Antiviral decorative plate and method for manufacturing antiviral decorative plate

The present invention relates to an antiviral decorative board and a method for producing an antiviral decorative board.

Conventionally, decorative boards having antifouling properties, antibacterial properties, antiviral properties, etc. have been provided by adding or applying a functional substance such as a photocatalyst to a decorative board such as a melamine decorative board. ..

Patent Document 1 discloses an antibacterial functional material in which an inorganic binder containing Al and / or Ga-doped zinc oxide particles is baked onto the surface of a substrate.

<p><patcit num="1"><text>Japanese Unexamined Patent Publication No. 2011-190155</text></patcit></p>

<p>In the example of Patent Document 1, zinc oxide particles doped with Ga or Al are dispersed in water, and this is added to an aqueous solution of water glass and mixed to prepare a spray liquid, and the spray liquid is applied to the surface of ceramic tiles. Antibacterial tiles are made by spraying and then baking. The antibacterial activity of the obtained antibacterial tile has been measured using Escherichia coli and Staphylococcus aureus. Furthermore, the antibacterial activity after immersion in warm water has been measured, and the correlation between the antibacterial activity at the initial stage and after durability and the doped metal species has been evaluated.</p><p>Patent Document 1 describes the range of the average particle size of the zinc oxide particles used, the weight-blending ratio of the antibacterial particles (conductive zinc oxide) and the inorganic binder, etc., but is formed after coating. The correlation between the thickness of the glass layer and the average particle size of the antibacterial particles and the expression of antibacterial activity are not described.</p><p>The present invention has been made in view of such a problem, and an object of the present invention is to provide a decorative board having excellent antiviral properties and excellent long-term durability in which the antiviral performance does not deteriorate with time. .. An object of the present invention is, in particular, to provide an antiviral decorative board that is suitably used for horizontal building materials.</p>

<p>The antiviral decorative board of the present invention is arranged on a substrate, a surface resin layer laminated on one or both sides of the substrate, and an antiviral functional layer containing inorganic antiviral particles. The ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.3 to 1.1 times. In the antiviral decorative board of the present invention, it is desirable that the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times.</p><p>In the antiviral decorative board of the present invention (hereinafter, also simply referred to as "the decorative board of the present invention"), the ratio of the thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.3 to 1.1 times. As a result, the risk of infection with viruses that cause diseases such as influenza virus can be significantly reduced. For example, assuming that 100,000 viruses contained in droplets discharged by sneezing or coughing adhere to spatial constituents of daily life such as building materials, the antivirus functional layer with respect to the average particle size of inorganic antiviral particles When the film thickness ratio is adjusted to 0.3 to 1.1 times, the anti-virus decorative plate of the present invention has high anti-virus performance, so the number of viruses even excluding the natural decrease due to conditions such as humidity. Can be reduced to 1/100 and the absolute number of viruses can be reduced to 1000 or less, greatly reducing the risk of infection.</p><p>Further, in the decorative board of the present invention, the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times, which means that the inorganic antiviral particles are on the surface of the antiviral functional layer. It means that it is exposed and placed. When the inorganic antiviral particles are buried inside the antiviral functional layer, the contact between the inorganic antiviral particles and the virus becomes insufficient, and the original functions of the inorganic antiviral particles cannot be exhibited. When the antiviral particles are exposed on the surface of the antiviral functional layer, the inorganic antiviral particles are exposed on the surface of the decorative plate, so that the functions such as antiviral property and antibacterial property can be sufficiently exhibited. Furthermore, when the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times, the inorganic antiviral particles are fixed to the antiviral functional layer without falling off, resulting in a physical load or the like. Since the inorganic antiviral particles do not easily fall off from the antiviral functional layer even if it is applied, the effect can be maintained for a long time.</p><p>If the ratio of the thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is less than 0.5 times, the inorganic antiviral particles become too large than the thickness of the antiviral functional layer, so that the antiviral functional layer is used. Insufficient number of immobilized inorganic antiviral particles. Therefore, it is not possible to obtain a numerical value indicating that the initial virus inactivity is equal to or better than -2.50, and sufficient antiviral and antibacterial properties cannot be exhibited. On the other hand, if the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is greater than 1.0 times, the inorganic antiviral particles are buried inside the antiviral functional layer, resulting in a high degree of virus inactivity. It is not possible to obtain a numerical value indicating that it is equivalent to or better than -2.50 in antiviral properties, and it is not possible to exhibit sufficient antiviral and antiviral properties.</p><p>On the other hand, when the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times, the virus inactivity is equal to or better than -2.50. Since it is a value, it can exhibit sufficient antibacterial and antiviral properties. Therefore, it can be applied to horizontal building materials such as housing equipment and public facilities, which are required to have both antiviral properties and long-term durability of antiviral performance without deterioration over time.</p><p>The virus inactivity is a numerical value (negative) indicated by the common logarithm log (1-X) when the amount of the original virus is 1 and the amount of virus deactivated after the virus deactivation process is X. (Indicated by the value), and the larger the absolute value, the higher the ability to inactivate the virus. For example, if 99.9% of the original virus is inactivated, the virus inactivity is expressed as log (1-0.999) =-3.00. The ratio of the amount of virus deactivated after virus deactivation processing to the total amount of virus before virus deactivation processing is expressed in% (99.9% in the above case) is called virus inactivation degree.</p><p>In the decorative board of the present invention, the average particle size of the inorganic antiviral particles is preferably 0.5 to 10 μm. If the average particle size of the inorganic antiviral particles is small, it is difficult to expose the inorganic antiviral particles to the surface of the antiviral functional layer even if the thickness of the antiviral functional layer is reduced, and the inorganic antiviral particles become antiviral. Since it is buried inside the functional layer, it becomes difficult to exert the original function of the inorganic antiviral particles. On the other hand, if the average particle size of the inorganic antiviral particles is large, not only the design of the decorative board is deteriorated, but also it is difficult to fix the inorganic antiviral particles to the antiviral functional layer, and the inorganic antiviral particles have an antiviral function. As it easily falls off the layer, it becomes difficult to exhibit antiviral properties and its long-term durability as a result.</p><p>In the decorative board of the present invention, the amount of the inorganic antiviral particles contained in the antiviral functional layer is 0.01 to 10 g / m.²It is desirable that it is 0.02 to 0.5 g / m.²Is more desirable. The amount of inorganic antiviral particles contained in the antiviral functional layer is 0.01 ~ 10g / m²If this is the case, the antiviral function can be exhibited without deteriorating the design of the decorative board due to discoloration or the like. The amount of inorganic antiviral particles contained in the antiviral functional layer is 0.01 g / m²If it is less than, the amount of inorganic antiviral particles is too small, and it is difficult to obtain sufficient antiviral and antibacterial properties. On the other hand, the amount of inorganic antiviral particles contained in the antiviral functional layer is 10 g / m.²If it exceeds, the design of the decorative board tends to be deteriorated by the inorganic antiviral particles.</p><p>In the decorative board of the present invention, it is desirable that the inorganic antiviral particles are composed of inorganic particles containing an antiviral metal, a metal ion or a metal compound. This is because by incorporating an antiviral metal, a metal ion or a metal compound into the inorganic particles, the inorganic antiviral particles immobilized on the antiviral functional layer come into contact with the virus and are easily inactivated. Incidentally, "inorganic particles antiviral metal, metal ions properly and contains a metal compound" refers to retain antiviral metal, metal ion or metal compound on the surface or inside of the inorganic particles , Antiviral metal, metal ion or metal compound and inorganic particles may be bonded directly or indirectly via a binder. Among them, the most preferable mode is to replace (ion exchange) a part of the constituent elements of the inorganic particles with metal ions.</p><p>In the decorative board of the present invention, the inorganic antiviral particles are copper (I) oxide, copper (II) oxide, copper (II) carbonate, copper (II) hydroxide, copper (II) chloride, silver ion and copper ion. On the other hand, the exchanged zeolite, alumina with at least one of nanosilver and copper, silica with at least one of nanosilver and copper, zinc oxide with at least one of nanosilver and copper, nano It is desirable that the inorganic particles consist of at least one selected from titanium oxide in which at least one of silver and copper is supported and calcium phosphate in which at least one of nanosilver and copper is supported.</p><p>In the decorative board of the present invention, it is desirable that the antiviral functional layer contains a dried product of an inorganic sol. Specifically, it is desirable that the antiviral functional layer has a film containing the inorganic antiviral particles, and the film contains a dried product of an inorganic sol. Since the dried body of the inorganic sol can form a film of the antiviral functional layer on the surface resin layer, the inorganic antiviral particles can be fixed.</p><p>In the decorative board of the present invention, it is desirable that the film further contains a dried or cured body of an inorganic polymer. Specifically, it is more desirable that the film further contains a dried product of an inorganic polymer containing siloxane. In this case, the lubricity of the surface of the antiviral functional layer and the feel to the touch can be improved. Specifically, siloxane is desirable as the inorganic polymer.</p><p>In the decorative board of the present invention, it is desirable that at least a part of the inorganic antiviral particles is exposed from the surface of the antiviral functional layer. Since at least a part of the inorganic antiviral particles is exposed from the surface of the antiviral functional layer, the inorganic antiviral particles, particularly the antiviral metal, metal ion or metal immobilized on the inorganic antiviral particles. This is because the probability that the compound comes into contact with the virus can be increased and the antiviral performance can be improved.</p><p>The method for producing an antiviral decorative board of the present invention includes a step of preparing a transfer film in which an antiviral functional layer containing inorganic antiviral particles is fixed on the surface of a base film, and one surface of a resin-impregnated paper serving as a substrate. Alternatively, a resin-impregnated paper to be a surface resin layer is laminated on both sides, and the transfer film is impregnated with a resin to be a surface resin layer so that the antivirus functional layer is in contact with the resin-impregnated paper to be the surface resin layer. A surface resin layer is formed on the substrate by the step of laminating on the paper and the laminate of the resin-impregnated paper to be the substrate, the resin-impregnated paper to be the surface resin layer, and the transfer film is hot-press molded. It is characterized by comprising a step of fixing the anti-virus functional layer on the surface resin layer.</p><p>In the method for producing an antiviral decorative board of the present invention, the antiviral functional layer is transferred to a resin-impregnated paper serving as a surface resin layer by using a transfer film coated with an antiviral functional layer during thermal pressure molding. Therefore, the antiviral functional layer can be fixed on the surface resin layer. As a result, a decorative board having excellent antiviral properties and long-term durability can be manufactured.</p><p>In the step of preparing the transfer film in the method for producing an antiviral decorative board of the present invention, it is desirable to spray a spray solution containing the inorganic antiviral particles on the surface of the base film. In this case, the amount of the inorganic antiviral particles sprayed on the surface of the base film is 1 to 10 g / m.²Is desirable.</p><p>In the step of preparing the transfer film in the method for producing an antiviral decorative board of the present invention, a coating liquid containing an inorganic sol is applied to the surface of the base film after spraying the spray liquid. , It is desirable to dry the above coating liquid. Since the film of the antiviral functional layer can be formed on the surface resin layer by the inorganic sol, the inorganic antiviral particles can be fixed.</p><p>In the method for producing an antiviral decorative board of the present invention, it is desirable that the coating liquid further contains an inorganic polymer. Specifically, it is desirable that the coating liquid further contains an inorganic polymer containing siloxane. The inorganic polymer can improve the lubricity and feel of the surface of the antiviral functional layer.</p><p>In the method for producing an antiviral decorative board of the present invention, in the transfer film, it is desirable that the antiviral functional layer is fixed on the surface of the base film subjected to the corona discharge treatment. When the surface of the base film is subjected to the corona discharge treatment, the wettability of the coating liquid is improved, so that a film in which the inorganic antiviral particles are uniformly dispersed can be formed.</p><p>In the method for producing an antiviral decorative board of the present invention, it is desirable that the average particle size of the inorganic antiviral particles is 0.5 to 10 μm.</p><p>In the method for producing a decorative board of the present invention, it is desirable that the inorganic antiviral particles are composed of inorganic particles containing an antiviral metal, a metal ion or a metal compound.</p><p>In the method for producing an antiviral decorative board of the present invention, the inorganic antiviral particles are copper (I) oxide, copper (II) oxide, copper (II) carbonate, copper (II) hydroxide, and copper (II) chloride. ), At least one of silver ion and copper ion exchanged zeolite, nano silver and at least one of copper supported alumina, nano silver and at least one of copper supported silica, nano silver and at least one of copper It is desirable that the inorganic particles consist of at least one selected from the supported zinc oxide, titanium oxide in which at least one of nano-silver and copper is supported, and calcium phosphate in which at least one of nano-silver and copper is supported.</p><p>The antiviral decorative board of the present invention is also arranged on a substrate, a surface resin layer laminated on one or both sides of the substrate, and the surface resin layer, and contains an inorganic antiviral particle. It is composed of a functional layer and is characterized in that cracks are formed in the antiviral functional layer.</p><p>The antiviral veneer of the present invention described above has cracks formed in the antiviral functional layer, and a fluid containing a virus can be trapped in the cracks, so that the veneer has even higher antiviral activity.</p><p>In the antiviral decorative board, it is desirable that the antiviral functional layer contains a dried product of an inorganic sol. When the antiviral functional layer contains a dried product of an inorganic sol, a film of the antiviral functional layer can be formed on the surface resin layer, so that the inorganic antiviral particles can be firmly fixed.</p><p>In the antiviral decorative board of the present invention, it is desirable that the antiviral functional layer has a film containing the inorganic antiviral particles, and the film further contains a dried or cured body of an inorganic polymer.</p><p>When the antiviral functional layer has a film containing the inorganic antiviral particles, and the film further contains a dried or cured product of an inorganic polymer, the surface lubricity and feel of the antiviral functional layer are improved. Can be good.</p>

<p>In the decorative board of the present invention, the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times, so that sufficient antiviral properties and long-term durability thereof can be exhibited. ..</p>

<figref num="1">FIG. 1 is a schematic cross-sectional view schematically showing a decorative board according to an embodiment of the present invention.</figref><figref num="2">2A, 2B, 2C, 2D, 2E and 2F are schematic cross-sectional views schematically showing an example of the method for manufacturing the decorative board shown in FIG.</figref><figref num="3">FIG. 3 is a cross-sectional SEM photograph of the decorative board produced in Example 1.</figref><figref num="4">FIG. 4 is a cross-sectional SEM photograph of the decorative board produced in Comparative Example 3.</figref><figref num="5">FIG. 5 is a graph showing the relationship between the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles and the degree of virus inactivity.</figref>

Hereinafter, the antiviral decorative board of the present invention (also simply referred to as the decorative board of the present invention) will be described in detail.

FIG. 1 is a schematic cross-sectional view schematically showing a decorative board according to an embodiment of the present invention. The decorative board 1 shown in FIG. 1 includes a substrate 11, a surface resin layer 12 laminated on the surface of the substrate 11, and an antiviral functional layer 13 arranged on the surface resin layer 12. The antiviral functional layer 13 contains inorganic antiviral particles 14.

The substrate used for the 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 papermaking 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.

The 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.

The 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 substrate is not particularly limited, and can be carried out by a general method. For example, when the surface resin layer is a melamine resin layer, 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 decorative board of the present invention include melamine resin, diallyl phthalate (DAP) resin, polyester resin, olefin resin, vinyl chloride resin, acrylic resin, epoxy resin, and urethane resin. , Phenolic resin, silicone resin, guanamine resin and the like. Among these, it is desirable to use a melamine resin. That is, in the decorative board of the present invention, it is desirable that the surface resin layer is a melamine resin layer.

Melamine resin is a resin with 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.

The 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.

The melamine resin layer may be formed by impregnating a pattern paper having a pattern or color printed on titanium paper with the above-mentioned melamine resin or the like and curing the pattern layer. Further, the melamine resin layer is made by impregnating transparent paper having a filler (inorganic particles such as titanium oxide, talc, calcium carbonate, etc.) of 5% by weight or less with the above-mentioned melamine resin, etc., and curing it, and laminating it on the pattern layer. , An overlay layer may be configured. Further, a backer layer may be provided on the back surface of a substrate made of a non-combustible base material made of a plurality or a single core paper and / or magnesia cement to prevent warpage.

In the decorative board of the present invention, an antiviral functional layer containing inorganic antiviral particles is arranged on the surface resin layer. It is desirable that at least a part of the inorganic antiviral particles is exposed from the surface of the antiviral functional layer. Further, it is desirable that the inorganic antiviral particles are dispersed and arranged near the surface of the antiviral functional layer.

When a virus or bacterium comes into contact with the inorganic antiviral particle, the active ingredient contained in the inorganic antiviral particle can completely decompose the virus or bacterium or damage a part of the bacterium, thus reducing the bacterium or virus. Can be made to. However, if the inorganic antiviral particles are agglomerated and present, the frequency of contact between the virus or fungus and the inorganic antiviral particles is locally reduced, and the expected antiviral and antibacterial properties are less likely to be exhibited. Therefore, it is desirable that the inorganic antiviral particles contained in the antiviral functional layer are uniformly dispersed.

The decorative board of the present invention is characterized in that the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times. As described above, when the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times, the virus inactivity is equal to or better than -2.50. Therefore, sufficient antibacterial and antiviral properties can be exhibited. Therefore, it can be applied to horizontal building materials that require both antiviral properties and long-term durability, such as housing equipment and public facilities.

In the decorative board of the present invention, the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is preferably 0.6 to 0.9 times. When the ratio of the thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.6 to 0.9 times, the virus inactivity is equal to or higher than -3.00, which is a value with excellent antiviral properties. Furthermore, it can exhibit sufficient antibacterial and antiviral properties.

The average particle size of the inorganic antiviral particles and the film thickness of the antiviral functional layer are calculated from the cross-sectional photographs taken by a scanning electron microscope (SEM) after the decorative plate is divided in the thickness direction. It can be obtained by doing. The average particle size of the inorganic antiviral particles is obtained by calculating the average particle size of any 10 inorganic antiviral particles. Specifically, the maximum diameter and the minimum diameter are measured by focusing on one inorganic anti-virus particle, the average is taken as the average particle diameter of the inorganic anti-virus particle, and the same measurement is performed on the other nine inorganic particles. The average particle size is measured by calculating the average of a total of 10 particles, which is also performed for anti-virus particles. On the other hand, the film thickness of the antiviral functional layer is obtained by calculating the average value of the film thickness at any 6 locations of the antiviral functional layer.

In the decorative board of the present invention, the average particle size of the inorganic antiviral particles is preferably 0.5 to 10 μm, and more preferably 1 to 5 μm. If the average particle size of the inorganic antiviral particles is less than 0.5 μm, the inorganic antiviral particles are likely to be embedded in the antiviral functional layer, so that the antiviral function of the decorative board tends to decrease. On the other hand, if the average particle size of the inorganic antiviral particles exceeds 10 μm, the immobilization of the inorganic antiviral particles becomes insufficient, and the inorganic antiviral particles easily fall off from the antiviral functional layer, so that the antiviral performance deteriorates. There is a tendency. Further, when the inorganic antiviral particles fall off from the antiviral functional layer, dents are formed on the surface, which causes problems in the appearance and design of the decorative board. On the other hand, when the average particle size of the inorganic antiviral particles is 0.5 to 10 μm, the function of the inorganic antiviral particles is fully exhibited. Further, there is no problem in the appearance and design of the decorative board.

In the decorative board of the present invention, the amount of inorganic antiviral particles contained in the antiviral functional layer is 0.01 to 10 g / m.²It is desirable that it is 0.02 to 0.5 g / m.²Is more desirable. The amount of inorganic antiviral particles contained in the antiviral functional layer is 0.01 ~ 10g / m²If this is the case, the antiviral function can be exhibited without deteriorating the design of the decorative board due to discoloration or the like. The amount of inorganic antiviral particles contained in the antiviral functional layer is 0.01 g / m²If it is less than, the amount of inorganic antiviral particles is too small, and it is difficult to obtain sufficient antiviral and antibacterial properties. On the other hand, the amount of inorganic antiviral particles contained in the antiviral functional layer is 10 g / m.²If it exceeds, the design of the decorative board tends to be deteriorated by the inorganic antiviral particles.

When the antiviral functional layer is formed by the method described later, the amount of the inorganic antiviral particles contained in the antiviral functional layer is the amount of the inorganic antiviral particles contained in the spray solution and the application efficiency of the spray. , And can be calculated from the area of the coated body. For example, the amount of inorganic antiviral particles contained in the spray solution is 1 to 10 g / m.²If, the amount of inorganic antiviral particles contained in the antiviral functional layer is 0.02 to 0.2 g / m if the spray application efficiency is 2%.²If the spray application efficiency is 5%, then 0.05 to 0.5 g / m²Will be.

In the decorative board of the present invention, it is desirable that the inorganic antiviral particles are made of a material having functions such as antibacterial property, antiviral property, antiallergenic property, and deodorant property. The inorganic antiviral particles are preferably inorganic particles containing an antiviral metal, metal ion or metal compound. This is because by incorporating an antiviral metal, a metal ion or a metal compound into the inorganic particles, the inorganic antiviral particles immobilized on the antiviral functional layer come into contact with the virus and are easily inactivated.

For example, examples of materials exhibiting antiviral and antibacterial properties include materials containing silver, copper, or both. Further, as the inorganic anti-virus particles, particles of a metal oxide or metal hydrate containing at least one metal selected from silver, copper, zinc, titanium and the like can also be used. Specific examples of the inorganic anti-virus particles include copper (I) oxide (copper oxide), copper (II) oxide, copper (II) carbonate, copper (II) hydroxide, copper (II) chloride, and silver ion. And zeolite in which at least one of the copper ions was exchanged, alumina in which at least one of nanosilver and copper was carried, silica in which at least one of nanosilver and copper was carried, and oxidation in which at least one of nanosilver and copper was carried. Examples thereof include inorganic particles such as titanium oxide in which at least one of zinc, nanosilver and copper is supported, and calcium phosphate in which at least one of nanosilver and copper is supported. These inorganic particles may be one kind or two or more kinds. Zeolites exchanged at least one of silver and copper ions may be further exchanged with other metal ions such as zinc ions. In the decorative plate of the present invention, the inorganic antiviral particles are supported by silver ion-exchanged zeolite, which is a white powder, alumina on which nanosilver is supported, and nanosilver so that the design of the decorative plate is not impaired by coloring the powder itself. It is desirable that the inorganic particles consist of silica, zinc oxide carrying nanosilver, titanium oxide carrying nanosilver, or calcium phosphate carrying nanosilver.

In the decorative board of the present invention, it is desirable that the antiviral functional layer contains a dried product of an inorganic sol. Specifically, it is desirable that the antiviral functional layer has a film containing inorganic antiviral particles, and the film contains a dried product of an inorganic sol. Since the dried body of the inorganic sol can form a film of the antiviral functional layer on the surface resin layer, the inorganic antiviral particles can be fixed.

Examples of the inorganic sol include alumina sol, silica sol, titania sol and the like. These may be one kind or two or more kinds. Above all, it is desirable to use silica sol.

In the decorative board of the present invention, it is desirable that the film of the anti-virus functional layer further contains a dried body or a cured body of an inorganic polymer in addition to the dried body of the inorganic sol. Specifically, it is desirable to include a dried product of an inorganic polymer containing siloxane. In this case, the lubricity of the surface of the antiviral functional layer and the feel to the touch can be improved.

Examples of the siloxane-containing inorganic polymer include silicone oil and a silane coupling agent. These may be one kind or two or more kinds. Further, as the inorganic polymer containing siloxane, for example, a commercially available product such as "My Block Wako 101" (manufactured by Wako Pure Chemical Industries, Ltd.) can be used. "My Block Wako 101" is an alkyl acrylate copolymer methylpolysiloxane ester.

The amount of the inorganic polymer added containing siloxane is preferably 15 wt% or less in terms of solid content weight ratio with respect to the inorganic antiviral particles. If the amount of the inorganic polymer added is greater than 15 wt% in terms of solid content weight ratio, the dried product of the inorganic polymer coats the inorganic antiviral particles, making it difficult for the antiviral function to be exhibited.

Next, the method for producing the antiviral decorative board of the present invention will be described.

2A, 2B, 2C, 2D, 2E and 2F are schematic cross-sectional views schematically showing an example of the method for manufacturing the decorative board shown in FIG.

First, as shown in FIGS. 2A and 2B, a transfer film 30 in which the antiviral functional layer 13 containing the inorganic antiviral particles 14 is fixed on the surface of the base film 20 is prepared.

As described in the veneer of the present invention, the antiviral functional layer is formed so that the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is 0.5 to 1.0 times. It is desirable, and it is more desirable that the above ratio is formed to be 0.6 to 0.9 times.

In the method for producing a decorative board of the present invention, it is desirable to spray a spray liquid containing inorganic antiviral particles onto the surface of the base film. In this case, the amount of the inorganic antiviral particles sprayed on the surface of the base film is 1 to 10 g / m.²Is desirable.

The spray liquid preferably further contains an inorganic sol, more preferably further contains an inorganic polymer in addition to the inorganic sol, and more specifically, more preferably further contains an inorganic polymer containing a siloxane. .. In this case, it is desirable that the inorganic sol contained in the spray liquid is the same as the inorganic sol contained in the coating liquid described later. Similarly, it is desirable that the inorganic polymer contained in the spray liquid is the same as the inorganic polymer contained in the coating liquid described later.

In the method for producing a decorative board of the present invention, it is desirable to apply a coating liquid containing an inorganic sol to the surface of the base film after spraying the spray liquid and dry the coating liquid. Since the film of the antiviral functional layer can be formed on the surface resin layer by the inorganic sol, the inorganic antiviral particles can be fixed.

It is desirable that the coating liquid further contains an inorganic polymer. Specifically, it is desirable to further contain an inorganic polymer containing siloxane. The inorganic polymer can improve the lubricity and feel of the surface of the antiviral functional layer.

The antiviral functional layer can be fixed on the surface of the base film by applying the coating liquid to a predetermined film thickness using a bar coater and allowing it to air dry.

The inorganic sol and the inorganic polymer contained in the coating liquid will be omitted because they have been described in the antiviral decorative board of the present invention.

In the method for producing a decorative board of the present invention, for example, a biaxially stretched polypropylene (OPP) film, a polyethylene terephthalate (PET) film or the like can be used as the base film.

It is desirable that the surface of the base film on the side where the antiviral functional layer is fixed is subjected to corona discharge treatment. Therefore, it is desirable to use an OPP film or a PET film whose surface has been subjected to corona discharge treatment as the base film.

The surface of the base film on the side where the antiviral functional layer is fixed may be matted, but the surface roughness Rmax of the base film is preferably 5 μm or less. If the surface roughness of the base film is large, fine irregularities are generated on the surface of the decorative board, and the design and feel are likely to be deteriorated.

Next, as shown in FIG. 2C, the resin-impregnated paper 32 to be the surface resin layer is laminated on the surfaces of the resin-impregnated papers 31a, 31b, 31c and 31d to be the substrate, and the antivirus functional layer 13 is the surface resin. The transfer film 30 is laminated on the resin-impregnated paper 32 which is the surface layer resin layer so as to be in contact with the resin-impregnated paper 32 which is the layer.

Subsequently, as shown in FIG. 2D, a laminate of the resin-impregnated papers 31a, 31b, 31c and 31d as the substrate, the resin-impregnated paper 32 as the surface resin layer and the transfer film 30 is hot-press molded. As a result, as shown in FIG. 2E, the surface layer resin layer 12 can be formed on the substrate 11, and the antiviral functional layer 13 can be fixed on the surface layer resin layer 12.

As described in the 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. As a specific method for forming the surface resin layer, for example, a substrate made of a laminated body of core paper is laminated with a resin-impregnated paper such as melamine resin on one side or both sides, and the resin-impregnated paper such as melamine resin is laminated. There is a method of hot-press molding. 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.

At this time, a transfer film coated with an antiviral functional layer is laminated on a resin-impregnated paper to be a surface resin layer, and these laminates are hot-press molded to impregnate the resin with the antiviral functional layer to be a surface resin layer. Transferred to paper. As a result, the antiviral functional layer can be fixed on the surface resin layer.

The temperature of the veneer 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) Can be. 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.

Then, by removing the base film 20 by peeling or the like, the decorative plate 1 shown in FIG. 1 can be obtained as shown in FIG. 2F.

<p>Hereinafter, examples in which the present invention is disclosed more specifically will be shown. The present invention is not limited to these examples.</p><p>(Example 1) (Primary melamine impregnation step) A paper roll having a thickness of 0.2 to 0.3 mm was immersed in a solution containing a 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.</p><p>(Drying step) The roll paper passed through the melamine solution was dried from a dryer at a temperature of 100 ° C. and a drying time of 30 seconds.</p><p>(Secondary melamine impregnation step) 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.</p><p>(Drying / cutting step) The roll paper passed through the melamine solution was dried from a dryer at a temperature of 100 ° C. and a drying time of 2 hours. After drying, it was cut into 300 mm × 300 mm.</p><p>(Preparation of transfer film 1: Inorganic anti-virus particle spraying process) As inorganic anti-virus particles, silver ion and zinc ion exchange zeolite powder (Zeomic AK-10N manufactured by Sinanen Zeomic) and silica sol (SiO) with an average particle diameter of 2.5 μm.₂A spray solution consisting of a mixed solution of methanol containing My Block Wako 101 (solid content concentration 30 wt%) and My Block Wako 101 (solid content concentration 30 wt%) in a weight ratio of 130: 20: 1 was prepared. The spray solution was filled in the spray at room temperature and sprayed onto the surface of the OPP film treated with corona discharge.</p><p>(Preparation of transfer film 2: Antiviral functional layer forming step) Silica sol (SiO) is applied to the surface of the OPP film to which inorganic antiviral particles are attached.₂A coating solution prepared by mixing My Block Wako 101 (solid content concentration 30 wt%) and methanol at a weight ratio of 20: 1:10 was applied using a coat bar with a count of 7 and then at room temperature. A transfer film in which an antiviral functional layer was fixed on the surface of the OPP film was prepared by air-drying with.</p><p>(Combination step) 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 was laminated on the four sheets. Furthermore, a transfer film was laminated on the melamine resin impregnated paper so that the antiviral functional layer was in contact with the melamine resin impregnated paper, and the temperature was 143 ° C and the press pressure was 80 kg / cm.², Thermocompression bonding was performed with a pressing time (including heating time) of 50 minutes. After that, the OPP film was further peeled off, thereby completing the production of a decorative board in which an antiviral functional layer containing inorganic antiviral particles was arranged on the melamine resin layer.</p><p>FIG. 3 is a cross-sectional SEM photograph of the decorative board produced in Example 1. From FIG. 3, it can be confirmed that the antiviral functional layer 13 containing the inorganic antiviral particles 14 is arranged on the melamine resin layer which is the surface resin layer 12. In FIG. 3, cracks are present in the antiviral functional layer, but the fluid containing the virus is trapped in the cracks and comes into contact with the antiviral particles, which is advantageous for the expression of the antiviral function. In Example 1, since the coefficient of thermal expansion of the dried product of the silica sol constituting the resin layer and the antiviral layer is different, it is considered that cracks are formed in the antiviral layer by cooling after pressing in the above combination step. Of course, the amount of Myblock Wako 101 (alkyl acrylate copolymer methylpolysiloxane ester), which is an inorganic polymer mixed in the silica sol, is adjusted to match the coefficient of thermal expansion between the antivirus layer and the resin layer. It is also possible to make a decorative board without cracks.</p><p>When the film thickness of the antiviral functional layer was measured from the cross-sectional observation of the SEM, the average film thickness of the antiviral functional layer was 2.3 μm. Therefore, the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 0.90 times.</p><p>In (Example 2) (Preparation of transfer film 2: Antiviral functional layer forming step), the weight ratio of silica sol, My Block Wako 101 and methanol was changed to 20: 1: 5, and the bar coat count was 7. A decorative board was prepared by the same method as in Example 1 except that the number was changed from No. 4.</p><p>The average film thickness of the antiviral functional layer of the decorative board produced in Example 2 was 1.6 μm, and the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 0.63 times.</p><p>(Example 3) In (Preparation of transfer film 2: Antiviral functional layer forming step), the weight ratio of silica sol, My Block Wako 101 and methanol was changed to 20: 1: 20, and the bar coat count was 7. A decorative board was prepared by the same method as in Example 1 except that the number was changed from No. 4.</p><p>The average film thickness of the antiviral functional layer of the decorative board produced in Example 3 was 1.4 μm, and the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 0.57 times.