Functional decorative plate, method for recovering function of functional decorative plate, and functionality imparting composition

0001The present invention relates to a functional decorative board, a method for recovering the function of the functional decorative board, and a composition for imparting functionality.

0002Conventionally, a functional decorative board having functionality such as antifouling property and antibacterial property has been provided by adding or applying a functional substance such as a photocatalyst to a decorative board such as a melamine decorative board.

0003Patent Document 1 proposes a functional building material characterized in that the functional material is fixed in the vicinity of the surface by being coated with a resin coating film containing a functional material having antibacterial and antiviral functions. ing.

0004Patent Document 2 proposes a manufacturing method for obtaining an antibacterial polyester veneer by applying an unsaturated polyester resin to which an antibacterial agent made of calcined calcium-based ceramics powder in which an antibacterial metal is supported is applied to the surface of the paper. Has been done.

<p num="0005"><patcit num="1"><text>Japanese Unexamined Patent Publication No. 2008-80210</text></patcit><patcit num="2"><text>Japanese Patent Application Laid-Open No. 07-304619</text></patcit></p>

<p num="0006">FIG. 4 is a schematic cross-sectional view schematically showing a conventional functional decorative board. In this functional decorative board 3, a functional substance 14 such as a photocatalyst is fixed to the surface resin layer 12.</p><p num="0007">In the functional decorative board 3 shown in FIG. 4, when the functional substance 14 such as a photocatalyst comes into contact with the surface resin layer 12 for a long time, the surface resin layer 12 may be deteriorated. Specifically, discoloration of the surface resin layer 12 and shedding of the functional substance 14 may occur. As a result, not only the functionality is deteriorated, but also the design of the functional decorative board 3 is deteriorated due to the discoloration of the surface resin layer 12, and the appearance of the functional decorative board 3 is deteriorated due to the occurrence of surface irregularities. there were.</p><p num="0008">In addition, a functional substance may be added or applied to the surface layer of the decorative board. In such a case, the functional substance is buried in the surface resin layer of the surface layer and there are few exposed parts in the surface layer, so that the functionality is sufficient. There was a problem that it could not be expressed. Furthermore, the decorative board may be required to have high antibacterial and antiviral properties equivalent to a virus inactivation degree of 99.9% or more (a virus concentration not inactivated against Escherichia coli is 1/1000 or less). In such a case, there is also a problem that the functionality cannot be fully expressed.</p><p num="0009">The present invention has been made in view of such a problem, and an object of the present invention is to provide a functional decorative board excellent in maintaining the effect of functionality by preventing deterioration of a surface resin layer made of a melamine resin or the like. To do. In particular, it is an object of the present invention to provide a functional decorative board excellent in maintaining antibacterial and antiviral effects.</p>

<p num="0010">The functional decorative board of the present invention comprises a substrate, a surface resin layer laminated on one or both sides of the substrate, ceramic particles exposed and arranged on the surface resin layer, and exposure of the ceramic particles. It is characterized in that it is composed of a functional substance carried on a surface via a dried body of an inorganic sol.</p><p num="0011">That is, the present invention has a substrate and a surface resin layer laminated on the surface of the substrate, ceramic particles are exposed and arranged on the surface resin layer, and a functional substance is ceramic through a dried body of an inorganic sol. It is a functional decorative board having a structure supported on particles.</p><p num="0012">In the present specification, the ceramic particles are preferably particles having an isoelectric point higher than the isoelectric point of the functional substance supported on the exposed surface of the ceramic particles. Here, the isoelectric point is a state in which the positive and negative charges of the solute particles become zero as a whole when the hydrogen ion concentration of the solution is changed, and the entire particles do not move even when an electric field is applied. It is a hydrogen ion index when the average charge of is 0, and the value is expressed as pH. This isoelectric point is a value defined by the substance, and as an example, the isoelectric point of the functional substance is often pH 5 to 6, whereas the ceramic particles are the isoelectric point of the functional substance. Those having a higher isoelectric point can be used. In particular, it is more desirable that the isoelectric point of the ceramic particles is pH 7 or higher. The isoelectric point can be measured by the electrophoresis method (JIS R 1638).</p><p num="0013">Specifically, as the ceramic particles, at least one selected from cerium, zirconium, strontium, aluminum, silicon, iron, cobalt, copper, chromium, nickel, tin, cadmium, magnesium, manganese, tungsten, vanadium, yttrium and the like. Ceramic particles made of metal oxide or metal hydrate particles containing the same metal, aluminum oxide-containing particles, silica-containing particles, and diatomaceous earth can be used. Also, regarding the isoelectric point, alumina (Al)₂O₃) Isoelectric point is pH: 7.4 ~ 9.2, boehmite (AlOOH) isoelectric point is pH 7.7 ~ 9.4, cadmium hydroxide (Cd (OH))₂) Has an isoelectric point of pH 10.5 or higher, cadmium oxide (CdO) has an isoelectric point of pH 7.7, and iron hydrate (Fe (OH)).₂) Isoelectric point is pH12, iron oxide (Fe)₃O₄) Isoelectric point is pH12, copper oxide (CuO) isoelectric point is pH9.5, copper hydrate (Cu (OH))₂The isoelectric point of) is pH 7.7. It is desirable that these components are combined and the isoelectric point of the ceramic particles is higher than the isoelectric point of the functional substance. Among the compounds constituting the ceramic particles described above, it is particularly desirable to use aluminum oxide-containing particles.</p><p num="0014">Ceramic particles have the effect of easily attracting bacteria and viruses. In the first place, bacteria and viruses are anionic substances because they contain proteins and fats, and the anionic substances have the property of being attracted to their opposite cation substances. That is, the bacteria and viruses existing on the surface layer of the decorative board are attracted to the ceramic particles, and the functional substances carried on the ceramic particles can reduce the bacteria and viruses, and the bacteria and viruses do not multiply. , It becomes easier to obtain antibacterial and antiviral effects. In the case of particles that are not ceramic particles, since the frequency of bacteria and viruses existing on the surface layer of the decorative board coming into contact with the functional substance is low, the bacteria and viruses remain or multiply, and it is difficult to obtain antibacterial and antiviral effects.</p><p num="0015">Further, the ceramic particles have a property of easily supporting a functional substance exposed and arranged on the surface resin layer at regular intervals. When a functional substance is supported on particles that are not ceramic particles, the spacing between the functional substances tends to be narrowed. Therefore, the frequency of contact between the fungus or virus and the functional substance is reduced, and the expected effect of reducing the fungus or virus is not exhibited. As a result, it takes time to reduce bacteria and viruses, and antibacterial and antiviral effects are less likely to be exhibited. On the other hand, since the ceramic particles used in the present invention are supported in a state of being exposed at regular intervals, the frequency of contact between bacteria and viruses with functional substances does not decrease, and bacteria and viruses are reduced in a desired time. It makes it easier for antibacterial and antiviral effects to appear. As described above, the ceramic particles have the effect of attracting bacteria and viruses by supporting the functional substances at regular intervals, and can improve the antibacterial and antiviral effects. When a bacterium or a virus comes into contact with a functional substance, the functional substance can completely decompose the bacterium or the virus or partially damage the bacterium or the virus, so that the bacterium or the virus can be reduced. The above-mentioned effect is obtained by supporting a functional substance on the exposed surface of the ceramic particles.</p><p num="0016">In the functional decorative board of the present invention, the functional substance is supported on the ceramic particles via the dried body of the inorganic sol. By adhering the inorganic sol and the functional substance to the surface layer of the ceramic particles and then drying, the functional substance is fixed by the dried body (inorganic binder) of the inorganic sol, and the functional substance is more firmly fixed. Can be done. As the inorganic sol, silica sol, alumina sol, silica-alumina sol, titania sol and the like can be used, and among them, silica sol is preferably used.</p><p num="0017">In the functional decorative board of the present invention, the weight ratio of the functional substance to the inorganic sol is preferably functional substance: inorganic sol = 3: 7 to 7: 3, and is 4: 6 to 6: 4. Is more desirable, especially 5: 5. If the ratio of the weight of the functional substance to the total weight of the functional substance and the inorganic sol is less than 30%, the functionality of the functional substance tends not to be sufficiently expressed due to the large amount of the inorganic sol, and the functional substance tends to be insufficient. When the ratio of the weight of the functional substance to the total weight of the inorganic sol exceeds 70%, the amount of the inorganic sol is small, so that the adhesion between the ceramic particles and the functional substance tends not to be sufficiently improved. As used herein, the weight of the inorganic sol means the weight of the solid content of the inorganic sol.</p><p num="0018">In the functional decorative board of the present invention, it is desirable to use aluminum oxide-containing particles as the ceramic particles. Further, as the ceramic particles, specifically, it is desirable to use particles made of either alumina or strontium aluminate. Alumina is the most easily used of the ceramic particles, and can efficiently utilize the action of reducing bacteria and viruses described above. Further, aluminate Sens strontium, since there is a phosphorescent effect, can also under light-free environment maintained for a long time the effect of reducing the bacteria and viruses.</p><p num="0019">In the functional decorative board of the present invention, it is desirable that the average particle size of the ceramic particles is 0.1 μm to 55 μm.</p><p num="0020">In the functional decorative board of the present invention, it is desirable that the ceramic particles are exposed at an area ratio of 5 to 30% with respect to the surface of the surface resin layer. When the ceramic particles are exposed at an area ratio of 5% or more with respect to the surface of the surface resin layer, a functional substance such as a photocatalyst can be sufficiently supported, so that the action of reducing bacteria and viruses is sufficient. It can be demonstrated. Further, when the ceramic particles are exposed at an area ratio of 30% or less with respect to the surface of the surface resin layer, the ceramic particles carrying the functional substance are firmly bonded to the surface resin layer and are difficult to fall off. And the action of reducing viruses can be sufficiently sustained.</p><p num="0021">In the functional decorative board of the present invention, it is desirable that the functional substance is a visible light responsive photocatalyst.</p><p num="0022">In the functional decorative plate of the present invention, the visible light responsive photocatalyst is a platinum-supported titania catalyst, a copper-supported titania catalyst, an iron-supported titania catalyst, a nitrogen-doped titania catalyst, a sulfur-doped titania catalyst, a carbon-doped titania catalyst, or oxidation. It is preferably tungsten. In particular, the isoelectric point of the visible light responsive photocatalyst is preferably pH 5 to 6.</p><p num="0023">In the functional decorative board of the present invention, the surface resin layer may contain a silicone resin and / or a silane coupling agent.</p><p num="0024">Further, the present invention comprises a substrate, a surface resin layer laminated on one or both sides of the substrate, ceramic particles exposed and arranged on the surface resin layer, and an exposed surface of the ceramic particles. The present invention relates to a method for recovering the function of a functional decorative board comprising a functional substance carried through a dried body of an inorganic sol. In the method for recovering the function of the functional decorative board of the present invention, the functional decorative board whose function is deteriorated or inactivated due to the above-mentioned functional substance being dropped or inactivated is composed of an inorganic sol, a functional substance and a solvent. It is characterized by applying the imparting composition. In the method for recovering the function of the functional decorative board of the present invention, the functional substance is supported on the exposed surface of the ceramic particles, which is an inorganic substance, via the dried body of the inorganic sol. It can be attached to the surface of the plate and the functionality can be restored.</p><p num="0025">A functionalizing composition can be used to restore the function of the functional decorative board having such a reduced function. Therefore, the present invention provides functionality to a decorative board composed of a substrate, a surface resin layer laminated on one or both sides of the substrate, and ceramic particles exposed and arranged on the surface resin layer. With respect to the functionalizing composition used to impart. The functionalizing composition of the present invention is characterized by comprising an inorganic sol, a functional substance and a dispersion medium. The functionalizing composition of the present invention may further contain a dispersant. By applying such a functionalizing composition to a functional decorative board having a reduced function, a simple and quick functional recovery can be realized.</p>

<p num="0026">In the functional decorative plate of the present invention, the ceramic particles are exposed and arranged on the surface resin layer, and the functional substance is supported on the exposed surface of the ceramic particles, so that the functional substance comes into direct contact with the surface resin layer. do not. Therefore, it is possible to prevent the deterioration of the surface resin layer due to the functional substance, and it is possible to prevent the functional substance from falling off due to discoloration of the surface resin layer, deterioration of the surface resin layer, and the like. Further, since the functional substance is supported on the exposed surface of the ceramic particles via the dried body (inorganic binder) of the inorganic sol, the adhesion between the ceramic particles and the functional substance can be improved. Furthermore, since the functional substance is not buried in the surface resin layer and the functional substance is exposed on the surface of the decorative board, it exhibits its original functions as a functional substance such as antibacterial and antiviral properties. And the effect can be maintained for a long period of time. Further, by applying the functionalizing composition of the present invention to a functional decorative board having reduced functionality, simple and quick functional recovery can be realized.</p>

0027<figref num="1">FIG. 1 is a schematic cross-sectional view schematically showing a functional decorative board according to an embodiment of the present invention.</figref><figref num="2">FIG. 2 is an explanatory diagram showing an area portion which is a basis for calculating the area ratio of the exposed portion of the ceramic particles constituting the functional decorative board of the present invention.</figref><figref num="3">FIG. 3 (a) is a schematic cross-sectional view schematically showing a functional decorative board according to one embodiment of the present invention, and FIG. 3 (b) is a functional cosmetic according to another embodiment of the present invention. It is the schematic sectional drawing which shows typically the plate.</figref><figref num="4">FIG. 4 is a schematic cross-sectional view schematically showing a conventional functional decorative board.</figref>

0028Hereinafter, the functional decorative board of the present invention will be described in detail. FIG. 1 is a schematic cross-sectional view schematically showing a functional decorative board according to an embodiment of the present invention.

0029The functional decorative plate 1 of the present invention has a substrate (not shown) and a surface resin layer 12 made of a melamine resin or the like laminated on the surface of the substrate, and ceramic particles 13 are exposed on the surface resin layer 12. The functional substance 14 has a structure in which the functional substance 14 is supported on the exposed surface of the ceramic particles 13 via the dried body 17 of the inorganic sol.

0030The substrate used for the functional decorative board of the present invention is not particularly limited, and a non-combustible base material such as core paper or magnesia cement generally used for the decorative board can be used. The core paper may be used alone or as a laminated body in which a plurality of core papers are laminated. The number of core papers is not particularly limited, but may be 1 to 20 sheets. As the core paper, for example, aluminum hydroxide paper can be used. The core paper can be impregnated with phenol resin. Further, the core paper and the magnesia cement non-combustible base material can be laminated to form a substrate.

0031The magnesia cement non-combustible substrate can be used alone, or can be laminated and arranged in the center of the core paper to form a substrate. Magnesia cement non-combustible plate is magnesium oxide (MgO) and magnesium chloride (MgCl)₂) Are mixed, and aggregate and water are added and kneaded, and the mixture is formed into a plate shape. As the aggregate, inorganic fibers such as rock wool and glass wool and organic fibers such as wood chips and pulp can be used. Further, in order to increase the strength of the magnesia cement non-combustible plate, a glass fiber layer formed in a mesh shape or the like can be provided as an intermediate layer.

0032The method for forming the surface resin layer on the surface of the substrate made of a plurality or a single core paper and / or a magnesia cement non-combustible base material is not particularly limited, and can be carried out by a general method. For example, a method of laminating melamine resin-impregnated paper on one side or both sides of the substrate and hot-press molding can be used. When the above method is used, the melamine resin of the melamine resin-impregnated paper permeates the core paper, and the curing reaction proceeds there to develop the adhesive force of the melamine resin-impregnated paper to the core paper. The resins that can be used for the surface resin layer constituting the functional decorative board of the present invention include melamine resin, diallyl phthalate (DAP) resin, polyester resin, olefin resin, vinyl chloride resin, acrylic resin, and epoxy resin. Examples thereof include urethane resin, phenol resin, silicone resin, and guanamine resin. Among these, it is desirable to use a melamine resin.

0033The melamine resin is a resin having improved dimensional stability and toughness without impairing optical and visual characteristics such as translucency. As the melamine resin, any known resin can be adopted as long as it is a resin using melamine and its derivative as a monomer. Further, the melamine resin may be a resin composed of a single monomer or a copolymer composed of a plurality of monomers. Examples of the melamine derivative include derivatives having a functional group such as an alkoxymethyl group such as an imino group, a methylol group, a methoxymethyl group and a butoxymethyl group. Further, a compound obtained by reacting a melamine derivative having a methylol group with a lower alcohol to partially or completely etherify it can be used as a monomer. Derivatives having a methylol group such as monomethylol melamine, dimethylol melamine, trimethylol melamine, tetramethylol melamine, pentamethylol melamine, hexamethylol melamine (hereinafter referred to as "methylolated melamine") are copolymerized with melamine as a cross-linking agent. A melamine resin can be used.

0034The melamine resin-impregnated paper is produced by impregnating a pattern paper with a melamine resin at a predetermined impregnation rate, and then heating and drying the paper. The pattern paper can be impregnated with the melamine resin by immersing the pattern paper in a melamine resin-containing solution using, for example, an aqueous formaldehyde solution as a solvent. Further, in order to impart bending workability to the melamine resin-impregnated paper, a solution containing a plasticizer can be impregnated together with the melamine resin. As the plasticizer, for example, ε-caprolactam, acetoguanamine, paratoluene sulfonic acid amide, urea and the like can be used. As the pattern paper, for example, titanium paper is used. The basis weight of the pattern paper is 80 to 150 g / m in consideration of the thickness and weight of the pattern paper.²Can be. The heating and drying temperatures can be set to 100 to 150 ° C to firmly adhere the melamine resin to the pattern paper.

0035The ceramic particles constituting the functional decorative plate of the present invention are not particularly limited as long as they have an isoelectric point higher than the isoelectric point of the functional substance and can carry the functional substance, but are oxidized. It is desirable that the particles contain aluminum. Specifically, as the ceramic particles, it is desirable to use particles made of either alumina or strontium aluminate.

0036In the functional decorative board of the present invention, the average particle size of the ceramic particles is preferably 0.1 to 55 μm, and more preferably 0.5 to 5 μm. When the average particle size of the ceramic particles is less than 0.1 μm, the ceramic particles tend to be easily embedded in the surface resin layer, and the functional substance tends to be difficult to be carried on the ceramic particles, and the average particle size of the ceramic particles exceeds 55 μm. As a result, the ceramic particles may fall off or irregularities may be formed on the surface resin layer, which tends to cause problems in the appearance and design of the decorative board. When the average particle size of the ceramic particles is 0.5 to 5 μm, the functionality as a functional substance is exhibited, and there is no problem in the appearance and design of the decorative board.

0037In the functional decorative board of the present invention, it is desirable that the ceramic particles are exposed at an area ratio of 5 to 30% with respect to the surface of the surface resin layer. When the ceramic particles are exposed at an area ratio of 5% or more with respect to the surface of the surface resin layer, a functional substance such as a photocatalyst can be sufficiently supported, so that the action of reducing bacteria and viruses is sufficient. It can be demonstrated. Further, when the ceramic particles are exposed at an area ratio of 30% or less with respect to the surface of the surface resin layer, the ceramic particles carrying the functional substance are firmly bonded to the surface resin layer and are difficult to fall off. And the action of reducing viruses can be sufficiently sustained. FIG. 2 is an explanatory diagram showing an area portion which is a basis for calculating the area ratio of the exposed portion of the ceramic particles constituting the functional decorative board of the present invention. The area ratio in the functional decorative board of the present invention means the ratio of the total surface area B of the surface area resin layer in which the ceramic particles 13 are exposed and present to the surface area A of the entire surface area resin layer in FIG. .. If the ceramic particles are exposed to the surface of the surface resin layer in an area ratio of less than 5%, the functionality of the functional substance tends to be insufficiently exhibited.

0038In the functional decorative board of the present invention, it is desirable that the functional substance is a functional material having functions such as antibacterial property, antiviral property, antiallergenic property, and deodorant property. For example, examples of antibacterial and antiviral functional substances include visible light responsive photocatalysts. Specific examples of this visible light-responsive photocatalyst include those in which titanium oxide is supported by a platinum group such as platinum, palladium, rhodium, or ruthenium, iron, copper, or the like. In the functional decorative plate of the present invention, the visible light responsive photocatalyst is a platinum-supported titania catalyst, a copper-supported titania catalyst, an iron-supported titania catalyst, a nitrogen-doped titania catalyst, a sulfur-doped titania catalyst, a carbon-doped titania catalyst, or tungsten oxide. It is more desirable that the catalyst is a copper-supported titania catalyst. Examples of the copper-supported titania catalyst include CuO / TiO described in JP-A-2006-232729.₂Anatase-type titanium oxide containing copper in the range of (% by weight) = 1.0 to 3.5, cuprous oxide (copper (I) oxide: Cu) described in JP-A-2012-210557₂A photocatalyst composition in which O) and titanium oxide are compounded, titanium oxide having a mixture containing a monovalent copper compound and a divalent copper compound described in JP-A-2013-166705 on its surface, and Titanium Oxide, which is published internationally. Examples thereof include copper and titanium-containing compositions containing titanium oxide containing crystalline rutile-type titanium oxide and a divalent copper compound described in 2013/094573.

0039In the functional decorative board of the present invention, the functional substance is supported on the ceramic particles via the dried body of the inorganic sol. By immobilizing the functional substance via a dried body (inorganic binder) of the inorganic sol, the functional substance can be immobilized more firmly. As the inorganic sol, silica sol, alumina sol, silica-alumina sol, titania sol and the like can be used, and among them, silica sol is preferably used. By using the silica sol, the adhesion between the functional substance and the ceramic particles can be improved, the detachment of the functional substance is suppressed, and the functionality is maintained.

0040In the functional decorative board of the present invention, the weight ratio of the functional substance to the inorganic sol is preferably functional substance: inorganic sol = 3: 7 to 7: 3, and is 4: 6 to 6: 4. Is more desirable, especially 5: 5. If the ratio of the weight of the functional substance to the total weight of the functional substance and the inorganic sol is less than 30%, the functionality of the functional substance tends not to be sufficiently expressed due to the large amount of the inorganic sol, and the functional substance tends to be insufficient. When the ratio of the weight of the functional substance to the total weight of the inorganic sol exceeds 70%, the amount of the inorganic sol is small, so that the adhesion between the ceramic particles and the functional substance tends not to be sufficiently improved.

0041In the functional decorative board of the present invention, the surface resin layer may contain a silicone resin and / or a silane coupling agent. As the silicone resin, for example, a silicone resin, a modified silicone oil, or the like can be used. As the modified silicone oil, a silicone oil having one or more functional groups in the molecule can be used. The position where the functional group is introduced is not particularly limited, and the functional group may be introduced at any position of one end, both ends, or a side chain of the polysiloxane main chain. Further, as the functional group, for example, a hydroxyl group, an amino group, a methoxy group, a hydrazino group, an epoxy group, a methacryl group, a carboxyl group, a carbinol group and the like can be introduced.

0042As the silane coupling agent, for example, one having a functional group such as a vinyl group, a propenyl group, a butadienyl group, a styryl group, an acryloyl group, a methacryloxy group, an amino group, a mercapto group and an isocyanate group is desirable. Examples of the silane coupling agent include vinyl trichlorosilane, vinyl trimethoxysilane, vinyl triethoxysilane, vinyl triisopropoxysilane, allyltrimethoxysilane, 3-glycidoxypropyltriethoxysilane, 2- (3,4). -Epoxycyclohexyl) ethyltrimethoxysilane, p-styryltrimethoxysilane, 3-methacryloxypropylmethyldimethoxysilane, 3-methacryloxypropyltrimethoxysilane, N- (2-aminoethyl) -3-aminopropyltrimethoxysilane , 3-Triethoxysilyl-N- (1,3-dimethyl-butylidene) propylamine, diallyldimethylsilane, 3-mercaptopropyltrimethoxysilane, 3-isosiane-topropyltriethoxysilane and the like.

0043Next, the method for producing the functional decorative board of the present invention will be described. First, a surface resin layer is formed on the surface of a substrate made of a plurality or a single core paper and / or a magnesia cement non-combustible base material or the like. The substrate, its manufacturing method, and the surface resin layer have been described in the description of the functional decorative board of the present invention, and will be omitted here.

