部 無機充填材(水酸化アルミニウム) 94重量部 その後、乾燥装置で150℃、10分間乾燥し芯材層用
シート材料を作製した。 坪量80g/m2 の化粧板用
化粧原紙に硬化剤を含むメラミン樹脂を浸漬方式で塗布
含浸し化粧層用シート材料Bを作製し、また坪量80g
/m2 の化粧原紙に硬化剤を含むメラミン樹脂を浸漬方
式で塗布含浸し化粧層用シート材料Cを作製した。ま
た、坪量210g/m2 のガラス織布に硬化剤を含むメ
ラミン樹脂を浸漬方式で塗布含浸し補強層用シート材料
を得た。作製した芯材層用シート材料を4枚使用し、2
枚ずつ重ね合わせ、その間に補強層用シート材料を挿入
し、表面に化粧層用シート材料Bを、裏面に化粧層用シ
ート材料Cを重ねて、最高温度140℃、圧力70kg
/cm2 で60分間加熱加圧成形して、厚さ3.3mm
の化粧板を得た。Example 1 A glass non-woven fabric having a basis weight of 75 g / m 2 was unwound, and subsequently a thermosetting resin composition A having the following composition was applied to a thickness of 1.000 using a comma roll coater.
Coating was performed so as to be 2 mm (after drying). (Compound A) 12 parts by weight of phenol resin (50% of non-volatile content) 94 parts by weight of inorganic filler (aluminum hydroxide) Thereafter, the resultant was dried at 150 ° C. for 10 minutes with a drier to prepare a core material layer sheet material. A melamine resin containing a curing agent is applied and impregnated on a decorative base paper for decorative board having a basis weight of 80 g / m 2 by a dipping method to prepare a sheet material B for a decorative layer.
/ M 2 of decorative base paper was coated with a melamine resin containing a curing agent by a dipping method and impregnated to prepare a decorative layer sheet material C. A melamine resin containing a curing agent was applied and impregnated on a glass woven fabric having a basis weight of 210 g / m 2 by a dipping method to obtain a sheet material for a reinforcing layer. Using 4 sheets of the prepared core material sheet, 2
The sheet material for the reinforcing layer is inserted between the sheets, and the sheet material B for the decorative layer is placed on the front surface, and the sheet material C for the decorative layer is placed on the back surface.
/ Cm 2 for 60 minutes under heat and pressure, thickness 3.3mm
Was obtained.
【0012】《比較例1》実施例1の熱硬化性樹脂配合
物Aに水を加えて1.5倍に希釈し、坪量75g/m2
のガラス不織布を基材として浸漬方式で塗布・含浸して
芯材層用シート材料を得た。作製した芯材層用シート材
料を6枚使用し、3枚ずつ重ね合わせ、その間に補強層
用シート材料を挿入し、表面に化粧層用シート材料B
を、裏面に化粧層用シート材料Cを重ねて、実施例1と
同条件で加熱加圧成形して厚さ3.2mmの化粧板を得
た。Comparative Example 1 Water was added to the thermosetting resin composition A of Example 1 to dilute it 1.5-fold, and the basis weight was 75 g / m 2.
The glass nonwoven fabric was applied and impregnated by a dipping method to obtain a core material layer sheet material. Six sheets of the prepared core material layer material are used, and three sheets are superimposed on each other, and the sheet material for the reinforcement layer is inserted between them, and the sheet material B for the decorative layer is formed on the surface.
Was laminated with a sheet material C for decorative layer on the back surface, and heated and pressed under the same conditions as in Example 1 to obtain a decorative plate having a thickness of 3.2 mm.
【0013】以上、実施例及び比較例で得られる化粧板
の製造工程については、実施例の方法は工程が単純であ
り、製造コスト的にも、実施例で得られた化粧板は、コ
ストの高いガラス繊維不織布の使用枚数が少ないため、
比較例で得られた化粧板に比べ30%程度低コスト化す
ることができた。また、無機充填材の使用量を多くする
ことができるので、耐燃性も優れたものとすることが可
能である。As described above, the steps of manufacturing the decorative boards obtained in the examples and the comparative examples are simple in the method of the examples, and the decorative boards obtained in the examples are less expensive in terms of manufacturing cost. Due to the small number of glass fiber nonwovens used,
The cost could be reduced by about 30% as compared with the decorative board obtained in the comparative example. Further, since the amount of the inorganic filler used can be increased, it is possible to improve the flame resistance.
