JP6411871B2 - Decorative plate and manufacturing method thereof - Google Patents
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- JP6411871B2 JP6411871B2 JP2014235238A JP2014235238A JP6411871B2 JP 6411871 B2 JP6411871 B2 JP 6411871B2 JP 2014235238 A JP2014235238 A JP 2014235238A JP 2014235238 A JP2014235238 A JP 2014235238A JP 6411871 B2 JP6411871 B2 JP 6411871B2
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- 238000004519 manufacturing process Methods 0.000 title claims description 11
- 239000010410 layer Substances 0.000 claims description 237
- 239000000758 substrate Substances 0.000 claims description 86
- 238000000576 coating method Methods 0.000 claims description 85
- 239000003973 paint Substances 0.000 claims description 85
- 239000011248 coating agent Substances 0.000 claims description 63
- 239000011247 coating layer Substances 0.000 claims description 52
- 238000005498 polishing Methods 0.000 claims description 37
- 238000005470 impregnation Methods 0.000 claims description 33
- 229910052602 gypsum Inorganic materials 0.000 claims description 26
- 239000010440 gypsum Substances 0.000 claims description 26
- 238000000034 method Methods 0.000 claims description 19
- 238000012360 testing method Methods 0.000 claims description 15
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 11
- 229920005989 resin Polymers 0.000 claims description 10
- 239000011347 resin Substances 0.000 claims description 10
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 claims description 5
- 235000002017 Zea mays subsp mays Nutrition 0.000 claims description 5
- 235000005822 corn Nutrition 0.000 claims description 5
- 229920002803 thermoplastic polyurethane Polymers 0.000 claims description 5
- 239000003822 epoxy resin Substances 0.000 claims description 4
- 229920000647 polyepoxide Polymers 0.000 claims description 4
- OEPOKWHJYJXUGD-UHFFFAOYSA-N 2-(3-phenylmethoxyphenyl)-1,3-thiazole-4-carbaldehyde Chemical compound O=CC1=CSC(C=2C=C(OCC=3C=CC=CC=3)C=CC=2)=N1 OEPOKWHJYJXUGD-UHFFFAOYSA-N 0.000 claims description 3
- 239000004925 Acrylic resin Substances 0.000 claims description 3
- 229920000178 Acrylic resin Polymers 0.000 claims description 3
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 claims description 3
- 229920005749 polyurethane resin Polymers 0.000 claims description 3
- 229920002050 silicone resin Polymers 0.000 claims description 3
- 241000209149 Zea Species 0.000 claims 2
- 239000007787 solid Substances 0.000 description 56
- 230000000052 comparative effect Effects 0.000 description 24
- 239000000463 material Substances 0.000 description 24
- 239000000378 calcium silicate Substances 0.000 description 19
- 229910052918 calcium silicate Inorganic materials 0.000 description 19
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 19
- 238000001035 drying Methods 0.000 description 19
- 238000001723 curing Methods 0.000 description 10
- 239000000919 ceramic Substances 0.000 description 8
- -1 etc.) Substances 0.000 description 8
- 238000010521 absorption reaction Methods 0.000 description 6
- 238000011156 evaluation Methods 0.000 description 6
- 239000002994 raw material Substances 0.000 description 6
- 239000002585 base Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000012948 isocyanate Substances 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- 239000002253 acid Substances 0.000 description 4
- 239000000835 fiber Substances 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 229920006305 unsaturated polyester Polymers 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 239000004593 Epoxy Substances 0.000 description 3
- 240000008042 Zea mays Species 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000010422 painting Methods 0.000 description 3
- 230000002265 prevention Effects 0.000 description 3
- KCTAWXVAICEBSD-UHFFFAOYSA-N prop-2-enoyloxy prop-2-eneperoxoate Chemical compound C=CC(=O)OOOC(=O)C=C KCTAWXVAICEBSD-UHFFFAOYSA-N 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 239000002344 surface layer Substances 0.000 description 3
- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 description 2
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 2
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 2
- VZCYOOQTPOCHFL-OWOJBTEDSA-N Fumaric acid Chemical compound OC(=O)\C=C\C(O)=O VZCYOOQTPOCHFL-OWOJBTEDSA-N 0.000 description 2
- 239000005057 Hexamethylene diisocyanate Substances 0.000 description 2
- 239000005058 Isophorone diisocyanate Substances 0.000 description 2
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 2
- 238000005336 cracking Methods 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- KWORUUGOSLYAGD-YPPDDXJESA-N esomeprazole magnesium Chemical compound [Mg+2].C([S@](=O)C=1[N-]C2=CC=C(C=C2N=1)OC)C1=NC=C(C)C(OC)=C1C.C([S@](=O)C=1[N-]C2=CC=C(C=C2N=1)OC)C1=NC=C(C)C(OC)=C1C KWORUUGOSLYAGD-YPPDDXJESA-N 0.000 description 2
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical class OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 description 2
- 238000011049 filling Methods 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- RRAMGCGOFNQTLD-UHFFFAOYSA-N hexamethylene diisocyanate Chemical compound O=C=NCCCCCCN=C=O RRAMGCGOFNQTLD-UHFFFAOYSA-N 0.000 description 2
- 230000001678 irradiating effect Effects 0.000 description 2
- 150000002513 isocyanates Chemical class 0.000 description 2
- NIMLQBUJDJZYEJ-UHFFFAOYSA-N isophorone diisocyanate Chemical compound CC1(C)CC(N=C=O)CC(C)(CN=C=O)C1 NIMLQBUJDJZYEJ-UHFFFAOYSA-N 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000012855 volatile organic compound Substances 0.000 description 2
- DKPFZGUDAPQIHT-UHFFFAOYSA-N Butyl acetate Natural products CCCCOC(C)=O DKPFZGUDAPQIHT-UHFFFAOYSA-N 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 239000004721 Polyphenylene oxide Substances 0.000 description 1
- 229920001131 Pulp (paper) Polymers 0.000 description 1
- 239000004115 Sodium Silicate Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 150000007513 acids Chemical class 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 125000000746 allylic group Chemical group 0.000 description 1
- QUDWYFHPNIMBFC-UHFFFAOYSA-N bis(prop-2-enyl) benzene-1,2-dicarboxylate Chemical class C=CCOC(=O)C1=CC=CC=C1C(=O)OCC=C QUDWYFHPNIMBFC-UHFFFAOYSA-N 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 238000004140 cleaning Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 125000004386 diacrylate group Chemical group 0.000 description 1
- 125000005442 diisocyanate group Chemical group 0.000 description 1
- 239000003085 diluting agent Substances 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000002845 discoloration Methods 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- CWAFVXWRGIEBPL-UHFFFAOYSA-N ethoxysilane Chemical compound CCO[SiH3] CWAFVXWRGIEBPL-UHFFFAOYSA-N 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 239000001530 fumaric acid Substances 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 150000002334 glycols Chemical class 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000009499 grossing Methods 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- FUZZWVXGSFPDMH-UHFFFAOYSA-M hexanoate Chemical compound CCCCCC([O-])=O FUZZWVXGSFPDMH-UHFFFAOYSA-M 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000001023 inorganic pigment Substances 0.000 description 1
- IQPQWNKOIGAROB-UHFFFAOYSA-N isocyanate group Chemical group [N-]=C=O IQPQWNKOIGAROB-UHFFFAOYSA-N 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- PAZHGORSDKKUPI-UHFFFAOYSA-N lithium metasilicate Chemical compound [Li+].[Li+].[O-][Si]([O-])=O PAZHGORSDKKUPI-UHFFFAOYSA-N 0.000 description 1
- 229910052912 lithium silicate Inorganic materials 0.000 description 1
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000013008 moisture curing Methods 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000009740 moulding (composite fabrication) Methods 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 238000007517 polishing process Methods 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 238000006068 polycondensation reaction Methods 0.000 description 1
- 229920000570 polyether Polymers 0.000 description 1
- 229920005862 polyol Polymers 0.000 description 1
- 150000003077 polyols Chemical class 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- SOGFHWHHBILCSX-UHFFFAOYSA-J prop-2-enoate silicon(4+) Chemical class [Si+4].[O-]C(=O)C=C.[O-]C(=O)C=C.[O-]C(=O)C=C.[O-]C(=O)C=C SOGFHWHHBILCSX-UHFFFAOYSA-J 0.000 description 1
- 229910000077 silane Inorganic materials 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 229910052911 sodium silicate Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000011550 stock solution Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 150000005846 sugar alcohols Polymers 0.000 description 1
- 239000012085 test solution Substances 0.000 description 1
- LFQCEHFDDXELDD-UHFFFAOYSA-N tetramethyl orthosilicate Chemical compound CO[Si](OC)(OC)OC LFQCEHFDDXELDD-UHFFFAOYSA-N 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 238000004383 yellowing Methods 0.000 description 1
Landscapes
- Finishing Walls (AREA)
- Laminated Bodies (AREA)
Description
本発明は、不燃性を有し、低湿度クリーンルーム等の湿度が極端に低い環境においても、内装材として使用できる窯業系化粧板及びその製造方法に関する。 The present invention relates to a ceramic decorative board that is nonflammable and can be used as an interior material even in an environment with extremely low humidity such as a low-humidity clean room, and a method for producing the same.
クリーンルーム等の湿度が低い環境における内装材として、従来からけい酸カルシウム板や繊維強化セメント板等の窯業系材料を基板とし、その表面に塗膜層を形成し、あるいは化粧フィルムを接着した不燃の窯業系化粧板が使用されている(特許文献1)。けい酸カルシウム板は、多孔質であるため断熱性が高く、一方、多孔質であっても吸放湿に伴う寸法変化が比較的小さい、すなわち寸法安定性が比較的優れた材料であることから、クリーンルーム用内装材に適した材料である。しかし、最近は、例えばリチウム電池製造設備等を設置するために用いる、湿度が極端に低い条件となるクリーンルームの需要が増加しつつある。けい酸カルシウム板は、多孔質であっても寸法安定性が比較的優れた材料ではあるが、湿度が極端に低くなると、吸放湿に伴う寸法変化により反り等が発生することがあるため、寸法安定性が更に高く、湿度が極端に低い環境における内装材に適した不燃の窯業系化粧板が必要とされている。 As an interior material in low-humidity environments such as clean rooms, ceramic materials such as calcium silicate boards and fiber reinforced cement boards have been used as substrates, and a non-combustible material with a coating layer formed on the surface or a decorative film adhered. Ceramic-type decorative boards are used (Patent Document 1). Calcium silicate plates are highly heat-insulating because they are porous. On the other hand, even if they are porous, the dimensional change associated with moisture absorption and release is relatively small, that is, they are materials with relatively excellent dimensional stability. It is a material suitable for interior materials for clean rooms. However, recently, there is an increasing demand for clean rooms that are used to install, for example, lithium battery manufacturing facilities and the like and have extremely low humidity conditions. Calcium silicate plate is a material that is relatively excellent in dimensional stability even though it is porous, but when the humidity is extremely low, warpage may occur due to dimensional changes associated with moisture absorption and release, There is a need for non-combustible ceramic decorative panels suitable for interior materials in environments with higher dimensional stability and extremely low humidity.
すなわち、本発明の課題は、十分な不燃性を確保しつつ、塗膜性能及び外観が良好で、極端な低湿度の環境に対して十分な適性を有する窯業系化粧板を提供することにある。 That is, an object of the present invention is to provide a ceramic-based decorative board having good coating film performance and appearance while ensuring sufficient nonflammability and sufficient suitability for an extremely low humidity environment. .
そこで本発明者は、前記課題を解決すべく、種々検討した結果、基板として抄造石膏板を用い、その表面に有機塗膜で形成された下塗り層及び上塗り層の膜厚、及びそれらの合計膜厚を一定の範囲とし、下塗り層表面を研磨することにより、十分な不燃性と寸法安定性とを有する窯業系化粧板が得られることを見出し、本発明を完成した。 Therefore, as a result of various studies to solve the above problems, the present inventor used a papermaking gypsum plate as a substrate, and the film thickness of an undercoat layer and an overcoat layer formed with an organic coating film on the surface thereof, and a total film thereof It was found that a ceramic decorative panel having sufficient incombustibility and dimensional stability can be obtained by polishing the surface of the undercoat layer within a certain range of thickness, thereby completing the present invention.
すなわち、本発明は、抄造石膏板を基板とし、該基板の表面は研磨処理及び含浸シーラー処理されてなり、該基板の表面の上に下塗り層及び上塗り層を、この順で有する有機塗膜層を有し、
(a)下塗り層が、表面研磨され、その膜厚が5〜120μm、
(b)上塗り層の膜厚が5〜40μm、
(c)下塗り層と上塗り層とからなる有機塗膜層の膜厚が140μm以下であることを特徴とする化粧板を提供するものである。
That is, the present invention uses a papermaking gypsum board as a substrate, the surface of the substrate is subjected to polishing treatment and impregnation sealer treatment, and an organic coating layer having an undercoat layer and an overcoat layer on the surface of the substrate in this order. Have
(A) The undercoat layer is surface-polished and has a thickness of 5 to 120 μm,
(B) The thickness of the overcoat layer is 5 to 40 μm,
(C) Provided is a decorative board characterized in that the thickness of an organic coating layer composed of an undercoat layer and an overcoat layer is 140 μm or less.
また、本発明は、抄造石膏板を基板とし、該基板の表面を研磨処理した後含浸シーラー処理し、次いで下塗り層及び上塗り層をこの順で形成する化粧板の製造方法であって、
(a)下塗り塗装として下塗り層形成用有機塗料を塗布し、硬化させ、表面研磨し、膜厚が5〜120μmの下塗り層を形成し、
(b)上塗り塗装として上塗り層形成用有機塗料を塗布し、硬化させ、膜厚が5〜40μmの上塗り層を形成し、
(c)ただし、前記下塗り層と前記上塗り層とからなる有機塗膜層の膜厚を140μm以下とすることを特徴とする化粧板の製造方法を提供するものである。
Further, the present invention is a method for producing a decorative board in which a papermaking gypsum board is used as a substrate, the surface of the substrate is polished and then impregnated with a sealer, and then an undercoat layer and an overcoat layer are formed in this order.
(A) Applying an organic paint for forming an undercoat layer as an undercoat, curing, surface polishing, and forming an undercoat layer having a thickness of 5 to 120 μm;
(B) Applying an organic paint for forming an overcoat layer as the top coat and curing it to form an overcoat layer having a thickness of 5 to 40 μm;
(C) However, the present invention provides a method for producing a decorative board, wherein the thickness of the organic coating layer composed of the undercoat layer and the overcoat layer is 140 μm or less.
本発明によれば、吸放湿に伴う寸法安定性が非常に高く、かつコーンカロリーメータ法発熱性試験による総発熱量が法定の8MJ/m2以下をクリアした窯業系化粧板を提供できる。 ADVANTAGE OF THE INVENTION According to this invention, the dimensional stability accompanying moisture absorption / release is very high, and the ceramics type decorative board which cleared the total calorific value by the corn calorimeter method exothermic test below legal 8MJ / m < 2 > can be provided.
本発明の化粧板は、抄造石膏板を基板とし、該基板の表面は研磨処理及び含浸シーラー処理されてなり、該基板の表面の上に下塗り層及び上塗り層を、この順で有する有機塗膜層を有し、
(a)下塗り層が、表面研磨され、その膜厚が5〜120μm、
(b)上塗り層の膜厚が5〜40μm、
(c)下塗り層と上塗り層とからなる有機塗膜層の膜厚が140μm以下であることを特徴とする化粧板である。
The decorative board of the present invention has a papermaking gypsum board as a substrate, the surface of the substrate is subjected to polishing treatment and impregnation sealer treatment, and an organic coating film having an undercoat layer and an overcoat layer on the surface of the substrate in this order. Has a layer,
(A) The undercoat layer is surface-polished and has a thickness of 5 to 120 μm,
(B) The thickness of the overcoat layer is 5 to 40 μm,
(C) A decorative board characterized in that the organic coating layer composed of an undercoat layer and an overcoat layer has a film thickness of 140 μm or less.
本発明において、基板として用いる抄造石膏板は、マトリックス形成原料である水和性石膏、無機系混和材(炭酸カルシウム粉末等)及び繊維原料(木質パルプ等)を主原料とし、これらの原料に水を加えて混合して原料スラリーを形成し、原料スラリーを丸網抄造機等により所定の厚さに抄造して未硬化状態の生板(グリーンシート)を形成し、生板に対して必要に応じてプレス成形を行い、養生硬化することにより得られる材料である。 In the present invention, the papermaking gypsum board used as a substrate is mainly composed of hydrated gypsum, which is a matrix forming raw material, an inorganic admixture (calcium carbonate powder, etc.), and a fiber raw material (wood pulp, etc.). Is added to mix to form a raw material slurry, and the raw material slurry is made into a predetermined thickness by a round net making machine to form an uncured green plate (green sheet), which is necessary for the raw plate It is a material obtained by performing press molding in response to curing and curing.
抄造石膏板は、見掛け密度が概ね1.5〜1.7g/cm3であり、従来から一般のクリーンルーム用化粧板の基板として使用されているけい酸カルシウム板(以下:けい酸カルシウム板)の見掛け密度よりも高い。一方、抄造石膏板の平衡含水率は0.3%程度であり、けい酸カルシウム板の平衡含水率よりも低い。また、寸法安定性を評価するための試験である吸水による長さ変化率が、抄造石膏板は0.05〜0.07%程度であり、けい酸カルシウム板に比べ小さいことから、吸放湿に伴う寸法安定性が更に高く、湿度が極端に低い環境用の窯業系化粧板の基板に適している。 The paper-made gypsum board has an apparent density of approximately 1.5 to 1.7 g / cm 3 , and is a calcium silicate board (hereinafter referred to as a calcium silicate board) that has been used as a substrate for general clean room decorative boards. It is higher than the apparent density. On the other hand, the equilibrium moisture content of the papermaking gypsum board is about 0.3%, which is lower than the equilibrium moisture content of the calcium silicate board. In addition, the rate of change in length due to water absorption, which is a test for evaluating dimensional stability, is about 0.05 to 0.07% for a paper-made gypsum board, and is smaller than that of a calcium silicate board. Therefore, it is suitable for a ceramic decorative board for an environment that has higher dimensional stability and extremely low humidity.
一方、抄造石膏板及びけい酸カルシウム板は、ともに抄造法によって製造される材料である。抄造法においては、抄造繊維として原料にパルプが用いられ、抄造石膏板もけい酸カルシウム板もパルプの配合比率はほぼ同程度である。抄造石膏板は、けい酸カルシウム板よりも見掛け密度が高いから、単位体積当たり含有されるパルプの質量は、けい酸カルシウム板よりも多い。パルプは可燃物であるから、抄造石膏板の単位体積当たりの発熱量は、けい酸カルシウム板よりも多くなる。また、クリーンルームの内装材として使用する場合、抄造石膏板及びけい酸カルシウム板とも厚さに差はない。従って、不燃の窯業系化粧板の基板として抄造石膏板を用いる場合、不燃性能を確保するため、けい酸カルシウム板を用いる場合よりも塗膜層の発熱量を低くしなければならない。 On the other hand, a papermaking gypsum board and a calcium silicate board are both materials manufactured by a papermaking method. In the papermaking method, pulp is used as a raw material as a papermaking fiber, and the blending ratio of the pulp is about the same in both the papermaking gypsum board and the calcium silicate board. Since the paper-made gypsum board has an apparent density higher than that of the calcium silicate board, the mass of the pulp contained per unit volume is larger than that of the calcium silicate board. Since the pulp is a combustible material, the calorific value per unit volume of the papermaking gypsum board is greater than that of the calcium silicate board. Moreover, when using it as an interior material of a clean room, there is no difference in thickness with a papermaking gypsum board and a calcium silicate board. Therefore, when a papermaking gypsum board is used as a substrate for a noncombustible ceramics decorative board, the heating value of the coating layer must be made lower than when a calcium silicate board is used in order to ensure nonflammability performance.
窯業系材料を基板とした化粧板において、クリーンルーム用として適した塗料は今のところ樹脂系の有機塗料であり、使用されている樹脂の発熱量にはあまり差がないことから、塗膜の発熱量を低くするためには、塗膜の膜厚を薄くする必要がある。しかし、膜厚を薄くすると、基板隠蔽性(基板自体の色が化粧板の外観に影響を与えないように隠蔽する)や塗膜性能が低下する危険性がある。従って、化粧板においては、塗膜性能を確保することができる範囲でなるべく薄い膜厚で有機塗膜層を形成することが望ましい。 For decorative boards with ceramic materials as substrates, paints suitable for clean rooms are currently resin-based organic paints, and there is not much difference in the amount of heat generated by the resin used, so the heat generated by the paint film In order to reduce the amount, it is necessary to reduce the thickness of the coating film. However, when the film thickness is reduced, there is a risk that the substrate concealing property (concealing so that the color of the substrate itself does not affect the appearance of the decorative board) and the coating film performance are deteriorated. Therefore, in the decorative board, it is desirable to form the organic coating film layer as thin as possible within a range in which the coating film performance can be ensured.
なお、本発明において、基板及び化粧板の厚さは、JIS A 5430:2008 10.2.2項b)に従い測定した値である。見かけ密度は、JIS A 5430:2008 10.5項に準拠し、吸水による長さ変化率は、JIS A 5430:2008 10.7項に準拠して測定した値であるが、基板に石膏系材料を使用しているため、乾燥についてはJIS A 1476:2006 7.2項の表2に示された基準乾燥温度40℃±2℃の条件で行った。なお、塗装工程において、基板に対し工業的なスケールで加熱乾燥を行う場合には、実用上問題ないとされている90〜110℃雰囲気中での短時間処理を行うのが一般的である。
また、平衡含水率は、JIS A 5404:2007 付属書A.2.6項に従い23℃±2℃、相対湿度50%±5%において恒量となったときの質量、及びJIS A 1476:2006 7.2項の表2に示された基準乾燥温度40℃±2℃の条件で乾燥させたときの質量をもとに以下の式で求めた値である。
In addition, in this invention, the thickness of a board | substrate and a decorative board is the value measured according to JIS A 5430: 2008 10.2.2 paragraph b). The apparent density is in accordance with JIS A 5430: 2008 10.5, and the rate of change in length due to water absorption is a value measured in accordance with JIS A 5430: 2008 10.7. Therefore, drying was performed under the conditions of a standard drying temperature of 40 ° C. ± 2 ° C. shown in Table 2 of JIS A 1476: 2006 7.2. In the coating process, when the substrate is heat-dried on an industrial scale, it is common to perform a short-time treatment in an atmosphere of 90 to 110 ° C., which is regarded as a practical problem.
In addition, the equilibrium moisture content is JIS A 5404: 2007 Appendix A. According to the paragraph 2.6, the mass at a constant weight at 23 ° C. ± 2 ° C. and a relative humidity of 50% ± 5%, and the standard drying temperature 40 ° C. ± shown in Table 2 of JIS A 1476: 2006 7.2 It is the value calculated | required with the following formula | equation based on the mass when it dried on 2 degreeC conditions.
(数1)
平衡含水率=(恒量時の質量−乾燥後の質量)/乾燥後の質量×100(%)
(Equation 1)
Equilibrium moisture content = (mass at constant weight−mass after drying) / mass after drying × 100 (%)
基板及び化粧板の総発熱量は、コーンカロリーメータ法発熱性試験(ISO5660−1:2002準拠)により測定した。 The total calorific value of the substrate and the decorative board was measured by a corn calorimeter method exothermic test (ISO 5660-1: 2002 compliant).
塗膜性能を確保することができる範囲でなるべく薄い膜厚で有機塗膜層を形成するため、基板の少なくとも塗膜層を形成する側の表面(以下、基板の表面)を研磨処理し、平滑度を高める。基板の塗膜層を形成する側とは反対側の面(以下、基板の裏面)も研磨すれば、平滑度をさらに高めやすい。研磨方法としては、ベルトサンダーやプラテン研磨機等が好適に用いられる。これらの研磨機は、円筒状のローラーやプラテンパッドでベルト状の研磨紙を保持しつつ基板表面を連続研磨するため、ローラーやパッドの平滑面を利用して、基板の凸部のみを周囲よりも多く研磨することができる。またロールの位置やパッドの圧力等を変更することで、基板に加わる圧力や研磨負荷を任意に調整できるため、基板の凹凸に合わせた最適研磨条件が得易く、全面を均一に研磨することもできる。また研磨機と研磨紙を基板に合わせたサイズとすることで、連続して基板表面を研磨でき、連続したベルト状の研磨紙を利用しているため研磨粉塵の排出性にも優れることから、他の研磨方式に比べ、加工速度に優れる特徴を有する。抄造石膏板は、けい酸カルシウム板よりも柔らかく研磨により表面平滑性が得やすい材料であり、けい酸カルシウム板を基板として用いた場合に比べ、比較的薄い塗膜でも、塗膜として必要な外観と性能とを得ることができる。なお、抄造石膏板は、研磨処理に先立って、含水率を0.1〜2%に調整しておくことが好ましい。 In order to form an organic coating layer as thin as possible within the range that can ensure the coating performance, at least the surface of the substrate on which the coating layer is formed (hereinafter referred to as the substrate surface) is polished and smoothed. Increase the degree. If the surface of the substrate opposite to the side on which the coating film layer is formed (hereinafter referred to as the back surface of the substrate) is also polished, the smoothness can be further enhanced. As a polishing method, a belt sander, a platen polishing machine or the like is preferably used. These polishing machines continuously polish the substrate surface while holding the belt-like abrasive paper with a cylindrical roller or platen pad, so that only the convex part of the substrate is removed from the surroundings using the smooth surface of the roller or pad. Can also be polished. Also, by changing the position of the roll, the pressure of the pad, etc., the pressure applied to the substrate and the polishing load can be adjusted arbitrarily, so it is easy to obtain the optimum polishing conditions according to the unevenness of the substrate, and the entire surface can be uniformly polished it can. Also, by making the size of the polishing machine and polishing paper matched to the substrate, the substrate surface can be polished continuously, and because it uses a continuous belt-like polishing paper, it is excellent in discharging dust, Compared to other polishing methods, it has a feature of excellent processing speed. Paper-made gypsum board is a material that is softer than calcium silicate board and is easy to obtain surface smoothness by polishing. Compared to the case where calcium silicate board is used as a substrate, the appearance required as a coating film is relatively thin. And performance. In addition, it is preferable that a papermaking gypsum board adjusts a moisture content to 0.1 to 2% prior to a grinding | polishing process.
基板の表面に、含浸シーラー処理を行う。含浸シーラー処理を行うことにより、基板の表層が強化されるとともに、その上層となる下塗り層との密着性も向上する。
含浸シーラー層は、公知のシーラーを用いて形成させることができ、例えば湿気硬化型ウレタン系樹脂、エポキシ系樹脂等の硬化性樹脂を用い、基板の表面に塗布し硬化させること等により行われる。含浸シーラーは基板への含浸性が良く、高不揮発分であり、かつ、基板中の水分や雰囲気の湿気と反応して三次元架橋し、耐水性能等が良いポリイソシアネート又はポリイソシアネートとポリオールとの反応生成物である遊離イソシアネート基を有するプレポリマー及び酢酸ブチルのような溶剤を主成分とする湿気硬化型ウレタン系のものが好適である。また、化粧板としての黄変が問題となる場合には、HDI(ヘキサメチレンジイソシアネート)等の脂肪族イソシアネート、IPDI(イソホロンジイソシアネート)等の脂環族イソシアネート、MDI(メチレンビス(4,1−フェニレン)=ジイソシアネート)等の芳香族イソシアネートを使用することが好ましい。なお、昨今の揮発性有機化合物(VOC)対策の観点から溶剤を含んでいない無溶剤シーラーを使用することや、ケイ酸リチウムあるいはケイ酸ナトリウムなどのケイ酸塩系シーラー等の無機シーラーや、テトラエトキシシランやテトラメトキシシランなどを主成分とするシラン化合物系シーラーも使用できる。
含浸シーラー処理は、抄造石膏板の表面温度を5〜50℃の範囲に調整し、公知のロールコーター、スプレー等の方法で含浸シーラーを塗布し、次いで硬化することにより行うことができる。含浸シーラーの粘度は、使用する含浸シーラーの種類、塗装方法を勘案して適宜決めることができ、硬化は、例えば加熱乾燥することにより行うことができる。
An impregnation sealer treatment is performed on the surface of the substrate. By performing the impregnation sealer treatment, the surface layer of the substrate is strengthened, and the adhesion with the undercoat layer as an upper layer is also improved.
The impregnated sealer layer can be formed using a known sealer. For example, the impregnated sealer layer is formed by applying a curable resin such as a moisture curable urethane resin or an epoxy resin to the surface of the substrate and curing it. The impregnation sealer has good impregnation into the substrate, has a high non-volatile content, and reacts with moisture in the substrate or moisture in the atmosphere to form a three-dimensional cross-link. A moisture-curing urethane-based material mainly comprising a prepolymer having a free isocyanate group as a reaction product and a solvent such as butyl acetate is preferred. When yellowing as a decorative board is a problem, aliphatic isocyanates such as HDI (hexamethylene diisocyanate), alicyclic isocyanates such as IPDI (isophorone diisocyanate), MDI (methylene bis (4,1-phenylene) It is preferred to use aromatic isocyanates such as = diisocyanate). In addition, from the viewpoint of volatile organic compound (VOC) countermeasures, a solventless sealer that does not contain a solvent, an inorganic sealer such as a silicate sealer such as lithium silicate or sodium silicate, tetra Silane compound sealers mainly composed of ethoxysilane, tetramethoxysilane or the like can also be used.
The impregnation sealer treatment can be performed by adjusting the surface temperature of the papermaking gypsum plate to a range of 5 to 50 ° C., applying the impregnation sealer by a method such as a known roll coater or spray, and then curing. The viscosity of the impregnating sealer can be appropriately determined in consideration of the type of impregnating sealer to be used and the coating method, and the curing can be performed by, for example, drying by heating.
また、本発明においては、基板の裏面も含浸シーラー処理し補強を行うのが好適である。化粧板の施工方法としては、接着工法が多く用いられており、基板の裏面を補強しておくと、施工性が向上するからである。基板の裏面についても含浸シーラー処理する場合、後述する下塗り層を形成する前に裏面の含浸シーラー処理を行うのが一般的であるが、下塗り層を形成した後に行ってもよい。 Further, in the present invention, it is preferable to reinforce the back surface of the substrate by impregnating the sealer. This is because a bonding method is often used as a method for applying the decorative plate, and if the back surface of the substrate is reinforced, the workability is improved. When the impregnation sealer treatment is performed also on the back surface of the substrate, the back surface impregnation sealer treatment is generally performed before the undercoat layer described later is formed, but may be performed after the undercoat layer is formed.