0044As described in the functional decorative board of the present invention, the method of forming the surface resin layer on the surface of the substrate is not particularly limited, and can be performed by a general method. Specific methods for forming the surface resin layer include, for example, a laminating step of laminating a resin-impregnated paper such as melamine resin on one side or both sides of a substrate made of a laminated body of core paper, and laminating resin-impregnated paper such as melamine resin. Examples thereof include a method including a hot-press molding step of hot-press molding the formed substrate. When the above method is used, the melamine resin of the melamine resin-impregnated paper permeates the core paper, and the curing reaction proceeds there to develop the adhesive force of the melamine resin-impregnated paper to the core paper.

0045The temperature of the decorative board can be 125 to 150 ° C as the heating condition for hot pressure molding, and 1.96 to 9.80 MPa (20 to 100 kg / cm) as the pressurizing condition.²). When the temperature is less than 125 ° C or the pressure is less than 1.96 MPa, the adhesion of the resin-impregnated paper to the substrate is insufficient and peeling is likely to occur. On the other hand, if the temperature exceeds 150 ° C or the pressure exceeds 9.80 MPa, cracks may occur.

0046As a method of fixing the ceramic particles on the surface of the surface resin layer having the surface resin layer on the substrate, for example, a method of spraying a spray liquid containing the ceramic particles on the surface of the surface resin layer, drying, and then thermocompression bonding is adopted. it can. By the above method, the ceramic particles can be exposed and fixed on the resin surface.

0047After the above step, the substrate on which the ceramic particles are arranged is immersed in a solution containing the functional substance and the inorganic sol and dried to allow the functional substance to be exposed on the exposed surface of the ceramic particles through the dried body of the inorganic sol. Can be carried on top. Further, a solution containing the functional substance and the inorganic sol is applied onto a substrate on which the ceramic particles are arranged and dried to support the functional substance on the exposed surface of the ceramic particles via the dried body of the inorganic sol. You may let me.

0048In the method for producing a functional decorative board of the present invention, the immobilization of the functional substance can be reinforced by supporting the functional substance on the ceramic particles via a dried body (inorganic binder) of the inorganic sol. .. As the inorganic sol, silica sol, alumina sol, silica-alumina sol, titania sol and the like can be used, and it is desirable to use silica sol.

0049In the method for producing a functional decorative board of the present invention, the weight ratio of the functional substance to the inorganic sol is preferably functional substance: inorganic sol = 3: 7 to 7: 3, and 4: 6 to 6: 3. A value of 4 is more desirable, and a value of 5: 5 is particularly desirable.

0050In the method for producing a functional decorative plate of the present invention, when the ceramic particles are thermocompression-bonded to the surface of the surface resin layer, a release cushion material made of polyethylene terephthalate (PET) is formed between the ceramic particle spraying surface and the thermocompression-bonding press surface. Can be performed with the intervention of. As a result, it is possible to prevent the ceramic particles from being buried in the surface resin layer, and it is possible to expose and fix the ceramic particles on the surface of the surface resin layer.

0051As another method for producing the functional decorative plate of the present invention, a spray liquid containing ceramic particles is sprayed on the transfer film, and then the ceramic particle adhesion surface of the transfer film is opposed to the resin surface of the substrate having the surface resin layer. Then, a method of thermally transferring the ceramic particles can be mentioned.

0052When the surface resin layer contains a silicone resin and / or a silane coupling agent, the surface resin layer contains the silicone resin and / or the silane coupling agent by containing the silicone resin and / or the silane coupling agent in the melamine resin solution. A method of impregnating with a silane coupling agent can be used.

0053FIG. 3 (a) is a schematic cross-sectional view schematically showing a functional decorative board according to one embodiment of the present invention, and FIG. 3 (b) is a functional cosmetic according to another embodiment of the present invention. It is the schematic sectional drawing which shows typically the plate. When the surface resin layer contains a silicone resin and / or a silane coupling agent, water repellency can be imparted to the surface of the melamine resin or the like. When the functional substance is supported on the exposed surface of the ceramic particles, as shown schematically in FIG. 3A, if the surface resin layer 12 does not contain the silicone resin and the silane coupling agent, the ceramic The functional substance 14 may adhere not only to the surface of the particles 13 but also to the surface 15 of the surface resin layer. On the other hand, as schematically shown in FIG. 3 (b), when the surface layer resin layer 12 contains a silicone resin and / or a silane coupling agent, the surface layer containing the silicone resin and / or the silane coupling agent. Due to the water repellency of the resin layer surface 16, the functional substance 14 avoids the surface of the surface resin layer 12 and adheres to the exposed surface of the ceramic particles 13 as much as possible, and comes into direct contact with the surface of the surface resin layer 12. The amount of the functional substance 14 can be further reduced. Further, when the surface layer resin layer contains a silane coupling agent, curability can be imparted to the melamine resin or the like, and it is possible to prevent the ceramic particles from being buried in the surface layer resin layer when thermocompression bonding is performed.

0054By containing a silicone resin and / or a silane coupling agent in the surface resin layer, the ceramic particles can be immobilized without being buried, and there is an effect that the functional substance is less likely to adhere to the surface resin layer. Specifically, even if the excess functional substance adheres to the surface resin layer during the process, it can be easily removed after the cleaning process. Further, contaminated water containing bacteria and viruses is easily attracted to hydrophilic ceramic particles and functional substances, and the functionality is easily exhibited. In particular, when a melamine resin is used for the surface resin layer, the above-mentioned actions and effects can be easily obtained.

