U.S. patent application number 14/249363 was filed with the patent office on 2015-07-09 for decorated fireproof building substrate.
This patent application is currently assigned to Prior Company Limited. The applicant listed for this patent is Prior Company Limited. Invention is credited to Ju-En Hou, Man-Ling Lu.
Application Number | 20150191908 14/249363 |
Document ID | / |
Family ID | 51395840 |
Filed Date | 2015-07-09 |
United States Patent
Application |
20150191908 |
Kind Code |
A1 |
Hou; Ju-En ; et al. |
July 9, 2015 |
DECORATED FIREPROOF BUILDING SUBSTRATE
Abstract
A decorated fireproof building substrate includes a fireproof
building substrate and a decorated multilayer. The fireproof
building substrate includes a substrate and a fireproof layer,
wherein the fireproof layer covers the surface of the substrate.
The decorated multilayer includes an adhesive layer, a printed
layer, a grain layer and a hard coating layer disposed on the
fireproof building substrate subsequently. The hard coating layer
is located at the outermost side of the decorated multilayer,
wherein the grain layer also can has the function of the hard
coating layer so as to omit the disposal of the hard coating
layer.
Inventors: |
Hou; Ju-En; (Taoyuan County,
TW) ; Lu; Man-Ling; (Taoyuan County, TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Prior Company Limited |
Taipei City |
|
TW |
|
|
Assignee: |
Prior Company Limited
Taipei City
TW
|
Family ID: |
51395840 |
Appl. No.: |
14/249363 |
Filed: |
April 10, 2014 |
Current U.S.
Class: |
428/195.1 |
Current CPC
Class: |
Y10T 428/24802 20150115;
E04B 1/941 20130101 |
International
Class: |
E04B 1/94 20060101
E04B001/94 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 6, 2014 |
TW |
103200221 |
Claims
1. A decorated fireproof building substrate, comprising: a
fireproof building substrate, comprising a substrate and a
fireproof layer, wherein the fireproof layer covers a surface of
the substrate; and a decorated multilayer, comprising a printed
layer, a grain layer, and a hard coating layer disposed on the
fireproof building substrate subsequently, wherein the hard coating
layer is located at the outermost side of the decorated
multilayer.
2. The decorated fireproof building substrate as claimed in claim
1, wherein the decorated multilayer further comprises an adhesive
layer, and the adhesive layer adheres between the fireproof layer
and the printed layer.
3. The decorated fireproof building substrate as claimed in claim
1, wherein the surface of the substrate has a plurality of pores,
and the fireproof layer at least fills the pores.
4. The decorated fireproof building substrate as claimed in claim
1, wherein the printed layer, the grain layer, or the hard coating
layer are further added with a fireproof material.
5. The decorated fireproof building substrate as claimed in claim
1, wherein the grain layer has a planar surface relatively far from
the fireproof layer and a patterned surface relatively close to the
fireproof layer, and the patterned surface has a texture structure
thereon.
6. The decorated fireproof building substrate as claimed in claim
5, wherein the printed layer has another patterned surface, and the
patterned surface of the printed layer and the patterned surface of
the grain layer are adhered to each other, such that the patterned
surface of the printed layer has the texture structure thereon.
7. The decorated fireproof building substrate as claimed in claim
1, wherein an outer surface of the hard coating layer has a texture
structure thereon.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the priority benefit of Taiwan
application serial no. 103200221, filed on Jan. 6, 2014. The
entirety of the above-mentioned patent application is hereby
incorporated by reference herein and made a part of this
specification.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a fireproof building substrate, and
more particularly, to a decorated fireproof building substrate.
[0004] 2. Description of Related Art
[0005] With people's increasing attention on quality of residential
security, a variety of fireproof building substrates which are used
as materials to build the building have been introduced to the
market. At the same time, in order to meet the needs of aesthetics,
a common approach is to adhere a decoration film to the fireproof
building substrate. However, for the fireproof building substrate
with the adhered decoration film thereto, the decoration film may
have a grain layer, a pattern layer, and a membrane thereon, which
improves the flammability of the decorated fireproof building
substrate. Accordingly, it is often for the decorated fireproof
building substrate not passing a flame resistant test of the
fireproof building substrate.
SUMMARY OF THE INVENTION
[0006] The invention provides a decorated fireproof building
substrate, which has good decorative effects and fireproof effects
simultaneously.
[0007] The decorated fireproof building substrate of the invention
includes a fireproof building substrate and a decorated multilayer.
The fireproof building substrate includes a substrate and a
fireproof layer, wherein the fireproof layer covers a surface of
the substrate. The decorated multilayer includes a printed layer, a
grain layer, and a hard coating layer disposed on the fireproof
building substrate subsequently, and the hard coating layer is
located at the outermost side of the decorated multilayer.
[0008] In an embodiment of the invention, the decorated multilayer
above-mentioned further comprises an adhesive layer, and the
adhesive layer adheres between the fireproof layer and the printed
layer.
[0009] In an embodiment of the invention, the surface of the
substrate above-mentioned has a plurality of pores, and the
fireproof layer at least fills the pores.
[0010] In an embodiment of the invention, the printed layer, the
grain layer, or the hard coating layer above-mentioned are further
added with a fireproof material.
[0011] In an embodiment of the invention, the grain layer
above-mentioned has a planar surface relatively far from the
fireproof layer and a patterned surface relatively close to the
fireproof layer, and the patterned surface has a texture structure
thereon.
[0012] In an embodiment of the invention, the printed layer
above-mentioned has another patterned surface, and the patterned
surface of the printed layer and the patterned surface of the grain
layer are adhered to each other, such that the patterned surface of
the printed layer has the texture structure thereon.
[0013] In an embodiment of the invention, an outer surface of the
above-mentioned hard coating layer has a texture structure
thereon.
[0014] According to the above, the decorated fireproof building
substrate of the invention is disposed with the decorated
multilayer and the fireproof layer, so as to provide the good
decorative effects and the fireproof effects.
[0015] In order to make the aforementioned and other features and
advantages of the invention comprehensible, embodiments accompanied
with figures are described in detail below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 to FIG. 3 are schematic flow diagrams of
manufacturing a decorated fireproof building substrate of an
embodiment of the invention.
[0017] FIG. 4 to FIG. 5 are schematic flow diagrams of
manufacturing a decorated fireproof building substrate of another
embodiment of the invention.
DESCRIPTION OF EMBODIMENTS
[0018] The invention is described in detail with reference to the
accompanying figures. However, the invention may be embodied in
various forms and is not limited to the embodiments described
herein. Orientation terms used in the following embodiments, such
as "above,", "below, and the like, are merely referring to the
orientation illustrated in the figures. Therefore, the orientation
terms are used to describe the invention in detail rather than to
limit the invention. In addition, the size and relative size of
each layer may be exaggerated in the figures for clarity.
[0019] FIG. 1 to FIG. 3 are schematic flow diagrams of
manufacturing a decorated fireproof building substrate of an
embodiment of the invention. Please first refer to FIG. 1. First, a
fireproof building substrate 100 is provided. The fireproof
building substrate 100 includes a substrate 110 and a fireproof
layer 120, wherein the fireproof layer 120 covers a surface of the
substrate 110. Material of the substrate 110 includes material of
first-order flame resistance, material of second-order flame
resistance, or material of third-order flame resistance. The
substrate 110 is such as material which is used to build the
buildings, for example, wood, marble, a cement board, a calcium
silicate board, or other material which may have a function of
flame resistance after being treated.
[0020] The fireproof layer 120 covers a surface of the substrate
110. In detail, material with the fireproof effects may be coated
on the surface of the substrate 110 through coating methods. Then,
after procedures such as drying, planarization, etc, the fireproof
layer 120 with the fireproof effects may be formed. The fireproof
layer 120 is a coating layer with the flame-resistant effects and
the flame-retardant effects. For example, the substrate 110 is such
as a material with a plurality of pores. When the material with the
fireproof effects is coated on the surface of substrate 110, the
fireproof material may penetrate into the pores of the substrate
110 to fill the pores. Preferably, besides filling the pores, the
material with the fireproof effects may further cover the surface
of the substrate 110 completely. In addition, after the procedures
such as drying and planarization, the fireproof layer 120 may
provide a planar surface, so as to facilitate a decoration film to
follow adhere to the surface of the fireproof layer 120
sequentially, and detachment due to poor adhesion is less likely to
occur. In other words, the fireproof layer 120 not only can improve
the fireproof properties of the substrate 110, but also can enhance
the adhesion strength between the decoration film and the substrate
110.
[0021] Next, please first refer to FIG. 2. A decoration film 200 is
adhered to the fireproof building substrate 100. The decoration
film 200 includes an adhesive layer 210, a printed layer 220, a
grain layer 230, a hard coating layer 240, a release layer 250, and
a membrane 260 which are adhered together subsequently.
[0022] The membrane 260 is such as a flexible membrane, wherein the
material thereof may be polycarbonate (PC), acrylonitrile butadiene
styrene (ABS), polyethylene terephthalate (PET),
polymethylmethacrylate (PMMA), polyoxymethylene (POM), polybutylene
terephthalate (PBT), polypropylene (PP), methylmethacrylate-styrene
(MMA-St, MS) copolymer, polystyrene (PS), polyethylene
terephthalate (PET), or the combinations thereof, but the invention
is not limited thereto.
[0023] The release layer 250 is disposed on the surface of the
membrane 260, and the release layer 250 is interposed between the
membrane 260 and the hard coating layer 240. The release layer 250
is mainly disposed to make the membrane 260 temporarily adhere to
the other film layers (such as the adhesive layer 210, the printed
layer 220, the grain layer 230, the hard coating layer 240, etc.),
and to trip the other film layers from the membrane 260 after the
transfer process. In addition, the release layer 250 is typically a
film layer of low surface tension. The release layer 250 is
composed of, for example, a matrix material (a thermo-curable resin
or a photo-curable resin) selectively added with at least one of
wax, paraffin, and silicone, or, the release layer 250 may also be
composed of highly smooth and impermeable polymers.
[0024] The hard coating layer 240 may be a UV-curable resin which
has high light transmittance and anti-reflective characteristics,
for example, an acrylic resin, polyurethane (PU), an epoxy resin,
etc. The hard coating layer 240 may has a quite hardness to provide
scratch-resistant and wear-resistant effects.
[0025] The grain layer 230 is disposed on the hard coating layer
240. The grain layer 230 has a planar surface 230a and a patterned
surface 230b. The planar surface 230a is relatively far from the
fireproof layer 120 and contacts with the hard coating layer 240.
The patterned surface 230b is relatively close to the fireproof
layer 120 and contacts with the printed layer 220. The patterned
surface 230b has a texture structure thereon. The texture structure
is such as designed text or pattern which is wish to achieve the
decorative effects, wherein the texture structure may be formed by
texture stamping methods. The grain layer 230 may be the UV-curable
resin which has the high light transmittance and the
anti-reflective characteristics, for example, the acrylic resin,
polyurethane (PU), the epoxy resin, etc. In other embodiments, the
grain layer 230 may also be a layer of which both sides are planar
surfaces and without the texture structure.
[0026] The printed layer 220 is disposed on the grain layer 230.
The printed layer 220 may also has a patterned surface 220a,
wherein the patterned surface 220a of the printed layer 220 and the
patterned surface 230b of the grain layer 230 are adhered to each
other such that the patterned surface 220a has another texture
structure. In detail, the printed layer 220 is formed on the grain
layer 230, so that a coating layer which contacts with the surface
of the grain layer 230 is formed. Accordingly, on the surface of
the printed layer 220 is also formed with the texture structure
which is complementary to the texture structure of the grain layer
230, but the invention is not limited thereto. In other
embodiments, the printed layer 220 may also be a layer of which
both sides are planar surfaces and without the texture structure.
The printed layer 220 may be composed of printing inks or printable
material. For example, the pattern layer 220 may be an ink single
layer, an ink multilayer, or a patterned ink layer, so as to show a
single-color pattern, a multi-color pattern, or a desired pattern,
respectively. By any suitable printing process (such as gravure
printing process, screen printing process, flexographic printing
process, offset printing process, reverse printing process, inkjet
printing process, etc.), the ink is able to be transferred on the
grain layer 230 to form the printed layer 220. Material of the
pattern layer 220 includes polyurethane (PU) or polyacrylate, etc.
which is mixed with inorganic material. Material of the printed
layer 220 includes polyurethane (PU) or polyacrylate, etc. which is
mixed with inorganic material.
[0027] