JP2012131092A - Non-combustible decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a nonflammable decorative panel which can be easily bent outward during construction while maintaining the surface hardness of a melamine decorative board, and has a sufficient nonflammability by suppressing a calorific value. .
A nonflammable decorative panel having a structure in which a surface decorative layer, a first metal layer, a core material layer, and a second metal layer are laminated in this order, the surface decorative layer having a design surface and A surface comprising a surface decorative layer base material carrying a resin containing a melamine resin on the first surface side, and carrying a solid content of the thermoplastic emulsion resin on the second surface side in contact with the first metal layer A nonflammable decorative panel comprising a decorative layer material, wherein the solid content of the thermoplastic emulsion resin comprises urethane acrylic composite particles having a heterophase structure of an acrylic resin and a urethane resin in a single particle. In addition, the urethane acrylic composite particles are preferably an aqueous clear type having a core-shell structure with an acrylic component as a core and a urethane component as a shell.
[Selection] Figure 1

Description

  The present invention relates to a nonflammable decorative panel.

Melamine decorative boards are hard and have good water resistance, stain resistance, and scratch resistance, and thus have been used in various fields such as furniture, architectural walls, and vehicle interior applications. The decorative layer on the surface uses decorative paper impregnated with melamine resin, and the core material layer uses kraft paper impregnated with phenolic resin, glass paper coated with thermosetting resin and flame retardant, and aluminum. There are various combinations of melamine decorative boards, and in each case, a decorative layer having a melamine resin is formed on the surface, and decorative boards having good scratch resistance and stain resistance have been provided. On the other hand, since general melamine decorative boards are hard, they are unsuitable for processing applications such as bending, and so-called melamine resins for post foam that can be used for 6-8R bending applications have been developed. The decorative plate can be heated and bent and has been used for doors and the like.
In a field where nonflammability is required, a melamine decorative board in which a melamine decorative layer and a metal layer such as aluminum are combined is used (see, for example, Patent Document 1). In order to bond the melamine decorative layer and aluminum. A kraft paper layer impregnated with phenolic resin is required, and the thickness of the melamine decorative board is increased by the amount of this phenolic resin layer, which limits the bending workability and limits the bending process of 1000 mmR at room temperature. Met.

  In addition, with regard to the heat resistance required for such materials, the Building Standards Act was revised in 2000, complying with the technical standards stipulated by a Cabinet Order for falling under non-combustible materials specified in Article 2-9. The nonflammable material test, which is a criterion for determining whether or not it is suitable, has been changed from a surface combustion test and a base material combustion test to a corn calorimeter exothermic test and a gas hazard test. It is necessary to suppress the calorific value.

JP 2002-137327 A

  The present invention provides a nonflammable decorative panel that can be easily bent outward during construction while maintaining the surface hardness of the melamine decorative board, and that has sufficient nonflammability by suppressing the amount of heat generated. To do.

Such an object is achieved by the following present invention [1] to [10].
[1] A nonflammable decorative panel having a structure in which a surface decorative layer, a first metal layer, a core material layer, and a second metal layer are laminated in this order,
The surface decorative layer carries a resin containing a melamine resin on a first surface side which is a design surface, and carries a solid content of a thermoplastic emulsion resin on a second surface side in contact with the first metal layer. A nonflammable decorative panel comprising a surface decorative layer material comprising a surface decorative layer base material.
[2] The non-combustible decorative panel according to [1], wherein the solid content of the thermoplastic emulsion resin includes emulsion resin particles having an average particle size of 30 to 100 nm.
[3] The nonflammable decorative panel according to [1] or [2], wherein the solid content of the thermoplastic emulsion resin is water-insoluble.
[4] The solid content of the thermoplastic emulsion resin according to any one of [1] to [3], wherein the single particle includes urethane acrylic composite particles having a heterophase structure of an acrylic resin and a urethane resin. Nonflammable decorative panel as described.
[5] The nonflammable decorative panel according to [4], wherein the urethane-acrylic composite particles are an aqueous clear type having a core-shell structure in which an acrylic component is a core and a urethane component is a shell.
[6] The nonflammable decorative panel according to any one of [1] to [5], wherein the first metal layer and the second metal layer have a thickness of 0.3 to 0.8 mm.
[7] The nonflammable decorative panel according to any one of [1] to [6], wherein the first metal layer and the second metal layer are aluminum layers.
[8] The nonflammable decorative panel according to any one of [1] to [7], wherein the core layer has a thickness of 2.0 to 6.0 mm.
[9] The nonflammable decorative panel according to any one of [1] to [8], wherein the core layer includes phenol resin-impregnated paper.
[10] The nonflammable decorative panel according to any one of [1] to [8], wherein the core layer includes a phenol resin foam or a polycarbonate resin foam.