0055Hereinafter, the functionalizing composition of the present invention will be described. The functionalizing composition of the present invention is formed on a decorative board composed of a substrate, a surface resin layer laminated on one or both sides of the substrate, and ceramic particles exposed and arranged on the surface resin layer. , A functionalizing composition used to impart functionality, characterized in that it comprises an inorganic sol, a functional substance and a dispersion medium.

0056By applying the composition composed of an inorganic sol, a functional substance and a dispersion medium to the surface resin layer of the decorative board and drying the composition, the functional substance becomes an inorganic sol on the ceramic particles exposed from the surface resin layer. Since it adheres through the dried body, the functional substance can be surely adhered to the ceramic particles, and as a result, the function of the functional veneer that has been deteriorated due to the functional substance falling off or being deactivated can be restored. Can be done. In particular, when the ceramic particles are aluminum oxide-containing particles such as alumina particles, the adhesion between the inorganic sol and the aluminum oxide-containing particles is excellent, so that the functional substance can be reliably supported.

0057As the inorganic sol and the functional substance used in the functionalizing composition of the present invention, the same ones as those described above can be used. As the inorganic sol, silica sol, peroxy titanate sol or a mixture thereof is most suitable. As the dispersion medium, water, ethanol, methanol, isopropyl alcohol, xylene and the like can be used.

0058In the functional-imparting composition of the present invention, the content of the functional substance is preferably 1 to 10% by weight, more preferably 1 to 5% by weight, based on the solid content of the functional-imparting composition. The content of the inorganic sol is preferably 90 to 99% by weight based on the solid content of the functionalizing composition.

0059The functionalizing composition of the present invention may further contain a dispersant. As the dispersant, various dispersants such as formalin naphthalene sulfonate, polyethylene glycol, polyether, and alkyl sulfonate can be used. It is desirable that the dispersant is added in an amount of about 0.1% by weight based on the solid content of the functionalizing composition.