</p><p>In (Example 4) (Preparation of transfer film 2: Antiviral functional layer forming step), the weight ratio of silica sol, My Block Wako 101 and methanol was changed to 20: 1:10, and the bar coat count was 7. A decorative board was prepared by the same method as in Example 1 except that the number was changed from No. 4.</p><p>The average film thickness of the antiviral functional layer of the decorative board produced in Example 4 was 1.3 μm, and the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 0.50 times.</p><p>(Comparative Example 1) In (Preparation of transfer film 2: Antiviral functional layer forming step), the weight ratio of silica sol, My Block Wako 101 and methanol was changed to 20: 1: 50, and the bar coat count was 7. A decorative board was prepared by the same method as in Example 1 except that the number was changed from No. 4.</p><p>The average film thickness of the antiviral functional layer of the decorative board produced in Comparative Example 1 was 0.5 μm, and the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 0.20 times.</p><p>(Comparative Example 2) In (Preparation of transfer film 2: Antiviral functional layer forming step), the weight ratio of silica sol, My Block Wako 101 and methanol was changed to 20: 1: 5, and the bar coat count was 7. A decorative board was prepared by the same method as in Example 1 except that the number was changed from No. 9.</p><p>The average film thickness of the antiviral functional layer of the decorative board produced in Comparative Example 2 was 3.1 μm, and the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 1.23 times.</p><p>(Comparative Example 3) In (Preparation of transfer film 2: Antiviral functional layer forming step), the weight ratio of silica sol, My Block Wako 101 and methanol was changed to 20: 1: 2, and the bar coat count was 7. A decorative board was prepared by the same method as in Example 1 except that the number was changed from No. 14.</p><p>FIG. 4 is a cross-sectional SEM photograph of the decorative board produced in Comparative Example 3. From FIG. 4, it can be confirmed that the antiviral functional layer 13 containing the inorganic antiviral particles 14 is arranged on the melamine resin layer which is the surface resin layer 12.</p><p>The average film thickness of the antiviral functional layer of the decorative board produced in Comparative Example 3 was 3.5 μm, and the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles was 1.40 times.</p><p>(Evaluation of design) When the appearance of the decorative board produced in each Example and Comparative Example was visually observed, it was confirmed that there was no problem in any of them.</p><p>(Evaluation of antiviral property) In order to evaluate the antiviral property of the decorative board produced in each Example and Comparative Example, JIS R 1756 The antiviral property was measured by a modified method of the antiviral property test method of the visible light responsive photocatalytic material. The modification is that "1000 lux light irradiation for 4 hours" is changed to "leaving under indoor fluorescent light (about 300 lux)". The measurement result is expressed by 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. Phagevirus Qβ concentration: 8.3 million cells / milliliter is used to measure the concentration of a virus that can infect 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 that cannot infect Escherichia coli with respect to the concentration of phage virus Qβ, and (phage virus Qβ concentration-concentration of virus that can infect 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 higher the absolute value of the virus inactivity), the better the antiviral property.</p><p>The virus inactivity was determined from the virus inactivity for the decorative boards produced in each Example and Comparative Example. Table 1 summarizes the film thickness of the antiviral functional layer, the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles, and the degree of virus inactivity. In addition, Fig. 5 shows the relationship between the ratio of the thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles and the degree of virus inactivity. In Table 1 and FIG. 5, the ratio of the film thickness of the antiviral functional layer to the average particle size of the inorganic antiviral particles is described as "antiviral functional layer film thickness / average particle size ratio".</p><p><tables num="1"><img file="JP2019025918A_D0001.tif" /></tables></p><p>From Table 1 and FIG. 5, the results of Examples 1 to 3 show that the virus inactivity is 99.9% or more (the virus inactivity is equal to or higher than -3.00, or has better antiviral properties). Was done. Further, in Example 4, the result that the virus inactivity was 99.84% or more (the virus inactivity was equal to or higher than -2.80 or more excellent in antiviral property) was obtained. On the other hand, in Comparative Examples 1 to 3, the virus inactivity was 96.84% (virus inactivity was about -1.50), and it was confirmed that the antiviral property was lower than that in Examples 1 to 4.</p><p>(Wipe durability test) In order to evaluate the durability against the wiping load of the decorative board produced in Example 2, a wiping test was performed 3650 times at a pressure of 150 Pa using a microfiber cloth soaked with tap water. carried out.</p><p>After wiping 3650 times with 150Pa, the virus inactivity is 99.75% or more (virus inactivity is equal to -2.60 or better than that), and the antiviral function is maintained. It was confirmed that it was done.</p>

1 Decorative board 11 Substrate 12 Surface resin layer 13 Anti-virus functional layer 14 Inorganic anti-virus particles 20 Base film 30 Transfer film 31a, 31b, 31c, 31d Resin-impregnated paper as substrate 32 Resin-impregnated paper as surface resin layer