  According to the present invention, while maintaining the surface hardness of the melamine decorative board, the end portion can be easily bent outward during construction, and the nonflammable decorative panel has sufficient nonflammability by suppressing the amount of generated heat. Can be provided.

It is a conceptual diagram showing an example of a structure of the nonflammable decorative panel of this invention.

Hereinafter, the nonflammable decorative panel of the present invention will be described in detail.
FIG. 1 shows a cross-sectional configuration of a nonflammable decorative panel according to an embodiment of the present invention.
The non-combustible decorative panel 101 includes a surface decorative layer 10, a first metal layer 11, a core material layer 12, and a second metal layer 13.
The nonflammable decorative panel of the present invention can be manufactured by laminating a surface decorative layer, a first metal layer, a core material layer, and a second metal layer in this order.

Below, the nonflammable decorative panel of this invention is demonstrated in detail.
The nonflammable decorative panel of the present invention (hereinafter sometimes simply referred to as “decorative panel”)
A nonflammable decorative panel having a structure in which a surface decorative layer, a first metal layer, a core material layer, and a second metal layer are laminated in this order,
The surface decorative layer carries a resin containing a melamine resin on a first surface side which is a design surface, and carries a solid content of a thermoplastic emulsion resin on a second surface side in contact with the first metal layer. It is characterized by comprising a surface decorative layer material comprising a surface decorative layer base material.

First, the surface decorative layer used for the decorative panel of the present invention will be described.
The surface decorative layer material of the present invention carries a resin containing a melamine resin on the first surface side which is the design surface of the surface decorative layer base material and is in contact with the first metal layer (that is, opposite to the design surface). The solid surface of the thermoplastic emulsion resin is supported on the second surface side.
The surface decorative layer substrate used in the surface decorative layer material of the present invention is a sheet-shaped substrate having a design surface formed on the first surface side. The material of the surface decorative layer base material is not particularly limited, but preferably, pulp, linter, synthetic fiber, glass fiber, or the like can be used, and if necessary, titanium oxide-containing makeup containing a pigment such as titanium oxide. Paper or the like can be used. Although the basic weight of a surface decoration layer base material is not specifically limited, It is preferable that it is 40-150 g / m < ² > of basic weight. If the basis weight is less than the lower limit value, coating treatment is difficult due to problems of cutting and wrinkling in the resin impregnation step, and further supported on each of the first and second surfaces, which is a feature of the present invention. It is also difficult to adjust the amount of resin impregnated. On the other hand, when the basis weight exceeds the above upper limit, the resin impregnation unevenness occurs in the resin impregnation amount carried by the surface decorative layer base material, and the flexibility of the melamine decorative board 12 is lowered, and the productivity is lowered and the cost is increased. It is not preferable because it causes.

In the surface decorative layer material of the present invention, a resin containing a melamine resin is supported on the first surface side of the surface decorative layer base material. Thereby, the surface hardness suitable for the surface by the side of the 1st surface of surface decorative layer material, ie, a decorative panel surface, can be provided.
Although it does not specifically limit as a melamine resin, For example, what is obtained by making melamine and formaldehyde react under neutrality or weak alkali can be used. The reaction molar ratio of formaldehyde to melamine (the value of (molar amount of formaldehyde) / (molar amount of melamine), hereinafter simply referred to as “reaction molar ratio”) is not particularly limited, but is 1.0 to What was obtained by making it react as 4.0, preferably 1.0-2.0, more preferably 1.1-1.8 can be used suitably.
When the reaction molar ratio is less than the lower limit, unreacted components increase, resulting in a decrease in storage stability and cost. When the reaction molar ratio exceeds the upper limit, the resin flexibility after curing becomes significant. In addition, as a melamine resin, what is contained individually by 1 type can also be used, and what contains 2 or more types of melamine resins in which reaction molar ratios, weight average molecular weights, etc. differ can be used.
Moreover, as a melamine resin, a commercially available thing, such as a melamine resin by Sumitomo Chemical Co., Ltd., can also be used.

  Although the weight average molecular weight of a melamine resin is not specifically limited, 200-500 are preferable and 250-350 are especially preferable. When the molecular weight is smaller than the lower limit value, the amount of unreacted components increases, and the storage stability is lowered. When the molecular weight is larger than the upper limit value, the impregnation property to the substrate is lowered. The weight average molecular weight can be measured, for example, by GPC (gel permeation chromatography, standard substance: converted to polystyrene).