本発明においては、含浸シーラーの成分中の有機固形分量が、基板の単位面積(m2)当たり3〜100gとなるように設定するのが好ましい。有機固形分量が少なすぎると基板の表層がそれほど強化されない可能性がある。また、その上層となる下塗り層との密着性が低下する可能性もある。有機固形分量が多すぎると、基板の表層に余分な有機固形分が残り、この有機固形層が原因となって凝集剥離や後工程での発泡、わき等の不良が生じる可能性がある。なお、わきとは発泡において、泡の中にある気体が塗膜を破ってできた微小な穴であり、塗装時の局部的厚膜に起因し、主に乾燥時の急激な昇温により生じる。含浸シーラーの成分中の有機固形分量は、基板の単位面積(m2)当たり3〜80gとなるように設定するのがさらに好ましい。また、基板の裏面に含浸シーラー処理する場合、含浸シーラーの成分中の有機固形分量は、基板の単位面積(m2)当たり10〜30gとなるように設定するのがさらに好ましい。 In this invention, it is preferable to set so that the amount of organic solids in the component of an impregnation sealer may be 3-100g per unit area (m < 2 >) of a board | substrate. If the organic solid content is too small, the surface layer of the substrate may not be strengthened so much. In addition, the adhesion with the undercoat layer that is the upper layer may be lowered. If the amount of organic solids is too large, excess organic solids remain on the surface layer of the substrate, and this organic solid layer may cause defects such as cohesive peeling, foaming in the subsequent process, and side. In addition, aside is a minute hole made by the gas in the foam breaking the coating in foaming. It is caused by a local thick film at the time of painting, and is mainly caused by a rapid temperature rise at the time of drying. . More preferably, the organic solid content in the impregnated sealer component is set to 3 to 80 g per unit area (m 2 ) of the substrate. Further, when the impregnation sealer treatment is performed on the back surface of the substrate, the organic solid content in the component of the impregnation sealer is more preferably set to be 10 to 30 g per unit area (m 2 ) of the substrate.
なお、本発明において、有機固形分量は、塗料原液の組成、希釈溶剤の使用量、実塗布量から算出することができる。 In the present invention, the amount of organic solids can be calculated from the composition of the coating stock solution, the amount of diluent used, and the actual coating amount.
本発明の化粧板は、含浸シーラー処理した基板の上に下塗り層を有し、その下塗り層の表面は研磨されており、膜厚は5〜120μmであることが重要である。下塗り層を形成することにより、基板の表面に存在する大小の凹凸部や、空隙部が塗料により充填され、凹凸感、塗料の吸い込み斑による光沢・色のばらつき感が抑制される。また、化粧板にピンホールのような不良が生じる可能性も減じられる。また、下塗り層を形成した後は、表面を研磨処理する。研磨処理を行うことにより、下地が平滑となり、その上に形成される上塗り層の塗膜の意匠性が損なわれず、良好な塗膜性能を確保することができる。 The decorative board of the present invention has an undercoat layer on an impregnated sealer-treated substrate, the surface of the undercoat layer is polished, and it is important that the film thickness is 5 to 120 μm. By forming the undercoat layer, large and small uneven portions and void portions existing on the surface of the substrate are filled with the paint, and the uneven feeling and the gloss / color variation feeling due to the paint suction spots are suppressed. In addition, the possibility of defects such as pinholes on the decorative board is reduced. Further, after the undercoat layer is formed, the surface is polished. By performing the polishing treatment, the base becomes smooth, and the design properties of the coating film of the overcoat layer formed thereon are not impaired, and good coating film performance can be ensured.
下塗り層の膜厚は、5〜120μmであるのが、化粧板の表面平滑性、上塗り層の塗膜との密着性、基板隠蔽性、防水性、基板成分の析出防止性、塗膜ピンホールの防止、塗膜硬化性、表面異物埋没性、膜厚管理の容易性の点で重要である。5μm未満では、その上層及び下層の塗膜との密着性が低下する可能性がある。一方120μmを超えると総発熱量が増加し、不燃性の悪化につながる可能性があり、また、極端な低湿度環境で使用された場合には塗膜の乾燥収縮による化粧板の反りが発生しやすくなる。好ましい塗膜は5〜70μmであり、より好ましくは10〜50μmである。 The film thickness of the undercoat layer is from 5 to 120 μm. The surface smoothness of the decorative board, the adhesion to the coating film of the topcoat layer, the substrate concealing property, the waterproof property, the precipitation prevention property of the substrate components, the coating film pinhole Are important in terms of prevention of coating, film curability, surface foreign matter burying property, and ease of film thickness control. If it is less than 5 micrometers, there exists a possibility that adhesiveness with the upper layer and the lower layer coating film may fall. On the other hand, if it exceeds 120 μm, the total calorific value increases, which may lead to deterioration of nonflammability, and when used in an extremely low humidity environment, the decorative board warps due to drying shrinkage of the coating film. It becomes easy. A preferable coating film is 5-70 micrometers, More preferably, it is 10-50 micrometers.
下塗り層を形成するための塗料は、基板隠蔽性、表面平滑性、耐薬品性、塗膜密着性、研磨加工性、塗膜硬度、塗装容易性、クラック防止性の点から、ラジカルオリゴマー系塗料やモノマーラジカル系塗料、例えばエポキシ系アクリレート、ウレタン系アクリレート、エステル系アクリレート、アクリル系アクリレート、シリコン系アクリレート、不飽和ポリエステル系塗料が好ましく、具体的にはエポキシアクリレート、ウレタンアクリレート、フタル酸ジアリルエステルなどのアリル系不飽和ポリエステル、無水マレイン酸やフマル酸などの不飽和二塩基酸とグリコール類との重縮合によるマレイン酸系不飽和ポリエステル、官能基としてカルボキシル基や水酸基を持つポリエステルモノアクリレート、アクリル酸と2塩基酸と2価アルコールから得られるポリエステルジアクリレート、3価以上の多価アルコールと2塩基酸とアクリル酸から得られるポリエステルポリアクリレート等のポリエステルアクリレート、エポキシアクリレートオリゴマー、エポキシオリゴマー等のオリゴマー類、アクリルポリエーテル、ポリエーテルアクリレート等が挙げられる。また、下塗り層を形成するための塗料は紫外線硬化型塗料とすることが、塗布容易性や、塗膜の硬化速度が早い点、塗膜の被研削性や耐久性、基板や上塗り塗料との密着性に優れることから好ましい。塗料を塗布した後は、紫外線を照射して塗料を硬化させ、下塗り層を形成し、次いで研磨を行う。また、下塗り層を形成するための塗料は基板隠蔽性の確保および可燃物の含有率を減らして発熱量を低減させる目的から、炭酸カルシウムなどの無機顔料を添加したものが好ましい。下塗り塗料の塗布方法は、ロールコーターやフローコーター等を用いる方法が挙げられ、中でも、基板表面に存在する大小の凹凸部や、空隙部を塗料により充填する効果を考慮すると、ロールコーターが適している。 The paint used to form the undercoat layer is a radical oligomer based paint in terms of substrate concealment, surface smoothness, chemical resistance, paint film adhesion, polishing processability, paint film hardness, ease of painting, and crack prevention. And monomer radical paints such as epoxy acrylates, urethane acrylates, ester acrylates, acrylic acrylates, silicon acrylates, unsaturated polyester paints, specifically epoxy acrylates, urethane acrylates, diallyl phthalate esters, etc. Allylic unsaturated polyesters, maleic unsaturated polyesters by polycondensation of unsaturated dibasic acids such as maleic anhydride and fumaric acid with glycols, polyester monoacrylates having a carboxyl group or a hydroxyl group as functional groups, acrylic acid And dibasic acid and divalent al Polyester diacrylate obtained from a polyol, polyester acrylate such as polyester polyacrylate obtained from trihydric or higher polyhydric alcohol, dibasic acid and acrylic acid, oligomers such as epoxy acrylate oligomer and epoxy oligomer, acrylic polyether, poly Examples include ether acrylate. In addition, the coating material for forming the undercoat layer should be an ultraviolet curable coating material. It is easy to apply, has a fast coating curing speed, is easy to grind and has durability, and is compatible with the substrate and top coating. It is preferable because of excellent adhesion. After applying the paint, the paint is cured by irradiating with ultraviolet rays to form an undercoat layer and then polished. Further, the coating material for forming the undercoat layer is preferably one to which an inorganic pigment such as calcium carbonate is added for the purpose of securing the substrate concealing property and reducing the heat generation amount by reducing the content of combustible materials. Examples of the method of applying the undercoat paint include a method using a roll coater, a flow coater, etc. Among them, a roll coater is suitable in consideration of the effect of filling large and small uneven portions and voids on the substrate surface with the paint. Yes.
本発明においては、下塗り層の成分中の有機固形分量は、基板の単位面積(m2)当たり3〜60g、好ましくは3〜35g、より好ましくは5〜25gに設定するのがよい。 In the present invention, the organic solid content in the component of the undercoat layer is set to 3 to 60 g, preferably 3 to 35 g, more preferably 5 to 25 g per unit area (m 2 ) of the substrate.
下塗り層を形成するための下塗り塗装は、1回で所定の膜厚の下塗り層を形成することもできるし、2回以上行って所定の膜厚の下塗り層を形成することもできる。例えば、下塗り塗装を2回行って所定の膜厚の下塗り層を形成する場合は、1回目の下塗り塗装を行った後、紫外線を照射して下塗り塗料を硬化させる際に、紫外線の照射量を加減して完全には硬化しないようにし、その上に2回目の下塗り塗装を行った後に再度紫外線を照射して、下塗り塗料全体を完全に硬化させ下塗り層を形成する。また、3回以上の下塗り塗装を行う場合も、2回の場合と同様に、最後の下塗り塗装を行った後の紫外線照射により、下塗り塗料全体を完全に硬化させ下塗り層を形成する。本発明の化粧板においては、けい酸カルシウム板よりも発熱量の多い抄造石膏板を基板として用いるため、必要な塗膜性能と不燃性とを確保するには、塗膜厚さの制御が重要である。この観点から、基板表面に存在する大小の凹凸部や空隙部を塗料により充填する効果と、表面平滑性をさらに向上させる効果とを効率よく得るため下塗り塗装を2回行うことにより下塗り層の塗膜を形成するのがよい。 The undercoating for forming the undercoating layer can be performed once to form an undercoating layer having a predetermined thickness, or can be performed twice or more to form an undercoating layer having a predetermined thickness. For example, in the case of forming the undercoat layer of a predetermined film thickness by performing the undercoat coating twice, when the undercoat paint is cured by irradiating ultraviolet rays after the first undercoat coating, It is adjusted so as not to be completely cured, and after the second undercoat is applied thereon, ultraviolet rays are irradiated again to completely cure the entire undercoat and form an undercoat layer. Also, when the undercoat is applied three or more times, as in the case of twice, the entire undercoat is completely cured by ultraviolet irradiation after the last undercoat is applied to form an undercoat layer. In the decorative board of the present invention, a paper-made gypsum board having a higher calorific value than that of the calcium silicate board is used as a substrate. Therefore, in order to ensure the required coating film performance and nonflammability, it is important to control the coating thickness. It is. From this viewpoint, in order to efficiently obtain the effect of filling large and small uneven portions and voids existing on the substrate surface with the paint and the effect of further improving the surface smoothness, the coating of the undercoat layer is performed twice. A film should be formed.
下塗り層形成後にその表面を研磨する手段としては、バフ研磨、プラテン研磨、ポリシャー研磨、ブラスト研磨、エッチング研磨、砥石研磨、フェルト研磨、ブラシ研磨、レーザー研磨、エンドミルあるいはバイト等による切削等が挙げられるが、下塗り層の表面を平滑にする点、研磨性の点からプラテン研磨が好ましい。プラテン研磨は、周回駆動される無端ベルト状の研磨紙を、柔らかなパッドで研磨対象に押し当てた状態で、研磨対象を進行させて研磨するものである。また、下塗り塗装を複数回行う場合には、形成された下塗り層の表面のみを研磨してもよいし、下塗り塗装し硬化(半硬化)させるたびに表面研磨を行うこともできる。下塗り層の研磨により、最終的な下塗り層の膜厚を前記5〜120μm、好ましくは5〜70μm、より好ましくは10〜50μmに調整する。 Examples of means for polishing the surface after forming the undercoat layer include buffing, platen polishing, polisher polishing, blast polishing, etching polishing, grindstone polishing, felt polishing, brush polishing, laser polishing, cutting with an end mill or a bite, and the like. However, platen polishing is preferable from the viewpoint of smoothing the surface of the undercoat layer and polishing properties. In the platen polishing, an endless belt-like polishing paper that is driven to rotate is pressed against the object to be polished with a soft pad, and the object to be polished is advanced and polished. When the undercoating is performed a plurality of times, only the surface of the formed undercoating layer may be polished, or surface polishing can be performed every time the undercoating is applied and cured (semi-cured). By polishing the undercoat layer, the final undercoat layer thickness is adjusted to 5 to 120 μm, preferably 5 to 70 μm, more preferably 10 to 50 μm.
本発明の化粧板は、上記下塗り層の上層に膜厚5〜40μmの上塗り層を有する。当該上塗り層を形成することにより、本発明化粧板に良好な外観、クリーンルーム等の用途に適した塗膜性能(発塵防止、空調風圧等による振動耐久性、補修性、清掃作業耐性、耐乾燥クラック性、平滑性、下地隠蔽性等)を付与することができる。また、上塗り層の膜厚は、前記した特性を付与するため、5〜40μmであることが必要であり、10〜40μmがより好ましく、25〜40μmがさらに好ましい。上塗り層の膜厚が40μmを越えると、化粧板の不燃性能が低下する可能性があり、また、極端な低湿度環境で使用された場合には塗膜の乾燥収縮による化粧板の反りが発生しやすくなる。また、上塗り層膜厚が5μmを下回ると、塗膜性能が低下することから好ましくない。 The decorative board of the present invention has an overcoat layer having a thickness of 5 to 40 μm as an upper layer of the undercoat layer. By forming the overcoat layer, the decorative panel of the present invention has a good appearance, and coating film performance suitable for applications such as clean rooms (anti-dust generation, vibration durability due to air-conditioning wind pressure, repairability, cleaning work resistance, drying resistance, etc. (Cracking property, smoothness, base concealing property, etc.). The film thickness of the overcoat layer needs to be 5 to 40 μm, more preferably 10 to 40 μm, and still more preferably 25 to 40 μm, in order to impart the above-described characteristics. If the film thickness of the overcoat layer exceeds 40 μm, the nonflammable performance of the decorative board may be reduced, and when used in an extremely low humidity environment, the decorative board warps due to drying shrinkage of the coating film. It becomes easy to do. Moreover, it is not preferable that the film thickness of the overcoat layer is less than 5 μm because the coating film performance is deteriorated.
上塗り層の形成に用いられる塗料としては、塗装作業性、塗装後の塗膜乾燥性、安全性、塗装後の耐久性、塗膜表面硬度、塗膜の耐薬品性や耐汚染性の点から、アクリルウレタン樹脂塗料が好ましく、2液硬化型アクリルウレタン樹脂塗料がより好ましい。また、アクリル樹脂塗料、エポキシ樹脂塗料、ポリウレタン樹脂塗料、塩化ビニル樹脂塗料、塩化ビニリデン樹脂塗料、アクリルシリコーン樹脂塗料、フッ素樹脂塗料などを、単層で、同一塗料の塗膜を積層して、又は異なる塗料の塗膜を積層して上塗り層を形成する。 The paint used for forming the topcoat layer is from the viewpoint of coating workability, coating film drying property after coating, safety, durability after coating, coating surface hardness, coating chemical resistance and stain resistance. An acrylic urethane resin paint is preferable, and a two-component curable acrylic urethane resin paint is more preferable. Also, acrylic resin paints, epoxy resin paints, polyurethane resin paints, vinyl chloride resin paints, vinylidene chloride resin paints, acrylic silicone resin paints, fluororesin paints, etc., in a single layer, with the same paint film laminated, or A top coat layer is formed by laminating coatings of different paints.
上塗り層を形成するための上塗り塗装方法は、ロールコーター、フローコーター、スプレーコーター等を用いる方法が挙げられる。上塗り塗装は、1回で所定の膜厚の上塗り層を形成することもできるし、2回以上行って所定の膜厚の上塗り層を形成することもできる。本発明の化粧板においては、けい酸カルシウム板よりも発熱量の多い抄造石膏板を基板として用いるため、必要な塗膜性能と不燃性とを確保するには、塗膜厚さの制御が重要である。この観点から、上塗り塗装を2回行うことにより上塗り層の塗膜を形成するのがよく、1回目にロールコーターにて上塗り塗装を行い、2回目にフローコーターにて上塗り塗装を行うのが特に好ましい。 Examples of the top coating method for forming the top coating layer include a method using a roll coater, a flow coater, a spray coater and the like. The top coat can form an overcoat layer having a predetermined film thickness once, or can be performed twice or more to form an overcoat layer having a predetermined film thickness. In the decorative board of the present invention, a paper-made gypsum board having a higher calorific value than that of the calcium silicate board is used as a substrate. Therefore, in order to ensure the required coating film performance and nonflammability, it is important to control the coating thickness. It is. From this point of view, it is preferable to form a coating film of the top coating layer by performing the top coating twice, and it is particularly preferable to perform the top coating with a roll coater at the first time and the top coating with a flow coater at the second time. preferable.
本発明においては、上塗り層の成分中の有機固形分量は、基板の単位面積(m2)当たり5〜35gとなるように設定するのが好ましく、さらに10〜33gとするのがより好ましい。1回目にロールコーターにて上塗り塗装を行い、2回目にフローコーターにて上塗り塗装を行う場合、基板の単位面積(m2)当たりの有機固形分量が1回目にロールコーターで1〜15g、より好ましくは2〜13g、2回目にフローコーターで4〜20g、より好ましくは8〜20gとなるよう塗布するのがよい。 In the present invention, the amount of organic solids in the components of the topcoat layer is preferably set to be 5 to 35 g per unit area (m 2 ) of the substrate, and more preferably 10 to 33 g. When the top coat is applied with the roll coater for the first time and the top coat is applied for the second time with the flow coater, the organic solid content per unit area (m 2 ) of the substrate is 1 to 15 g with the roll coater for the first time. Preferably it is 2-13g, and it is good to apply | coat so that it may become 4-20g with a flow coater in the 2nd time, More preferably, it is 8-20g.
上塗り塗装した後、基板をしばらくの間水平に保持して上塗り塗料をレベリングさせて塗装面を平滑にした後、加熱乾燥を行い、上塗り塗料を硬化させて上塗り層が形成される。加熱乾燥は、90〜110℃雰囲気中で30分程度行うのがよい。 After the top coat is applied, the substrate is held horizontally for a while to level the top coat and smooth the coated surface, followed by heat drying to cure the top coat and form the top coat layer. Heat drying is preferably performed in an atmosphere of 90 to 110 ° C. for about 30 minutes.
本発明の化粧板において、不燃性を確保するためには、下塗り層と上塗り層とからなる有機塗膜層の厚さが140μm以下、好ましくは100μm以下である。前記したとおり抄造石膏板はけい酸カルシウム板と比較して、単位体積当たりの発熱量が多いことから、有機塗膜層の厚さを前記条件にすることは、化粧板として必要な塗膜性能と不燃性とを確保するうえで重要である。また、極端な低湿度環境で使用された場合に有機塗膜層が厚すぎると塗膜の乾燥収縮による化粧板の反りが発生しやすくなる。また、下塗り層と上塗り層の有機塗膜層の合計の厚さは、10μm以上が好ましく、20μm以上がより好ましい。この場合、下塗り層と上塗り層の有機塗膜層の有機固形分の合計量は、基板の単位面積(m2)当たり70g以下が好ましく、より好ましくは58g以下である。また、当該合計量は、基板の単位面積(m2)当たり8g以上が好ましく、より好ましくは15g以上である。 In the decorative board of the present invention, in order to ensure nonflammability, the thickness of the organic coating layer composed of the undercoat layer and the topcoat layer is 140 μm or less, preferably 100 μm or less. As described above, the paper-made gypsum board has a large calorific value per unit volume compared to the calcium silicate board, so that the thickness of the organic coating layer is the above-mentioned condition, the coating film performance necessary as a decorative board And incombustibility are important. Further, when the organic coating layer is too thick when used in an extremely low humidity environment, the decorative board is likely to warp due to drying shrinkage of the coating. Further, the total thickness of the organic coating layer of the undercoat layer and the topcoat layer is preferably 10 μm or more, and more preferably 20 μm or more. In this case, the total amount of organic solids in the organic coating layer of the undercoat layer and the overcoat layer is preferably 70 g or less, more preferably 58 g or less, per unit area (m 2 ) of the substrate. The total amount is preferably 8 g or more per unit area (m 2 ) of the substrate, more preferably 15 g or more.
本発明の化粧板は、抄造石膏板を基板とし、該基板の表面を研磨処理した後含浸シーラー処理し、次いで下塗り層及び上塗り層をこの順で形成する化粧板の製造方法であって、(a)下塗り塗装として下塗り層形成用有機塗料を塗布し、硬化させ、研磨し、膜厚が5〜120μmの下塗り層を形成し、
(b)上塗り塗装として上塗り層形成用有機塗料を塗布し、硬化させ、膜厚が5〜40μmの上塗り層を形成し、
(c)ただし、前記下塗り層と前記上塗り層とからなる有機塗膜層の膜厚を140μm以下とすることによって製造できる。各塗膜層の形成方法は、前述のとおりである。
The decorative board of the present invention is a method for producing a decorative board in which a paper-made gypsum board is used as a substrate, the surface of the substrate is polished and then impregnated with a sealer, and then an undercoat layer and an overcoat layer are formed in this order. a) Applying an organic paint for forming an undercoat layer as an undercoat, curing, polishing, and forming an undercoat layer having a thickness of 5 to 120 μm;
(B) Applying an organic paint for forming an overcoat layer as the top coat and curing it to form an overcoat layer having a thickness of 5 to 40 μm;
(C) However, it can be produced by setting the film thickness of the organic coating layer composed of the undercoat layer and the overcoat layer to 140 μm or less. The method for forming each coating layer is as described above.
本発明の化粧板は、コーンカロリーメータ法発熱性試験による総発熱量が8MJ/m2以下である必要がある。この要件を満たすことにより、JIS A 5430:2008で規定する発熱性1級(加熱時間20分)を満たし、高い不燃性を示す。さらに好ましい総発熱量は、7.2MJ/m2以下である。 The decorative board of the present invention needs to have a total calorific value of 8 MJ / m 2 or less by a corn calorimeter exothermic test. Satisfying this requirement satisfies exothermic first grade (heating time 20 minutes) defined in JIS A 5430: 2008, and exhibits high nonflammability. A more preferable total calorific value is 7.2 MJ / m 2 or less.
製造した化粧板を、保管や輸送のために重ね合わせて積み込む場合は、所謂ブロッキングを避けるために、板温を40℃以下まで冷却させてから行うのが好ましい。 When the manufactured decorative board is stacked and loaded for storage or transportation, it is preferable to cool the board to 40 ° C. or lower in order to avoid so-called blocking.
以上、基板の片面に塗膜層を設ける方法について記述したが、本発明においては、基板の裏面についても塗膜層を設けることができる。基板の裏面にも塗膜層を設けることは、化粧板の寸法安定性を更に高めることができる。ただし、基板の裏面にも塗膜層を設ける場合には、不燃性能を確保するために、基板の表面及び裏面の有機塗膜層の膜厚を合計して140μm以下とする必要がある。 The method for providing a coating layer on one side of the substrate has been described above. However, in the present invention, a coating layer can also be provided on the back side of the substrate. Providing a coating layer on the back surface of the substrate can further enhance the dimensional stability of the decorative board. However, when a coating layer is provided also on the back surface of the substrate, the total film thickness of the organic coating layer on the front surface and the back surface of the substrate needs to be 140 μm or less in order to ensure nonflammability performance.
以下、本発明を実施例及び比較例によりさらに説明するが、本発明は下記例に制限されない。 EXAMPLES Hereinafter, although an Example and a comparative example further demonstrate this invention, this invention is not restrict | limited to the following example.
(1)抄造石膏板(基板)
基板として、厚さ5mmのエフジーボード((株)エーアンドエーマテリアル製)を使用した。実施例及び比較例において使用したエフジーボードは、有機繊維原料としてパルプが5.5質量%配合されたものであり、見掛け密度は1.6g/cm3、吸水による長さ変化率は0.06%、平衡含水率は0.3%であった。
(1) Paper plasterboard (substrate)
As the substrate, an FG board (manufactured by A & A Materials Co., Ltd.) having a thickness of 5 mm was used. The FG board used in the examples and comparative examples is a blend of 5.5% by mass of pulp as an organic fiber raw material, the apparent density is 1.6 g / cm 3 , and the length change rate due to water absorption is 0.06. %, The equilibrium water content was 0.3%.
(2)塗料
各塗装は、次の塗料を使用して行った。
含浸シーラー1:DIC株式会社 UCシーラーW004K(イソシアネート系)
含浸シーラー2:大日本塗料株式会社 Vセラン#100NSシーラー(イソシアネート系)
下塗り塗料1:DIC株式会社 SKS−WP(不飽和ポリエステル系)
下塗り塗料2:大日本塗料株式会社 ルーセン#600NR−1(エポキシアクリレート系)
下塗り塗料3:大日本塗料株式会社 ルーセン#600NR−2(エポキシアクリレート系)
上塗り塗料:大日本塗料株式会社 ASA#100PRTR(アクリルウレタン系)
(2) Paint Each painting was performed using the following paint.
Impregnation sealer 1: DIC Corporation UC sealer W004K (isocyanate type)
Impregnated sealer 2: Dai Nippon Paint Co., Ltd. V Seran # 100 NS sealer (isocyanate type)
Undercoat paint 1: DIC Corporation SKS-WP (unsaturated polyester)
Undercoat paint 2: Dainippon Paint Co., Ltd. Lucen # 600NR-1 (epoxy acrylate)
Undercoat paint 3: Dainippon Paint Co., Ltd. Lucen # 600NR-2 (epoxy acrylate)
Top coating: Dainippon Paint ASA # 100PRTR (acrylic urethane)
実施例1
含水率を0.5%に調整した基板の表面にロールコーターを用いて、有機固形分濃度が40%の含浸シーラー1を70g/m2塗布し、一方、基板の裏面には、前記浸シーラー1を20g/m2塗布し、基板の表裏面全体で有機固形分が36g/m2となる含浸シーラー層を形成した。
次にロールコーターを用いて基板表面側に下塗り塗料1を50g/m2塗布した後、紫外線照射により下塗り塗料を一部硬化させて塗膜を形成し、次いで再度ロールコーターを用いて、前記塗膜の上に前記下塗り塗料1を50g/m2塗布した後、紫外線照射により下塗り塗料を完全に硬化させて塗膜を形成した。次に、プラテン研磨機により前記塗膜の表面を平滑に研磨して、膜厚が40μmで有機固形分量が20g/m2となる下塗り層を形成した。
さらに下塗り層の上から、ロールコーターを用いて上塗り塗料を10g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を95g/m2塗布し、熱風式乾燥機を用い100℃の雰囲気中で30分加熱乾燥して上塗り塗膜を硬化させ、膜厚が30μmで有機固形分量が26g/m2となる上塗り層を形成し、化粧板を得た。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は70μmであった。
Example 1
Using a roll coater, 70 g / m 2 of impregnation sealer 1 having an organic solid content concentration of 40% is applied to the surface of the substrate adjusted to a moisture content of 0.5%, while the immersion sealer is applied to the back surface of the substrate. 1 was applied at 20 g / m 2 to form an impregnated sealer layer having an organic solid content of 36 g / m 2 over the entire front and back surfaces of the substrate.
Next, after applying 50 g / m 2 of the undercoat paint 1 to the substrate surface side using a roll coater, the undercoat paint is partially cured by ultraviolet irradiation to form a coating film, and then again using the roll coater, After applying 50 g / m 2 of the undercoat paint 1 on the film, the undercoat paint was completely cured by ultraviolet irradiation to form a coating film. Next, the surface of the coating film was smoothly polished by a platen polishing machine to form an undercoat layer having a thickness of 40 μm and an organic solid content of 20 g / m 2 .
Furthermore, after applying a top coat of 10 g / m 2 using a roll coater from above the undercoat layer, applying the same top coat of 95 g / m 2 using a flow coater, and using a hot air dryer at 100 ° C. Then, the top coat film was cured by heating for 30 minutes to form a top coat layer having a film thickness of 30 μm and an organic solid content of 26 g / m 2 to obtain a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 70 μm.
実施例2
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が8μmで下塗り層の有機固形分量が4g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を10g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を95g/m2塗布し、膜厚が30μmで上塗り層の有機固形分量が26g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は38μmであった。
Example 2
An impregnation sealer treatment was performed in the same manner as in Example 1 to form an undercoat layer having an undercoat layer thickness of 8 μm and an organic solid content of the undercoat layer of 4 g / m 2 using the same paint and coating method as in Example 1. did. Next, in the same manner as in Example 1, a top coat was applied at 10 g / m 2 using a roll coater, and then the same top coat was applied at 95 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 26 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 38 μm.
実施例3
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が120μmで下塗り層の有機固形分量が60g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を5g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を58g/m2塗布し、膜厚が18μmで上塗り層の有機固形分量が15.6g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は138μmであった。
Example 3
An impregnation sealer treatment was performed in the same manner as in Example 1 to form an undercoat layer having an undercoat layer thickness of 120 μm and an organic solid content of the undercoat layer of 60 g / m 2 using the same paint and coating method as in Example 1. did. Next, in the same manner as in Example 1, 5 g / m 2 of the top coating was applied using a roll coater, and then 58 g / m 2 of the same top coating was applied using a flow coater. An overcoat layer having an organic solid content of 15.6 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 138 μm.
実施例4
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、ロールコーターを用いて一回塗りにて上塗り塗料を21g/m2塗布し、膜厚が6μmで上塗り層の有機固形分量が5.2g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は46μmであった。
Example 4
An impregnation sealer treatment was performed in the same manner as in Example 1, and an undercoat layer having an undercoat layer thickness of 40 μm and an undercoat layer organic solid content of 20 g / m 2 was formed using the same paint and coating method as in Example 1. did. Next, 21 g / m 2 of the top coating material was applied by a single application using a roll coater to form a top coating layer having a film thickness of 6 μm and an organic solid content of the top coating layer of 5.2 g / m 2. Was made. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 46 μm.
実施例5
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を18g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を115g/m2塗布し、膜厚が38μmで上塗り層の有機固形分量が32.9g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は78μmであった。
Example 5
An impregnation sealer treatment was performed in the same manner as in Example 1, and an undercoat layer having an undercoat layer thickness of 40 μm and an undercoat layer organic solid content of 20 g / m 2 was formed using the same paint and coating method as in Example 1. did. Next, in the same manner as in Example 1, the top coat was applied at 18 g / m 2 using a roll coater, and then the same top coat was applied at 115 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 32.9 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 78 μm.
比較例1
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が4μmで下塗り層の有機固形分量が2g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を10g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を95g/m2塗布し、膜厚が30μmで上塗り層の有機固形分量が26g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は34μmであった。
Comparative Example 1
An impregnation sealer treatment was performed in the same manner as in Example 1 to form an undercoat layer having an undercoat layer thickness of 4 μm and an organic solid content of the undercoat layer of 2 g / m 2 using the same paint and coating method as in Example 1. did. Next, in the same manner as in Example 1, a top coat was applied at 10 g / m 2 using a roll coater, and then the same top coat was applied at 95 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 26 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 34 μm.
比較例2
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が140μmで下塗り層の有機固形分量が70g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を30g/m2塗布し、膜厚が9μmで上塗り層の有機固形分量が7.4g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は149μmであった。
Comparative Example 2
An impregnation sealer treatment was performed in the same manner as in Example 1 to form an undercoat layer having an undercoat layer thickness of 140 μm and an undercoat layer organic solid content of 70 g / m 2 using the same paint and coating method as in Example 1. did. Next, in the same manner as in Example 1, a top coat was applied at 30 g / m 2 using a roll coater to form a top coat layer having a film thickness of 9 μm and an organic solid content of the top coat layer of 7.4 g / m 2 . A decorative board was produced. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 149 μm.
比較例3
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、ロールコーターを用いて一回塗りで上塗り塗料を7g/m2塗布し、膜厚が2μmで上塗り層の有機固形分量が1.7g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は42μmであった。
Comparative Example 3
An impregnation sealer treatment was performed in the same manner as in Example 1, and an undercoat layer having an undercoat layer thickness of 40 μm and an undercoat layer organic solid content of 20 g / m 2 was formed using the same paint and coating method as in Example 1. did. Then, a top coat paint in a single coat using a roll coater 7 g / m 2 was applied, the film thickness to form a top coat layer organic solid content of the overcoat layer is 1.7 g / m 2 at 2 [mu] m, the veneer Produced. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 42 μm.
比較例4
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を20g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を160g/m2塗布し、膜厚が51μmで上塗り層の有機固形分量が44.5g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は91μmであった。
Comparative Example 4
An impregnation sealer treatment was performed in the same manner as in Example 1, and an undercoat layer having an undercoat layer thickness of 40 μm and an undercoat layer organic solid content of 20 g / m 2 was formed using the same paint and coating method as in Example 1. did. Next, in the same manner as in Example 1, after applying the top coat 20 g / m 2 using a roll coater, the same top coat was applied 160 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 44.5 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 91 μm.
比較例5
実施例1と同様に含浸シーラー処理し、実施例1と同様の塗料と塗装方法を用いて、下塗り層の膜厚が115μmで下塗り層の有機固形分量が57.5g/m2である下塗り層を形成した。次いで、実施例1と同様に、ロールコーターを用いて上塗り塗料を12g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を125g/m2塗布し、膜厚が39μmで上塗り層の有機固形分量が33.8g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は154μmであった。
Comparative Example 5
Undercoating sealer treatment as in Example 1, and using the same paint and coating method as in Example 1, the undercoating layer has a thickness of 115 μm and the organic solid content of the undercoating layer is 57.5 g / m 2 Formed. Next, in the same manner as in Example 1, a top coat was applied at 12 g / m 2 using a roll coater, and then the same top coat was applied at 125 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 33.8 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 154 μm.
比較例6
下塗り塗膜の表面を研磨しなかったことを除き、実施例1と同様の化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は130μmであった。
Comparative Example 6
A decorative board similar to that of Example 1 was produced except that the surface of the undercoat coating was not polished. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 130 μm.
(3)評価
有機塗膜層の性能評価:JIS K 5600−6−1:1999 9項に準拠し、化粧板の耐薬品性を評価した。塗膜に滴下する試験液には、表1に記載の酸及びアルカリ、有機溶剤を用い24時間経過し、外観に変化が認められないものを◎、外観に若干の変退色が認められるが使用上問題ないものを○、外観に変退色が認められるため使用条件が制限されるものを△、外観に明らかな変退色や変形が認められたものを×とした。
総発熱量:コーンカロリーメータ法発熱性試験(ISO5660−1:2002準拠)により測定した。
外観:目視観察により良好なものを◎、良好でないものを×として、これらの中間(ほぼ良好)を○とした。
(3) Evaluation Performance evaluation of the organic coating layer: The chemical resistance of the decorative board was evaluated according to JIS K 5600-6-1: 1999, paragraph 9. For the test solution dropped on the coating film, the acid, alkali and organic solvents listed in Table 1 were used for 24 hours, and no change was observed in the appearance. A slight discoloration was observed in the appearance. The case where there was no problem was indicated by ◯, the case where the use conditions were restricted because the appearance was observed to be changed, and the case where the appearance was clearly changed or changed.
Total calorific value: Measured by a cone calorimeter method exothermic test (ISO 5660-1: 2002 compliant).
Appearance: Excellent by visual observation, ◎, unsatisfactory by x, intermediate (substantially good) by ◯.
得られた評価結果を表1に示す。 The obtained evaluation results are shown in Table 1.
実施例6
含水率を0.5%に調整した基板の表面にロールコーターを用いて、有機固形分濃度が100%の含浸シーラー2を25g/m2塗布し、一方、基板の裏面には、前記浸シーラー2を10g/m2塗布し、基板の表裏面全体で有機固形分が35g/m2となる含浸シーラー層を形成した。
次にロールコーターを用いて基板表面側に下塗り塗料2を50g/m2塗布した後、紫外線照射により下塗り塗料を一部硬化させて塗膜を形成し、次いで再度ロールコーターを用いて、前記塗膜の上に下塗り塗料3を50g/m2塗布した後、紫外線照射により下塗り塗料を完全に硬化させて塗膜を形成した。次に、プラテン研磨機により前記塗膜の表面を平滑に研磨して、膜厚が40μmで有機固形分量が20g/m2となる下塗り層を形成した。
さらに下塗り層の上から、ロールコーターを用いて上塗り塗料を10g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を95g/m2塗布し、熱風式乾燥機を用い100℃の雰囲気中で30分加熱乾燥して上塗り塗膜を硬化させ、膜厚が30μmで有機固形分量が26g/m2となる上塗り層を形成し、化粧板を得た。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は70μmであった。
Example 6
Using a roll coater, 25 g / m 2 of impregnated sealer 2 having an organic solid content concentration of 100% is applied to the surface of the substrate adjusted to a moisture content of 0.5%. 2 was applied at 10 g / m 2 to form an impregnated sealer layer having an organic solid content of 35 g / m 2 over the entire front and back surfaces of the substrate.
Next, after applying 50 g / m 2 of the undercoating material 2 to the substrate surface side using a roll coater, the undercoating material is partially cured by ultraviolet irradiation to form a coating film, and then again using the roll coater, After 50 g / m 2 of the undercoat paint 3 was applied on the film, the undercoat paint was completely cured by ultraviolet irradiation to form a coating film. Next, the surface of the coating film was smoothly polished by a platen polishing machine to form an undercoat layer having a thickness of 40 μm and an organic solid content of 20 g / m 2 .
Furthermore, after applying a top coat of 10 g / m 2 using a roll coater from above the undercoat layer, applying the same top coat of 95 g / m 2 using a flow coater, and using a hot air dryer at 100 ° C. Then, the top coat film was cured by heating for 30 minutes to form a top coat layer having a film thickness of 30 μm and an organic solid content of 26 g / m 2 to obtain a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 70 μm.
実施例7
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が8μmで下塗り層の有機固形分量が4g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を10g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を95g/m2塗布し、膜厚が30μmで上塗り層の有機固形分量が26g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は38μmであった。
Example 7
An impregnation sealer treatment was performed in the same manner as in Example 6, and an undercoat layer having an undercoat layer thickness of 8 μm and an undercoat layer organic solid content of 4 g / m 2 was formed using the same paint and coating method as in Example 6. did. Next, in the same manner as in Example 6, the top coat was applied at 10 g / m 2 using a roll coater, and then the same top coat was applied at 95 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 26 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 38 μm.
実施例8
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が121μmで下塗り層の有機固形分量が60.5g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を5g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を58g/m2塗布し、膜厚が18μmで上塗り層の有機固形分量が15.6g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は139μmであった。
Example 8
Undercoating sealer treatment in the same manner as in Example 6, using the same paint and coating method as in Example 6, the undercoating layer having an undercoating layer thickness of 121 μm and the organic solid content of the undercoating layer of 60.5 g / m 2 Formed. Next, in the same manner as in Example 6, after applying 5 g / m 2 of the top coat using a roll coater, 58 g / m 2 of the same top coat was applied using a flow coater. An overcoat layer having an organic solid content of 15.6 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 139 μm.
実施例9
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、ロールコーターを用いて一回塗りにて上塗り塗料を21g/m2塗布し、膜厚が6μmで上塗り層の有機固形分量が5.2g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は46μmであった。
Example 9
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having a thickness of 40 μm and an organic solid content of the undercoat layer of 20 g / m 2 using the same paint and coating method as in Example 6. did. Next, 21 g / m 2 of the top coating material was applied by a single application using a roll coater to form a top coating layer having a film thickness of 6 μm and an organic solid content of the top coating layer of 5.2 g / m 2. Was made. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 46 μm.
実施例10
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を18g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を115g/m2塗布し、膜厚が38μmで上塗り層の有機固形分量が32.9g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は78μmであった。
Example 10
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having a thickness of 40 μm and an organic solid content of the undercoat layer of 20 g / m 2 using the same paint and coating method as in Example 6. did. Next, in the same manner as in Example 6, the top coat was applied at 18 g / m 2 using a roll coater, and then the same top coat was applied at 115 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 32.9 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 78 μm.
比較例7
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が4μmで下塗り層の有機固形分量が2g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を10g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を95g/m2塗布し、膜厚が30μmで上塗り層の有機固形分量が26g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は34μmであった。
Comparative Example 7
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having an undercoat layer thickness of 4 μm and an organic solid content of the undercoat layer of 2 g / m 2 using the same paint and coating method as in Example 6. did. Next, in the same manner as in Example 6, the top coat was applied at 10 g / m 2 using a roll coater, and then the same top coat was applied at 95 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 26 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 34 μm.
比較例8
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が138μmで下塗り層の有機固形分量が69g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を30g/m2塗布し、膜厚が9μmで上塗り層の有機固形分量が7.4g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は147μmであった。
Comparative Example 8
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having a thickness of 138 μm and an organic solid content of the undercoat layer of 69 g / m 2 using the same paint and coating method as in Example 6. did. Next, in the same manner as in Example 6, a top coat was applied at 30 g / m 2 using a roll coater to form a top coat layer having a film thickness of 9 μm and an organic solid content of the top coat layer of 7.4 g / m 2 . A decorative board was produced. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 147 μm.
比較例9
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、ロールコーターを用いて一回塗りで上塗り塗料を7g/m2塗布し、膜厚が2μmで上塗り層の有機固形分量が1.7g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は42μmであった。
Comparative Example 9
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having a thickness of 40 μm and an organic solid content of the undercoat layer of 20 g / m 2 using the same paint and coating method as in Example 6. did. Then, a top coat paint in a single coat using a roll coater 7 g / m 2 was applied, the film thickness to form a top coat layer organic solid content of the overcoat layer is 1.7 g / m 2 at 2 [mu] m, the veneer Produced. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 42 μm.
