Decorative board

• US 10,449,748 B2
• Filed: 10/12/2012
• Issued: 10/22/2019
• Est. Priority Date: 10/13/2011
• Status: Active Grant

• Current Assignee: AICA Kogyo Company Limited
• Original Assignee: AICA Kogyo Company Limited
• Inventors: Yasui, Masataka, Kouyama, Kazuki, Ogino, Tomoya
• Primary Examiner(s): Piziali, Andrew T
• Application Number:
  US14/351,366
• Publication Number:
  US 20140242871A1
• Time in Patent Office: 2,566 Days
• Field of Search: 422412, 442412, 442297
• CPC Class Codes: A47B 13/086 Table tops provided with a protecting coating made of veneer, linoleum, paper or the like
• CPC Class Codes: A47B 96/18 Tops specially designed for working on table tops A47B13/08
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/04 4 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2260/023 Two or more layers
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2264/104 Oxysalt, e.g. carbonate, sulfate, phosphate or nitrate particles
• CPC Class Codes: B32B 2264/12 Mixture of at least two particles made of different materials
• CPC Class Codes: B32B 2307/3065 Flame resistant or retardant, fire resistant or retardant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2451/00 Decorative or ornamental articles wall paper B32B2607/02
• CPC Class Codes: B32B 2479/00 Furniture upholstery B32B2601/00
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 29/06 specially treated, e.g. surfaced, parchmentised
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/28 : impregnated with or embedded in a plastic substance not used
• CPC Class Codes: B44C 5/0423 : containing fibreglass elements
• CPC Class Codes: C08J 2333/08 : Homopolymers or copolymers of acrylic acid esters
• CPC Class Codes: C08J 2333/12 : Homopolymers or copolymers of methyl methacrylate
• CPC Class Codes: C08J 2361/28 : with melamine
• CPC Class Codes: C08J 2461/28 : with melamine
• CPC Class Codes: C08J 5/244 : using glass fibres
• CPC Class Codes: C08J 5/249 : characterised by the additives used in the prepolymer mixture
• CPC Class Codes: E04F 13/18 : of organic plastics with or without reinforcements or filling materials of plastic-bound fibres or chips E04F13/16 or with an outer layer of organic plastics with or without reinforcements or filling materials; plastic tiles E04F13/0864 takes precedence
• CPC Class Codes: E04F 2290/045 : against fire
• CPC Class Codes: Y10T 442/693 : Including a paper layer

Abstract

A decorative board 5 includes: a prepreg 2 that includes a binder component including: at least one thermoplastic resin selected from a group consisting of acrylic resin having a glass-transition temperature Tg exceeding 0° C., vinyl chloride resin having a glass-transition temperature Tg exceeding 0° C., acrylic urethane, and aqueous polyurethane resin, and a thermosetting resin, a mixing ratio of the at least one thermoplastic resin to the thermosetting resin being 1:0-0.5 in solid content ratio, and an endothermic metal hydroxide; and a thermosetting resin impregnated decorative paper 1, wherein the prepreg and the thermosetting resin impregnated decorative paper are stacked and integrated.

Claims

1. A decorative board comprising:

a prepreg comprising;

an inorganic fiber substrate;

at least one thermoplastic resin selected from a group consisting of acrylic resin emulsion having a glass transition temperature Tg exceeding 0°

C. and having an average particle diameter of 150-300 nm, and acrylic urethane;

a thermosetting resin, a mixing ratio of the thermoplastic resin to the thermosetting resin being 1;

0-0.5 in solid content ratio by weight; and

an endothermic metal hydroxide; and

a thermosetting resin impregnated decorative paper comprising;

a thermosetting resin; and

a decorative paper;

wherein the prepreg and the thermosetting resin impregnated decorative paper are stacked and integrated.

2. The decorative board as set forth in claim 1, wherein the prepreg further comprises a silane coupling agent.

3. The decorative board as set forth in claim 1, wherein the endothermic metal hydroxide is aluminum hydroxide.

4. The decorative board as set forth in claim 1, wherein the inorganic fiber substrate is a non-woven glass fiber fabric.

5. The decorative board as set forth in claim 2, wherein the silane coupling agent is an epoxy group-containing silane or an amino group-containing silane.

6. The decorative board as set forth in claim 2, wherein the silane coupling agent is 3-glycidoxypropyltrimethoxysilane.

7. The decorative board as set forth in claim 2, wherein a mixing ratio of the silane coupling agent is 0.7-0.9 weight % of an entire mixture of the binder component, the endothermic metal hydroxide, and the silane coupling agent.

8. The decorative board as set forth in claim 1, wherein the acrylic resin emulsion is formed by polymerizing ethyl acrylate and methyl methacrylate as main monomers.

9. The decorative board as set forth in claim 1, wherein the prepreg further comprises calcium carbonate.

10. The decorative board as set forth in claim 9, wherein an average particle diameter of the calcium carbonate is 0.05-10 μ

m.

11. The decorative board as set forth in claim 1, wherein the thermosetting resin impregnated decorative paper is a melamine resin impregnated decorative paper.

12. The decorative board as set forth in claim 1, wherein a resin impregnated balance paper obtained by impregnating a third resin into a surface paper is further stacked on and integrated with the prepreg and the thermosetting resin impregnated decorative paper.

13. The decorative board as set forth in claim 12, wherein the resin impregnated balance paper is a melamine resin impregnated balance paper.

14. The decorative board as set forth in claim 12, wherein the resin impregnated balance paper is obtained by impregnating the surface paper weighing between 18-40 g/m² with a thermosetting third resin with an impregnation rate of 260% to 320%.

15. The decorative board as set forth in claim 1, wherein the prepreg further includes a non-aqueous inorganic filler having an average particle diameter of 0.05-20 μ

m.

16. A decorative board comprising:

a melamine resin impregnated decorative paper obtained by impregnating a decorative paper weighing between 30-140 g/m² with a melamine resin with an impregnation rate of 80% to 300%;

a prepreg disposed next to the melamine resin impregnated decorative paper, the prepeg including;

an acrylic resin emulsion having a glass transition temperature Tg exceeding 0°

C. and having an average particle diameter of 150-300 nm;

an endothermic metal hydroxide having an average particle diameter of 1-50 μ

m;

a fiber substrate; and

a silane coupling agent; and

a resin impregnated balance paper disposed adjacent the prepeg, the resin impregnated balance paper obtained by impregnating a surface paper weighing between 18-40 g/m² with a melamine resin with an impregnation rate of 260% to 320%.

17. The decorative board as set forth in claim 16, wherein the prepreg further includes a non-aqueous inorganic filler having an average particle diameter of 0.05-20 μ

m.

18. The decorative board as set forth in claim 16, wherein the prepreg further includes a thermosetting resin, a mixing ratio of the acrylic resin emulsion to the thermosetting resin being 1:

0.5 in solid content ratio by weight.

19. A decorative board comprising, from a top to a bottom:

a melanine resin impregnated decorative paper;

a first prepreg layer including;

a first thermoplastic resin formed from a first acrylic resin emulsion having a glass transition temperature Tg exceeding 0°

C. and having an average particle diameter of 150-300 nm,

a first endothermic metal hydroxide,

a first fiber substrate,

a first non-aqueous inorganic filler with an average particle diameter of 1-5 μ

m, and

a first silane coupling agent with an impregnation rate of 700% to 1200%;

a second prepreg layer including;

a second thermoplastic resin,

a second endothermic metal hydroxide,

a second fiber substrate,

a second non-aqueous inorganic filler, and

a second silane coupling agent; and

a melanine resin impregnated non-decorative paper weighing between 18 g/m2 and 40 g/m2 with an impregnation rate of 260% to 320%.