  Although content of the said melamine resin in resin carry | supported by the 1st surface side of surface cosmetic layer material is not specifically limited, It is 80-100 mass%, and 95-100 mass% is especially preferable. When the content of the melamine resin is less than the lower limit, the surface hardness and the stain resistance are lowered.

  The method for supporting the resin containing the melamine resin on the first surface side of the surface decorative layer base material is not particularly limited, but a resin varnish obtained by dissolving the resin in a solvent, for example, a spray device, a shower device, Examples of the method include coating with a known apparatus such as a kiss coater and a comma coater and then drying by heating at about 80 to 130 ° C. In addition, it is preferable that 2-6 mass% volatile matter (solvent) remains in the resin-impregnated paper after the heat drying when the weight of the entire resin-impregnated paper is 100 mass%. This facilitates the handling of the resin-impregnated paper and improves the appearance and surface gloss of the decorative board by improving the resin flow of the melamine resin carried on the first surface side during thermoforming. Because it becomes. When the volatile content is 2% or less, the resin-impregnated paper is easily cracked and difficult to handle, and the resin flow is lowered, which hinders appearance formation. When the volatile content is 6% or more, the decorative board warpage (sheet curl) is likely to increase in a dry environment after molding, and when it is 7.5% or more, the gloss transfer property on the decorative board appearance is volatile. The effects of

  Although it does not specifically limit as a solvent which melt | dissolves resin containing the said melamine resin, For example, water, methanol, etc. are mentioned. Of these, water is preferred. Moreover, you may use a poor solvent in the range which does not exert a bad influence. The solid content of the resin varnish (all components excluding the solvent) is not particularly limited, but is preferably 30 to 70% by mass, and particularly preferably 45 to 60% by mass of the resin varnish. Thereby, the impregnation property to the base material of the resin varnish can be improved.

  In the surface decorative layer material of the present invention, the solid content of the thermoplastic emulsion resin is supported on the second surface side opposite to the design surface of the surface decorative layer base material. In the present invention, the thermoplastic emulsion resin includes a thermoplastic resin but is dispersed in a solvent to become an emulsion state. The solid content of the thermoplastic emulsion resin means a component obtained by removing the solvent from the thermoplastic emulsion resin.

  The solid content of the thermoplastic emulsion resin contains components present as emulsion resin particles, has adhesive properties with metals and various materials, and imparts flexibility to the melamine decorative board. Therefore, the solid content of the thermoplastic emulsion resin is carried on the second surface side, so that the adhesive strength between the surface decorative layer and the first metal layer can be improved, and the bending process of the melamine decorative plate is performed. Can be improved.

  The solid content of the thermoplastic emulsion resin is not particularly limited. For example, acrylic resin, urethane resin, vinyl acetate copolymer, urethane acrylic composite particles, styrene butadiene rubber (SBR), nitrile rubber (NBR), etc. The emulsion particle | grains of a thermoplastic resin are mentioned. Among these, urethane acrylic composite particles are preferable. In the present invention, the urethane-acrylic composite particles mean those having a heterogeneous structure of an acrylic resin and a urethane resin in a single particle. Since each of the urethane resin and the acrylic resin has high adhesive strength with the core material layer, good adhesive strength with the core material layer can be expressed by using urethane acrylic composite particles. Furthermore, the urethane resin is particularly excellent in toughness, elasticity, and flexibility, and the acrylic resin is particularly excellent in transparency, durability, weather resistance, chemical resistance, and film forming property. In the present invention, “heterophasic structure” means a structure in which a plurality of phases composed of different types of resins are present in one particle, and examples thereof include a core-shell structure, a localized structure, and a sea-island structure. Moreover, the arrangement state between the particles when the urethane acrylic composite particles are supported on the first surface side of the surface decorative layer material is not particularly limited, and examples thereof include a linear structure. The structure of the particles and the arrangement state between the particles can be confirmed by, for example, a scanning electron microscope (SEM). Among these, the urethane acrylic composite particles are particularly preferably an aqueous clear type having a core-shell structure in which an acrylic component is a core and a urethane component is a shell. When the urethane acrylic composite particles have the above-mentioned core-shell structure, when the surface outline is a urethane composition when supported on the second surface side of the surface decorative layer material, the second surface side of the surface decorative layer material is: While having the properties of both a urethane resin and an acrylic resin, the properties of the urethane resin are imparted to the outer shell. In the present invention, the term “aqueous clear” means that the resin solution is water-soluble, the coating film after the moisture is removed is non-aqueous, and the resin solution is transparent enough to clearly distinguish the underlying pattern. Means. When the resin carried on the second surface side of the surface decorative layer material is an aqueous clear type, the influence on the color tone of the design surface of the surface decorative layer can be suppressed.

In addition, as solid content of a thermoplastic emulsion resin, the thing containing one of these alone can also be used, and the thing containing 2 or more types of different thermoplastic resins can also be used.
In addition to the thermoplastic resin emulsion particles, the solid content of the thermoplastic emulsion resin may contain a small amount of a thickener, a penetration accelerator, an antifoaming agent, and the like, if necessary.

  The solid content of the thermoplastic emulsion resin preferably includes emulsion resin particles having an average particle diameter of 30 to 100 nm, and the average particle diameter of the emulsion resin particles is particularly preferably 60 to 90 nm. Thereby, since the impregnation property between the fibers of the surface decorative layer base material is improved and the surface decorative layer base material can be further impregnated, good flexibility can be imparted to the surface decorative layer.

  The solid content of the thermoplastic emulsion resin is preferably water-insoluble. As a result, the solid content of the thermoplastic emulsion resin moves to the first surface side of the surface decorative layer material, and is mixed with the melamine resin carried on the first surface side. It can prevent impairing the surface performance by the melamine resin.

  The method of supporting the solid content of the thermoplastic emulsion resin on the second surface side of the surface decorative layer base material is not particularly limited, and a resin containing a melamine resin is disposed on the first surface side of the surface decorative layer base material. It can carry out similarly to the above-mentioned method to carry | support. That is, a method in which the thermoplastic emulsion resin in an emulsion state dissolved in a solvent is applied and heat-dried can be used. In addition, it is preferable that 2-6 mass% of volatile matters remain in the resin-impregnated paper after the heat drying when the weight of the entire resin-impregnated paper is 100 mass%. This facilitates the handling of the resin-impregnated paper and improves the appearance and surface gloss of the decorative board by improving the resin flow of the melamine resin carried on the first surface side during thermoforming. Because it becomes.

Although it does not specifically limit as a solvent used for the said thermoplastic emulsion resin, For example, water etc. are mentioned. Moreover, you may use a poor solvent in the range which does not exert a bad influence.
The solid content (all components excluding the solvent) of the thermoplastic emulsion resin is not particularly limited, but is preferably 25 to 60% by mass, and particularly preferably 30 to 45% by mass, of the thermoplastic emulsion resin. Thereby, the impregnation property to the base material of the said thermoplastic emulsion resin can be improved.

Next, the first metal layer will be described.
The first metal layer is used for the decorative panel of the present invention. Thereby, moisture absorption from the atmosphere can be suppressed, swelling due to moisture absorption can be prevented, and occurrence of swelling on the surface of the decorative panel can be prevented.
Examples of the metal that forms the first metal layer include aluminum, copper, and stainless steel. Among these, it is preferable to use aluminum from the viewpoints of versatility, stability over time, and price.

The thickness of the first metal layer is not particularly limited, but is preferably 0.3 to 0.8 mm. Thereby, favorable nonflammability can be provided to the decorative panel of the present invention. Moreover, the mechanical strength of the decorative panel can be improved.
As the first metal layer, a metal foil, a metal plate, or the like having such a thickness can be used.

Next, the core material layer used in the decorative panel of the present invention will be described.
The thickness of the core material layer used here is 1.0 to 6.0 mm. More preferably, it is 2.0 to 4.0 mm. Thereby, the emitted-heat amount can be suppressed and sufficient nonflammability can be provided to a decorative panel by using with the said 1st metal layer.
Here, as the core material layer, for example, the following three forms can be applied.

  The core material layer of the first embodiment is a layer of resin-impregnated paper having a predetermined thickness as the intermediate core layer in the present invention, and is usually made of adhesive-impregnated paper, phenol resin-impregnated paper, or adhesive-impregnated paper. The phenol resin impregnated paper is usually 1 to 4 plies. The adhesion-impregnated paper is used for adhering a metal thin plate and a resin-impregnated paper, and is usually a phenol resin-impregnated paper or an epoxy resin-impregnated paper having good adhesion. The phenol resin-impregnated paper having good adhesiveness has a higher adhesive strength with a metal plate by increasing the resin content and reducing the volatile content compared to ordinary phenol resin-impregnated paper.

The core material layer of the second form is a phenol resin foam obtained by foaming and curing a phenol resin in a plate shape.
As a phenol resin used here, a resol type phenol resin is preferable. Specifically, a polymer obtained by polymerizing phenol and formaldehyde as raw materials in the temperature range of 40 to 100 ° C. in the presence of a basic catalyst can be suitably used. Water is used as the foaming agent, and an amount of water suitable for foaming is added. In addition, a foamable phenol resin composition obtained by adding a surfactant, an acid curing catalyst, or the like can be used as a raw material.
The phenolic resin foam is discharged in a predetermined amount from a mixing device or the like that has prepared the foamable phenolic resin composition, and then pressure is applied from above and below to obtain a predetermined thickness. It can be obtained by molding. In addition, you may arrange | position the said adhesive impregnation paper on both surfaces of a phenol resin foam.
When using this type of core material layer, the thickness of the core material layer to be formed can be, for example, 2.0 to 5.0 mm.

The core material layer of the third form is a polycarbonate resin foam obtained by foaming and curing a polycarbonate resin in a plate shape.
The polycarbonate resin used as the main raw material is a polycarbonate formed from carbonic acid and glycol or bisphenol. An aromatic polycarbonate having a diphenylalkane in the molecular chain is preferred because of its high crystallinity and high melting point, and excellent heat resistance, weather resistance and acid resistance. Such polycarbonates include 2,2-bis (4-oxyphenyl) propane (also known as bisphenol A), 2,2-bis (4-oxyphenyl) butane, and 1,1-bis (4-oxyphenyl) cyclohexane. And polycarbonates derived from bisphenols such as 1,1-bis (4-oxyphenyl) isobutane and 1,1-bis (4-oxyphenyl) ethane.

The powdery polycarbonate resin used in the present invention preferably has an average particle diameter in the range of 100 to 1000 μm, expressed in the range of 150 to 250 μm, when expressed by a 50% diameter (D50) by a sieving method. Those are more preferred. When the average particle diameter is less than 100 μm, it is difficult to keep the supply amount of the raw material resin to the extruder constant, and it may be difficult to obtain a stable extruded foam by causing surging or the like. When the average particle diameter exceeds 1000 μm, heating on the low temperature side where the resin can flow becomes insufficient in melting of the resin in the extruder, and it may be difficult to obtain a good extruded foam. There is. As a method for obtaining a powdery polycarbonate-based resin having an average particle diameter in the above range, a resin is produced in the form of powder in the process of producing a resin by a polymerization reaction, which is collected, dried, and then screened to obtain a desired average. Examples thereof include a method of obtaining a particle size and a method of obtaining a resin having a desired average particle size from a pulverized product after pelletizing the resin once and then pulverizing with a mill.

Generally as a foaming agent, a volatile foaming agent and an inorganic foaming agent can be used. Specific examples of the volatile blowing agent include aliphatic hydrocarbons, alicyclic hydrocarbons, aromatic hydrocarbons, aliphatic alcohols, aliphatic ketones, and halogenated hydrocarbons. Examples of the aliphatic hydrocarbon include propane, n-butane, i-butane, n-pentane, i-pentane, and hexane. Examples of alicyclic hydrocarbons include cyclobutane, cyclopentane, and cyclohexane. Aromatic hydrocarbons include benzene, toluene, xylene and the like. Examples of the aliphatic alcohol include methanol, ethanol and propanol. Examples of the aliphatic ketone include acetone and methyl ethyl ketone. Examples of the halogenated hydrocarbon include 1-chloro-1,1-difluoroethane, pentafluoroethane, 1,1,1,2, -tetrafluoroethane, 1,1-difluoroethane, and the like.

Examples of the inorganic foaming agent include inorganic gases such as carbon dioxide gas and nitrogen gas. The foaming agents described in detail above can be used alone or in combination of two or more. For example, different types of foaming agents such as an inorganic foaming agent and a volatile foaming agent can be used in combination.
When using this type of core material layer, the thickness of the core material layer to be formed can be, for example, 2.0 to 5.0 mm. The adhesive impregnated paper may be disposed on both sides of the polycarbonate resin foam.

Next, the second metal layer will be described.
The decorative panel of the present invention may further include a second metal layer on the outermost surface on the core material layer side. Thereby, higher mechanical strength can be imparted to the decorative panel.
Examples of the metal forming the second metal layer include aluminum, copper, and stainless steel. Among these, it is preferable to use aluminum from the viewpoints of versatility, stability over time, and price.
Although the thickness of a 2nd metal layer is not specifically limited, For example, it can be 0.3-3.0 mm. More preferably, it is 0.3 to 0.5 mm.
As the second metal layer, a metal foil, a metal plate, or the like having such a thickness can be used.