比較例10
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が40μmで下塗り層の有機固形分量が20g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を20g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を160g/m2塗布し、膜厚が51μmで上塗り層の有機固形分量が44.5g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は91μmであった。
Comparative Example 10
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having a thickness of 40 μm and an organic solid content of the undercoat layer of 20 g / m 2 using the same paint and coating method as in Example 6. did. Next, in the same manner as in Example 6, after applying the top coat 20 g / m 2 using a roll coater, the same top coat 160 g / m 2 was applied using a flow coater. An overcoat layer having an organic solid content of 44.5 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 91 μm.
比較例11
実施例6と同様に含浸シーラー処理し、実施例6と同様の塗料と塗装方法を用いて、下塗り層の膜厚が118μmで下塗り層の有機固形分量が59g/m2である下塗り層を形成した。次いで、実施例6と同様に、ロールコーターを用いて上塗り塗料を12g/m2塗布した後、フローコーターを用いて同一の上塗り塗料を125g/m2塗布し、膜厚が39μmで上塗り層の有機固形分量が33.9g/m2である上塗り層を形成し、化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は157μmであった。
Comparative Example 11
An impregnation sealer treatment was performed in the same manner as in Example 6 to form an undercoat layer having a thickness of 118 μm and an organic solid content of the undercoat layer of 59 g / m 2 using the same paint and coating method as in Example 6. did. Next, as in Example 6, the top coat was applied at 12 g / m 2 using a roll coater, and then the same top coat was applied at 125 g / m 2 using a flow coater. An overcoat layer having an organic solid content of 33.9 g / m 2 was formed to prepare a decorative board. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 157 μm.
比較例12
下塗り塗膜の表面を研磨しなかったことを除き、実施例6と同様の化粧板を作製した。この化粧板の下塗り層と上塗り層とを併せた有機塗膜層の膜厚は132μmであった。
Comparative Example 12
A decorative board similar to that of Example 6 was produced except that the surface of the undercoat film was not polished. The film thickness of the organic coating layer combining the undercoat layer and the topcoat layer of this decorative plate was 132 μm.
(4)評価
前記実施例1と同様に評価した。
得られた評価結果を表2に示す。
(4) Evaluation It evaluated similarly to the said Example 1.
The obtained evaluation results are shown in Table 2.
表1及び表2から明らかなように、抄造石膏板の表面に下塗り層及び上塗り層を形成させ、各層を所定の厚さとし、かつ下塗り層を研磨することにより、外観及び塗膜性能が良好で総発熱量8MJ/m2以下の優れた不燃性を有する化粧板が得られる。また、この化粧板は、低湿度のクリーンルームの内装材としての適性を有する。
一方、下塗り層が4μmと薄い比較例1及び比較例7は、基板の凹凸痕跡が表面にのこり平滑性が不十分なため外観不良であり、有機塗膜層合計厚みが140μmを越えている比較例2、比較例5、比較例8及び比較例11は、発熱量が8MJ/m2より高い値となっており、また、上塗り層が2μmと薄い比較例3及び比較例9は、耐薬品性が低下しているのに加え下地隠蔽性が不十分なため色ムラが生じて外観不良であり、また、下塗り塗膜の表面を研磨しなかった比較例6及び比較例12は、表面に基板の毛羽痕跡が残り表面平滑性が不十分であった。
As is clear from Table 1 and Table 2, the appearance and the coating film performance are good by forming an undercoat layer and an overcoat layer on the surface of the papermaking gypsum board, making each layer a predetermined thickness, and polishing the undercoat layer. A decorative board having excellent nonflammability with a total calorific value of 8 MJ / m 2 or less is obtained. Moreover, this decorative board has suitability as an interior material of a low humidity clean room.
On the other hand, Comparative Example 1 and Comparative Example 7 where the undercoat layer is as thin as 4 μm are poor in appearance because the uneven traces of the substrate remain on the surface and the smoothness is insufficient, and the total thickness of the organic coating layer exceeds 140 μm In Example 2, Comparative Example 5, Comparative Example 8 and Comparative Example 11, the calorific value is higher than 8 MJ / m 2 , and the overcoat layer is as thin as 2 μm. Comparative Example 6 and Comparative Example 12 in which the surface of the undercoat film was not polished were observed on the surface. The traces of fluff on the substrate remained and the surface smoothness was insufficient.
次に、実施例1及び比較例4の化粧板(縦1820mm×横910mm)を作製し、該化粧板を縦500mm×横400mmに切断して実施例1の試験片12枚、比較例の試験片12枚を作製して、湿度が極端に低い場合に対する適性試験を実施した。
(実施内容)
(1)乾燥室:複数の略透明樹脂板を組み合わせて囲った空間に、超低露点エアードライヤーを用いて乾燥空気を送り込み、内部を常に陽圧に保つことで外気の流入を防ぐようにした乾燥室を設けた。この乾燥室内部を、温度23℃±5℃で相対湿度が1%以下という極端な低湿度の環境に調整した。
(2)下地:50mm×50mmの角パイプ鋼材を用いて外寸500mm×400mmの枠体を組み、該枠体に縦500mm×横400mm、厚さ12.5mmのせっこうボード(JIS A 6901:2005)をビスで固定して試験体の下地とした。
(3)試験体:前記下地に前記試験片を固定して試験体とした。固定方法は一般的なクリーンルームの内装工法と同様に、両面テープと弾性接着剤を用いて行った。
(4)評価方法:前記試験体を前記乾燥室内に1ヶ月静置した後、乾燥収縮等による反り及びクラック発生の有無を目視にて判別した。
試験片各12枚について上記試験を実施した結果、比較例4の試験体は12体中4体について若干の反り発生が認められたのに対し、実施例1の試験体は12体すべてについて反り及びクラックの発生が認められなかった。従って本発明による化粧板は、極端な低湿度の環境で使用する窯業系化粧板として、十分な適性を有することが確認できた。
Next, decorative plates (1820 mm long × 910 mm wide) of Example 1 and Comparative Example 4 were prepared, and the decorative plate was cut into a length of 500 mm × width of 400 mm to test 12 test pieces of Example 1, a test of a comparative example. Twelve pieces were prepared, and an aptitude test was conducted for a case where the humidity was extremely low.
(Implementation content)
(1) Drying room: Dry air is sent into the space surrounded by a combination of multiple transparent resin plates using an ultra-low dew point air dryer, and the inside is always kept at positive pressure to prevent inflow of outside air. A drying chamber was provided. The inside of the drying chamber was adjusted to an extremely low humidity environment where the temperature was 23 ° C. ± 5 ° C. and the relative humidity was 1% or less.
(2) Base: A frame body having an outer dimension of 500 mm x 400 mm is assembled using a square pipe steel material of 50 mm x 50 mm, and a gypsum board (JIS A 6901: length 500 mm x width 400 mm, thickness 12.5 mm). 2005) was fixed with screws and used as the base of the test specimen.
(3) Specimen: The specimen was fixed to the base to obtain a specimen. The fixing method was performed using a double-sided tape and an elastic adhesive in the same manner as a general clean room interior construction method.
(4) Evaluation method: After the test specimen was left in the drying chamber for one month, the presence or absence of warpage and cracking due to drying shrinkage or the like was visually determined.
As a result of performing the above test on each of the 12 test pieces, a slight warpage was observed in 4 of 12 specimens in Comparative Example 4, whereas in all 12 specimens in Example 1 warped. No cracks were observed. Therefore, it was confirmed that the decorative board according to the present invention has sufficient suitability as a ceramic decorative board used in an extremely low humidity environment.
Claims (8)
(a)下塗り層が、表面研磨され、その膜厚が5〜120μm、
(b)上塗り層の膜厚が5〜40μm、
(c)下塗り層と上塗り層とからなる有機塗膜層の膜厚が140μm以下であることを特徴とする化粧板。 A papermaking gypsum board adjusted to a moisture content of 0.1 to 2% is used as a substrate, and the surface of the substrate is subjected to a polishing treatment followed by an impregnation sealer treatment. An undercoat layer and an overcoat layer are formed on the surface of the substrate. Has an organic coating layer in order,
(A) The undercoat layer is surface-polished and has a thickness of 5 to 120 μm,
(B) The thickness of the overcoat layer is 5 to 40 μm,
(C) A decorative board, wherein the organic coating layer comprising an undercoat layer and an overcoat layer has a thickness of 140 μm or less.
(a)下塗り塗装として下塗り層形成用有機塗料を塗布し、硬化させ、表面研磨し、膜厚が5〜120μmの下塗り層を形成し、
(b)上塗り塗装として上塗り層形成用有機塗料を塗布し、硬化させ、膜厚が5〜40μmの上塗り層を形成し、
(c)ただし、前記下塗り層と前記上塗り層とからなる有機塗膜層の膜厚を140μm以下とすることを特徴とする化粧板の製造方法。 A method for producing a decorative board in which a papermaking gypsum board adjusted to a moisture content of 0.1 to 2% is used as a substrate, the surface of the substrate is polished and then impregnated with a sealer, and then an undercoat layer and an overcoat layer are formed in this order Because
(A) Applying an organic paint for forming an undercoat layer as an undercoat, curing, surface polishing, and forming an undercoat layer having a thickness of 5 to 120 μm;
(B) Applying an organic paint for forming an overcoat layer as the top coat and curing it to form an overcoat layer having a thickness of 5 to 40 μm;
(C) However, the manufacturing method of the decorative board characterized by making the film thickness of the organic coating film layer which consists of the said undercoat layer and the said overcoat layer into 140 micrometers or less.
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JPS5899185A (en) * | 1981-12-04 | 1983-06-13 | 株式会社 朝日防火板工業所 | Inorganic undercoating material |
JPS634943A (en) * | 1986-06-25 | 1988-01-09 | ワシ中越ボ−ド株式会社 | Decorative board using calcium silicate group board material |
US6913819B2 (en) * | 2002-12-27 | 2005-07-05 | Christine E. Wallner | Cementitious veneer and laminate material |
US8182605B2 (en) * | 2002-12-27 | 2012-05-22 | Ecomeld Corp. | Cementitious veneer and laminate material incorporating reinforcing fibers |
JP4871521B2 (en) * | 2005-03-29 | 2012-02-08 | 株式会社エーアンドエーマテリアル | Inorganic board and method for producing the same |
JP5156605B2 (en) * | 2008-12-11 | 2013-03-06 | 株式会社エーアンドエーマテリアル | Decorative plate and manufacturing method thereof |
JP5409425B2 (en) * | 2010-02-15 | 2014-02-05 | 株式会社エーアンドエーマテリアル | Decorative plate and method for producing the same |
JP2012152944A (en) * | 2011-01-24 | 2012-08-16 | Kotobuki Kogyo Kk | Fluororesin coated plate |
JP5745910B2 (en) * | 2011-03-31 | 2015-07-08 | 株式会社エーアンドエーマテリアル | Paint plate and manufacturing method thereof |
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