<p num="0060">(Example 1) (Primary melamine impregnation process) Immerse a 0.2-0.3 mm thick paper roll in a solution containing melamine resin. The roll paper was impregnated with the melamine resin by passing the roll paper while immersing it in the solution so that the temperature of the solution was 20 ° C. and the immersion time was 2 minutes. The moving speed of the roll paper was 10 to 20 cm / sec. (Drying process) The roll paper that had passed through the melamine solution was dried by a dryer (manufactured by ESPEC, OVEN PH-201) at a temperature of 100 ° C. and a drying time of 30 seconds.</p><p num="0061">(Secondary melamine impregnation process) The paper roll that had undergone the drying step was immersed in a solution made of melamine resin. The paper roll was impregnated with the melamine resin by passing the roll paper while immersing it in the solution so that the temperature of the solution was 20 ° C. and the immersion time was 30 minutes. The moving speed of the roll paper was 10 to 20 cm / sec. (Drying / cutting process) The roll paper that had passed through the melamine solution was dried by a dryer (manufactured by ESPEC, OVEN PH-201) at a temperature of 100 ° C. and a drying time of 2 hours. After drying, it was cut into 910 mm × 1820 mm.</p><p num="0062">(Alumina particle spray process) A spray solution consisting of γ-alumina particles having an average particle size of 0.5 μm and ethanol was prepared. The spray solution was filled in the spray at room temperature and sprayed onto the cut melamine resin impregnated paper. (Drying process) The melamine resin-impregnated paper sprayed with alumina particles was dried by a dryer (manufactured by ESPEC, OVEN PH-201) at a temperature of 110 ° C. and a drying time of 2 minutes.</p><p num="0063">(Combination process) Four sheets of phenol resin impregnated core paper having a thickness of 0.3 to 0.4 mm were laminated, and melamine resin impregnated paper sprayed with the alumina particles obtained in the above step was laminated on the paper so that the alumina particle spraying surface was the outer surface. A release cushion material made of PET is interposed between the press surface of the press machine and the alumina particle spray surface of the melamine resin impregnated paper, and the temperature is 143 ° C and the press pressure is 80 kg / cm.², Thermocompression bonding was performed with a press time (including temperature rise time) of 50 minutes. As a result, the alumina particles were exposed and fixed on the melamine resin impregnated layer.</p><p num="0064">(Photocatalyst loading step) CuO-TiO with an average particle size of 100 nm₂Slurry (solid content concentration 25% by weight) in which the photocatalyst of No. 1 is dispersed in water and silica sol (SiO)₂A methanol mixture solution (photocatalyst concentration 0.05% by weight) containing 4.5: 5.5 weight ratio (solid content weight) was prepared. By applying the above methanol mixed solution using a spray to a substrate having a melamine resin impregnated layer on which the alumina particles obtained in the above step are exposed and arranged on the surface, and drying at 25 ° C. for 12 hours. , The production of a functional decorative plate in which the above-mentioned photocatalyst is supported on alumina particles via a dried product of silica sol has been completed.</p><p num="0065">(Comparative example 1) A melamine resin-impregnated paper was obtained in the same manner as in (Primary melamine impregnation step) to (Drying / cutting step) in Example 1 above. Next, four sheets of phenol resin impregnated core paper having a thickness of 0.3 to 0.4 mm were laminated, and the melamine resin impregnated paper obtained in the above step was placed on the stack, and the temperature was 143 ° C and the pressing pressure was 80 kg / cm by a press machine.², Thermocompression bonding was performed with a press time (including temperature rise time) of 50 minutes. As a result, a substrate having a melamine resin impregnated layer on the surface was obtained. Next, CuO-TiO with an average particle size of 100 nm₂Slurry (solid content concentration 25% by weight) in which the photocatalyst of No. 1 is dispersed in water and silica sol (SiO)₂A methanol mixture solution (photocatalyst concentration 0.05% by weight) containing 4.5: 5.5 weight ratio (solid content weight) was prepared. The methanol mixed solution is applied to a substrate having the melamine resin impregnated layer obtained in the above step on the surface using a spray, and dried at 25 ° C. for 12 hours to impregnate the melamine resin through a dried product of silica sol. The production of a functional decorative plate on which the photocatalyst is supported on the layer has been completed.</p><p num="0066">(Anti-virus evaluation) In order to evaluate the antiviral property of the functional decorative plate on which the photocatalyst was carried, which was obtained in Example 1 and Comparative Example 1, the antiviral property was determined according to the antiviral property test method of JIS R1756 visible light responsive photocatalyst material. Was measured. The measurement results were expressed as the virus concentration inactivated against Escherichia coli. Here, the concentration of the virus inactivated against Escherichia coli (virus inactivation degree) was used as an index of the virus concentration. Virus inactivity is an antiviral test using bacteriophage, and by measuring the concentration of virus that can infect E. coli using phage virus Qβ concentration: 8.3 million cells / milliliter, it becomes Escherichia coli. On the other hand, it is the result of calculating the concentration of the inactivated virus. That is, the virus inactivity is the degree of concentration at which Escherichia coli cannot be infected with respect to the phage virus Qβ concentration (phage virus Qβ concentration-concentration of virus capable of infecting Escherichia coli) / (phage virus). It can be calculated by (Qβ concentration) x 100. It can be said that the higher the virus inactivity value, the better the anti-virus property.</p><p num="0067">In the functional veneer of Example 1, the concentration of the virus capable of infecting Escherichia coli was 830 cells / milliliter or less, which was equivalent to 99.99% or more in terms of virus inactivity, and had high antiviral properties. It was confirmed to have. On the other hand, in the functional veneer of Comparative Example 1, the concentration of the virus capable of infecting Escherichia coli was about 8300 / ml, which was about 99.9% in terms of virus inactivity, which was a virus. It was confirmed that the degree of residual Escherichia coli was higher than that of Example 1 and the antiviral property was inferior to that of Example 1.</p><p num="0068">(Anti-virus property after cleaning) After wiping the surface of the functional decorative board according to Example 1 and Comparative Example 1 with a cloth containing water, the antiviral property was measured by the same method as described above. As a result, the functional veneer of Example 1 maintained high antiviral properties, whereas the functional veneer of Comparative Example 1 was compared to before wiping the surface of the veneer with a cloth. Furthermore, it was confirmed that the antiviral property was deteriorated.</p><p num="0069">(Example 2) (1) CuO-TiO with 0.11 g (solid content) of silica sol, 0.03 g (solid content) of peroxy titanate, and an average particle size of 100 nm.₂By mixing 0.01 g (solid content) of the photocatalyst and 14.6 g of methanol, and adding 0.1% dispersant (sodium alkylsulfonate) to the solid content in this mixed solution and mixing, the composition imparting functionality. Prepare things. (2) The functional decorative board of Example 1 is washed by spraying a cleaning agent composed of an aqueous solution of sodium hypochlorite on the decorative board, washed with water, and dried with hot air at 60 ° C. CuO-TiO₂The photocatalyst is inactivated by sodium hypochlorite. (3) The functionalizing composition of (1) above is sprayed onto the functional decorative board of (2) above, applied, and dried at 25 ° C. for 12 hours to achieve alumina via a dried body of silica sol. A functional decorative board in which the above photocatalyst is additionally supported on the particles is manufactured.</p><p num="0070">When the anti-virus property is measured in the same manner as in Example 1, it is equivalent to about 99.99% in terms of virus inactivity, and a decorative board having high anti-virus property can be obtained.</p>

00711,3 Functional veneer 12 Surface resin layer 13 Ceramic particles 14 Functional substances 15 Surface resin layer surface 16 Surface resin layer surface containing silicone resin and / or silane coupling agent 17 Dry body of inorganic sol (inorganic binder) A Surface area of the entire surface resin layer B The total surface area of the surface resin layer in which the ceramic particles are exposed.