Although it does not specifically limit as a manufacturing method of the decorative panel of this invention, For example, by laminating | stacking a surface decorative layer and a 1st metal layer previously, a decorative sheet is manufactured, and this is laminated | stacked with a core material layer etc. Can be manufactured.
Specifically, the decorative sheet is formed by arranging the design surface of the surface decorative layer on the outside and superposing the first metal layer on the opposite side of the design surface in this order at a molding temperature of 138 to 152 ° C. It can be produced by heating and pressing at a molding pressure of 6.5 to 9.0 MPa.
And the decorative panel of this invention can be manufactured by laminating | stacking a core material layer and a 2nd metal layer on the opposite side to the design surface of the obtained decorative sheet.

  The method for laminating the decorative sheet and the core material layer is not particularly limited, and examples thereof include a method in which each of the above components is superposed in the above order and then crimped by a cold press at 0.1 to 0.5 MPa. It is done.

  Hereinafter, the present invention will be described by way of examples.

Example 1
As the surface decorative layer substrate, titanium oxide-containing decorative paper having a weight of 80 g / m ² was used.
On the first surface side (design surface side) of the base material, a melamine resin (reaction molar ratio: 1.4, resin solid content: 50% by weight) was applied at a solid content of 50 g / m ² .
On the second surface side of the base material, an aqueous clear containing a urethane acrylic resin emulsion (“SU-100” manufactured by Chuo Rika Kogyo Co., Ltd., average particle size: 84 nm) is applied at a solid content of 40 g / m ² , Heat-dried to obtain impregnated paper 1 for surface decorative layer.
On the other hand, a water-soluble phenol resin having a molar ratio of formaldehyde to phenol of 1.3 and a viscosity of 38 cps / 20 ° C. was adjusted to a viscosity of 19 cps / 34 ° C. with methanol on a base material made of unbleached kraft paper having a weight of 190 g / m ² . Impregnation with a phenol resin varnish for impregnation and drying by heating gave a phenol resin impregnated paper 2 having a resin amount of 30% and a volatile content of 7%.
Further, an emulsification reaction was performed on a base material made of unbleached kraft paper having a weight of 145 g / m ² at a molar ratio of formaldehyde to phenol of 1.2 to obtain a dehydration-concentration type phenol resin varnish having a viscosity of 120 cps / 20 ° C. Thereafter, the resin was impregnated with a phenol resin varnish for impregnation adjusted to a viscosity of 27 cps / 35 ° C. with methanol and dried by heating to obtain an adhesive impregnated paper 3 having a resin amount of 48% and a volatile content of 5%.

Following these impregnated paper 1 for surface decorative layer and adhesive impregnated paper 3, a 0.8 mm thick aluminum plate (A3003P H16 defined in JIS H4000) sanded on both sides as a first metal layer is inserted, and phenol is added. After three sheets of resin-impregnated paper 2 and adhesive-impregnated paper 3 are assembled in this order, and then a 0.8 mm aluminum plate (A3003P H16 defined in JIS H4000, single-sided sanding processed product) is sequentially stacked as the second metal layer. In the same manner as in the pressure molding of a normal high-pressure melamine resin decorative board, the decorative sheet constituting material set is placed so that the stainless steel matte board and the impregnated paper 1 for the surface decorative layer are in contact with each other. Two sets were built back to back. The press was maintained at a pressure of 8.0 MPa. The hot platen temperature was set to 160 ° C., and heating was performed until the maximum product temperature reached 142 ° C., followed by cooling to obtain a metal-based melamine resin decorative board having a thickness of 3.1 mm.

(Example 2)
In the same manner as in Example 1, impregnated paper 1 for surface decorative layer and adhesive impregnated paper 3 were obtained.
Next, a surfactant was added to the liquid resol type phenol resin (PR-54070S, manufactured by Sumitomo Bakelite Co., Ltd.). The phenolic resin, foaming agent and acid catalyst are mixed in a mixer, and continuously discharged onto the above-mentioned various synthetic nonwoven fabric surface materials, and further coated with the same synthetic fiber nonwoven material surface material. Then, the continuous laminated body was formed, and this continuous laminated body was sandwiched and passed between double conveyors set at a predetermined temperature, and foamed and cured to obtain a phenol resin laminated foamed plate having a thickness of about 4 mm. The obtained foamed plate was cut to a length of about 120 cm and further heat-treated at 85 ° C. for 3 hours to complete the curing.

