DECORATIVE BOARD

• US 20100136351A1
• Filed: 03/25/2008
• Published: 06/03/2010
• Est. Priority Date: 04/26/2007
• Status: Active Grant

• Current Assignee: AICA Kogyo Company Limited
• Original Assignee: AICA Kogyo Company Limited
• Inventors: Iwasaki, Atsushi, Yokoi, Akitomo, Yasui, Masataka, Suzuki, Koshi
• Granted Patent: US 8,071,224 B2
• Time in Patent Office: Days
• US Class Current: 428/447
• CPC Class Codes: B32B 17/02 in the form of fibres or filaments
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer layers of natural mineral fibres or particles being impregnated in a plastic substance B32B19/02
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/10 Inorganic fibres layered products comprising a layer of natural mineral fibres B32B19/00
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/105 Ceramic fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2262/108 Rockwool fibres
• CPC Class Codes: B32B 2307/306 Resistant to heat
• 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 27/20 using fillers, pigments, thixotroping agents
• CPC Class Codes: B32B 27/42 comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines
• CPC Class Codes: B32B 29/02 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 5/022 Non-woven fabric
• CPC Class Codes: B32B 5/024 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: B44C 5/04 Ornamental plaques, e.g. decorative panels, decorative veneers
• CPC Class Codes: Y10T 428/31663 As siloxane, silicone or silane
• CPC Class Codes: Y10T 428/31942 Of aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31971 : Of carbohydrate
• CPC Class Codes: Y10T 428/31975 : Of cellulosic next to another carbohydrate
• CPC Class Codes: Y10T 428/31982 : Wood or paper
• CPC Class Codes: Y10T 428/31986 : Regenerated or modified
• CPC Class Codes: Y10T 428/31996 : Next to layer of metal salt [e.g., plasterboard, etc.]

Abstract

A decorative board in the present invention includes: a core layer constituted by a prepreg impregnated with a slurry containing (a) an organic resin component including a phenol-formaldehyde resin and an amino-formaldehyde resin, (b) one or more selected from a group consisting of carbonate, silica, talc and fly ash, and (c) a metal hydroxide; and a decorative layer.

Claims

1. A decorative board comprising:

a core layer comprising one or more prepreg layers, said prepeg layer including an inorganic fiber substrate impregnated with a slurry; and

a decorative layer disposed over at least part of said core layer, ‘

the slurry comprising containing (a) an organic resin component including a phenol-formaldehyde resin and an amino-formaldehyde resin, (b) one or more selected from a group consisting of carbonate, silica, talc and fly ash, and (c) a metal hydroxide.

2. The decorative board according to claim 1, wherein the slurry further comprises a silane coupling agent.

3. The decorative board according to claim 2, wherein the blending amount of the silane coupling agent in the slurry is 0.01-0.5 parts by weight per part by weight of a solid content of the component (a).

4. The decorative board according to claim 1, wherein a blending amount in solid equivalent of the amino-formaldehyde resin is 0.1-5 parts by weight per part by weight of a solid content of the phenol-formaldehyde resin in the slurry, and wherein a total blending amount in solid equivalent of the component (b) and the component (c) is 4-19 parts by weight per part by weight of a solid content of the component (a).

5. The decorative board according to claim 1, wherein the slurry further comprises:

a silane coupling agent; and

wherein a blending amount in solid equivalent of the amino-formaldehyde resin is 0.1-5 parts by weight per part by weight of a solid content of the phenol-formaldehyde resin in the slurry, and wherein a total blending amount in solid equivalent of the component (b) and the component (c) is 4-19 parts by weight per part by weight of a solid content of the component (a).

6. The decorative board according to claim 1, wherein the slurry further comprises:

a silane coupling agent;

wherein the blending amount of the silane coupling agent in the slurry is 0.01-0.5 parts by weight per part by weight of a solid content of the component (a); and

wherein a blending amount in solid equivalent of the amino-formaldehyde resin is 0.1-5 parts by weight per part by weight of a solid content of the phenol-formaldehyde resin in the slurry, and wherein a total blending amount in solid equivalent of the component (b) and the component (c) is 4-19 parts by weight per part by weight of a solid content of the component (a).

7. The decorative board according to claim 1, wherein the decorative layer comprises melamine resin impregnated paper.