【0014】[0014]
【発明の効果】本発明の化粧板の製造方法は、芯材層用
シート材料を作製する際に高粘度での塗工が可能である
ので、配合物を溶剤・水等で希釈する必要がなく、また
配合物の厚塗りが可能である。このことから化粧板中の
ガラス基材比率を低くでき、製造工程も簡単であるの
で、低コスト化の点で優れている。さらに、無機充填材
を多量に含む熱硬化性樹脂を使用できるので、耐燃性に
優れた化粧板を製造する方法として好適である。According to the method for producing a decorative sheet of the present invention, it is necessary to dilute the composition with a solvent, water, or the like, since high-viscosity coating is possible when preparing the core material layer sheet material. And thick coating of the formulation is possible. From this, the ratio of the glass base material in the decorative board can be reduced, and the manufacturing process is simple, which is excellent in terms of cost reduction. Further, since a thermosetting resin containing a large amount of an inorganic filler can be used, it is suitable as a method for producing a decorative board excellent in flame resistance.
【図1】 本発明の製造工程において、芯材層用シート
材料を作製する迄の工程を示す概略断面図。FIG. 1 is a schematic cross-sectional view showing a process of manufacturing a core material sheet in a manufacturing process of the present invention.
【図2】 本発明で得られる化粧板におけるシート材料
の構成を示す概略断面図。FIG. 2 is a schematic cross-sectional view showing a configuration of a sheet material in a decorative board obtained by the present invention.
1 巻き出し装置 2 長尺基材 3 搬送ローラー 4 (無機充填材入り)ワニス 5 コーター 6 乾燥装置 7 カッター 8 複合プリプレグ 11 芯材層用シート材料 12 化粧用シート材料 13 補強層用シート材料 14 化粧板 DESCRIPTION OF SYMBOLS 1 Unwinder 2 Long base material 3 Conveying roller 4 Varnish (with inorganic filler) 5 Coater 6 Drying device 7 Cutter 8 Composite prepreg 11 Sheet material for core layer 12 Sheet material for makeup 13 Sheet material for reinforcing layer 14 Makeup Board
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 FI // B29L 9:00 31:10 ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 6 Identification code FI // B29L 9:00 31:10
Claims (4)
ニウムを主成分とする無機充填材を含有する熱硬化性樹
脂を塗工し、加熱乾燥して芯材層用シート材料を作製す
る工程、ガラス織布に熱硬化性樹脂を含浸乾燥して補強
層用シート材料を作製する工程、化粧シートにメラミン
樹脂を含浸乾燥して化粧層用シート材料を作製する工
程、及び2枚以上の芯材層用シート材料の間に補強層用
シート材料を挿入し、表面に化粧層用シート材料を重ね
合わせ加熱加圧成形する工程を有することを特徴とする
耐燃性化粧板の製造方法。1. A step of applying a thermosetting resin containing an inorganic filler containing aluminum hydroxide as a main component from one side of a glass nonwoven fabric, heating and drying to prepare a core material layer sheet material, A step of producing a sheet material for a reinforcing layer by impregnating and drying a woven fabric with a thermosetting resin, a step of producing a sheet material for a decorative layer by impregnating a decorative sheet with a melamine resin, and two or more core material layers A method for producing a flame-resistant decorative board, comprising a step of inserting a sheet material for a reinforcing layer between sheet materials for a sheet, superimposing the sheet material for a decorative layer on the surface thereof, and subjecting the sheet material to heat and pressure molding.
充填材を含有する熱硬化性樹脂は、熱硬化性樹脂がメラ
ミン樹脂及び又はフェノール樹脂であり、熱硬化性樹脂
と無機充填材との割合が3〜15重量%対97〜85重
量部であるペースト状物である請求項1記載の化粧板の
製造方法。2. A thermosetting resin containing an inorganic filler containing aluminum hydroxide as a main component, wherein the thermosetting resin is a melamine resin and / or a phenol resin, and the ratio of the thermosetting resin to the inorganic filler is Is a paste-like material having a content of 3 to 15% by weight to 97 to 85 parts by weight.
樹脂が、メラミン樹脂である請求項1又は2記載の化粧
板の製造方法。3. The method for producing a decorative board according to claim 1, wherein the thermosetting resin impregnated in the sheet material for the reinforcing layer is a melamine resin.
れる全シート材料の中央に補強層用シート材料を置き、
芯材層用シート材料は無機充填材含有熱硬化性樹脂を塗
工した面を補強層用シート材料側に向けて重ね合わせる
請求項1,2又は3記載の化粧板の製造方法。4. A sheet material for a reinforcing layer is placed at the center of all sheet materials to be laminated when a decorative board is subjected to heat and pressure molding,
4. The method for producing a decorative board according to claim 1, wherein the core material layer sheet material is laminated with the surface coated with the thermosetting resin containing an inorganic filler facing the sheet material side for the reinforcing layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10072104A JPH11268186A (en) | 1998-03-20 | 1998-03-20 | Manufacture of decorative plate |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP10072104A JPH11268186A (en) | 1998-03-20 | 1998-03-20 | Manufacture of decorative plate |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH11268186A true JPH11268186A (en) | 1999-10-05 |
Family
ID=13479767
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP10072104A Pending JPH11268186A (en) | 1998-03-20 | 1998-03-20 | Manufacture of decorative plate |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH11268186A (en) |
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006111458A1 (en) * | 2005-04-18 | 2006-10-26 | Owens-Corning Intellectual Capital, Llc | Fire retardant laminate |
| WO2007098018A3 (en) * | 2006-02-17 | 2007-10-25 | Owens Corning Fiberglas Tech | Continuous pressed laminates |
| WO2012073812A1 (en) * | 2010-11-30 | 2012-06-07 | 住友ベークライト株式会社 | Decorative melamine board |
| KR101695624B1 (en) * | 2015-09-25 | 2017-01-13 | 김현재 | Semi-non-combustible material Panel and Method for producing thereof |
| CN107984898A (en) * | 2017-10-08 | 2018-05-04 | 刘道灵 | A kind of energy-efficient wall paper transfer fitting processing unit (plant) |
-
1998
- 1998-03-20 JP JP10072104A patent/JPH11268186A/en active Pending
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2006111458A1 (en) * | 2005-04-18 | 2006-10-26 | Owens-Corning Intellectual Capital, Llc | Fire retardant laminate |
| JP2008536721A (en) * | 2005-04-18 | 2008-09-11 | オウェンス コーニング インテレクチュアル キャピタル リミテッド ライアビリティ カンパニー | Flame retardant laminate |
| WO2007098018A3 (en) * | 2006-02-17 | 2007-10-25 | Owens Corning Fiberglas Tech | Continuous pressed laminates |
| WO2012073812A1 (en) * | 2010-11-30 | 2012-06-07 | 住友ベークライト株式会社 | Decorative melamine board |
| JP2012116091A (en) * | 2010-11-30 | 2012-06-21 | Sumitomo Bakelite Co Ltd | Decorative melamine board |
| US10279571B2 (en) | 2010-11-30 | 2019-05-07 | Sumitomo Bakelite Company Limited | Decorative melamine board |
| KR101695624B1 (en) * | 2015-09-25 | 2017-01-13 | 김현재 | Semi-non-combustible material Panel and Method for producing thereof |
| WO2017052224A1 (en) * | 2015-09-25 | 2017-03-30 | 김현재 | Eco-friendly semi-non-combustible panel applicable to furniture and construction materials and manufacturing method therefor |
| CN107984898A (en) * | 2017-10-08 | 2018-05-04 | 刘道灵 | A kind of energy-efficient wall paper transfer fitting processing unit (plant) |
| CN107984898B (en) * | 2017-10-08 | 2019-10-11 | 六安维奥智能科技有限公司 | A high-efficiency and energy-saving wall cloth transfer printing and laminating processing device |
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