After the impregnated paper 1 for surface decorative layer and the adhesive impregnated paper 3, a 0.8 mm thick aluminum plate (A3003P H16 defined in JIS H4000) sanded on both sides as a first metal layer is inserted. The phenolic resin foam plate obtained in the above and the adhesive impregnated paper 3 were assembled in this order, and then a 0.8 mm aluminum plate (A3003P H16 defined in JIS H4000, single-sided sanding treated product) was sequentially stacked as the second metal layer. Later, in the same manner as in the pressure molding of a normal high-pressure melamine resin decorative board, the stainless steel matte board and the surface decorative layer impregnated paper 1 are in contact with each other, and the decorative board constituting material set is set between the stainless steel boards. Two pairs were built back to back. The press was maintained at a pressure of 8.0 MPa. The hot platen temperature was set to 160 ° C., and heating was performed until the maximum product temperature reached 142 ° C., followed by cooling to obtain a metal-based melamine resin decorative board having a thickness of 5.1 mm.

Example 3
In the same manner as in Example 1, impregnated paper 1 for surface decorative layer and adhesive impregnated paper 3 were obtained.
To 100 parts by weight of a polycarbonate resin having a viscosity average molecular weight of 29000, 0.02 part by weight of talc is added as a foam regulator, and this is heated, melted and mixed in an extruder, and then 0.60 mol / kg of n-pentane. (Resin)] is press-fitted into the extruder so that the resin impregnated with the foaming agent is extruded into a tubular shape from the circular die at the tip of the extruder at a resin temperature of 220 ° C., and the inner and outer surfaces of the extruded tubular foam are blown with air The sheet was taken up with a mandrel having a diameter of 200 mm while being cooled, and then cut along the flow direction to obtain a sheet-like foam. The density of the obtained foamed board was 0.15 g / cm ² and the thickness was 2.3 mm.

After the impregnated paper 1 for surface decorative layer and the adhesive impregnated paper 3, a 0.8 mm thick aluminum plate (A3003P H16 defined in JIS H4000) sanded on both sides as a first metal layer is inserted. The polycarbonate resin foam plate obtained in the above and the adhesive impregnated paper 3 were assembled in this order, and then a 0.8 mm aluminum plate (A3003P H16 defined in JIS H4000, single-sided sanding processed product) was sequentially stacked as the second metal layer. Later, in the same manner as in the pressure molding of a normal high-pressure melamine resin decorative board, the stainless steel matte board and the surface decorative layer impregnated paper 1 are in contact with each other, and the decorative board constituting material set is set between the stainless steel boards. Two pairs were built back to back. The press was maintained at a pressure of 8.0 MPa. The hot platen temperature was set to 160 ° C., and heating was performed until the maximum product temperature reached 142 ° C., followed by cooling to obtain a metal-based melamine resin decorative board having a thickness of 5.3 mm.

(Comparative Example 1)
As the surface decorative layer substrate, titanium oxide-containing decorative paper having a weight of 80 g / m ² was used.
A total of 110 g / m ² of melamine resin (reaction molar ratio: 1.4, resin solid content: 50% by weight) was applied to the first and second surfaces of the substrate at a solid content of 55 g / m ² .
Moreover, the adhesive layer material which coated 110 g / m < ² > of resol type phenol resin by solid content was prepared using the kraft paper of 146 g / m < ² > of this.
The surface decorative layer material obtained above, the adhesive layer material on the second surface side of this surface decorative layer material, and the aluminum layer used in Example 2 on which the primer treatment has been applied are laminated on the adhesive layer material. Together
On the aluminum foil surface side, three phenol impregnated papers were superimposed, and on the phenol impregnated paper side, a primer treatment surface of 0.3 mm thick aluminum foil whose surface was subjected to primer treatment with an epoxy resin was superimposed. The pressure was maintained at 8.0 MPa. The hot platen temperature was set to 160 ° C., and heating was performed until the maximum product temperature reached 142 ° C., followed by cooling to obtain a metal-based melamine resin decorative board having a thickness of 3.0 mm.

(Comparative Example 2)
As the surface decorative layer substrate, titanium oxide-containing decorative paper having a weight of 80 g / m ² was used.
The surface of the first and second surfaces of the base material coated with 110 g / m ² of melamine resin (reaction molar ratio 1.4, resin solid content 50% by weight) in solid content of 55 g / m ² each. A decorative layer material was obtained.
The surface-coated layer material obtained above and the surface of the aluminum layer used in Example 2 on which the primer treatment was applied were superimposed on the second surface side of the surface-coated layer material, and the aluminum foil primer-treated surface was superimposed on the aluminum foil. On the surface side, the phenol resin foam used in Example 2 was superimposed, and on the phenol-impregnated paper side, a primer treatment surface of a 0.3 mm thick aluminum foil whose surface was subjected to primer treatment with an epoxy resin was superimposed, The press was maintained at a pressure of 8.0 MPa. The hot platen temperature was set to 160 ° C., and heating was performed until the maximum product temperature reached 142 ° C., followed by cooling to obtain a metal-based melamine resin decorative board panel material having a thickness of 3.0 mm.

  The characteristics of the metal-based melamine resin decorative boards obtained in Examples 1, 2, and 3 and Comparative Examples 1 and 2 were evaluated. The results are shown in Table 1.

(Test method)
1. Non-flammability test Japan Fireworks Testing Center Business Standard "Fireproof and Fireproof Performance Test / Evaluation Procedure Method" 4.10 (2) ii) Exothermic test / evaluation method of 4.10.2 in the non-flammability performance test / evaluation method and It was carried out by the gas toxicity test / evaluation method of 4.10.3.
The item of the above-mentioned business standard “Fireproofing Performance Test / Evaluation Business Method” describes the performance evaluation method related to the certification based on the provisions of Article 2, Item 9 (non-combustible material) of the Building Standard Law.
2. Pencil hardness test In accordance with JIS K5600-5-4 [General paint test method-Part 5: Mechanical properties of coating film-Section 4: Scratch hardness (pencil method)], a pencil is applied to the design surface of the decorative panel surface. A hardness test was performed.
3. Bending strength test The bending strength was measured according to JIS K7171 (Plastic-Determination of bending characteristics).
4). Bend formability test Outer bending was performed at room temperature (25 ° C.) and 200 mmR, and the presence or absence of cracks in the design surface was confirmed.
As is clear from the results shown in Table 1 above, the samples obtained in Examples 1, 2, and 3 had nonflammability conforming to the standards and the like, and had good bend formability.
On the other hand, the samples obtained in Comparative Examples 1 and 2 had good nonflammability, but the bend formability decreased.

The decorative panel according to the present invention has good bending workability, nonflammability, and bending strength.
And since the surface decorative layer base material similar to the conventional decorative plate can be used for the surface decorative layer, it can be freely selected from abundant color patterns and is subject to the regulation of nonflammable materials in vehicles and the like It can be widely applied to uses such as walls.

Claims (10)

A nonflammable decorative panel having a structure in which a surface decorative layer, a first metal layer, a core material layer, and a second metal layer are laminated in this order,
The surface decorative layer carries a resin containing a melamine resin on a first surface side which is a design surface, and carries a solid content of a thermoplastic emulsion resin on a second surface side in contact with the first metal layer. A nonflammable decorative panel comprising a surface decorative layer material comprising a surface decorative layer base material. The non-combustible decorative panel according to claim 1, wherein the solid content of the thermoplastic emulsion resin includes emulsion resin particles having an average particle size of 30 to 100 nm. The incombustible decorative panel according to claim 1 or 2, wherein the solid content of the thermoplastic emulsion resin is water-insoluble. The non-combustible decorative panel according to any one of claims 1 to 3, wherein the solid content of the thermoplastic emulsion resin includes urethane acrylic composite particles having a heterophase structure of an acrylic resin and a urethane resin in a single particle. . The non-flammable decorative panel according to claim 4, wherein the urethane acrylic composite particles are an aqueous clear type having a core-shell structure in which an acrylic component is a core and a urethane component is a shell. The nonflammable decorative panel according to any one of claims 1 to 5, wherein the first metal layer and the second metal layer have a thickness of 0.3 to 0.8 mm. The nonflammable decorative panel according to any one of claims 1 to 6, wherein the first metal layer and the second metal layer are aluminum layers. The non-combustible decorative panel according to any one of claims 1 to 7, wherein the core layer has a thickness of 2.0 to 6.0 mm. The non-combustible decorative panel according to any one of claims 1 to 8, wherein the core layer includes phenol resin-impregnated paper. The non-combustible decorative panel according to any one of claims 1 to 8, wherein the core material layer includes a phenol resin foam or a polycarbonate resin foam.

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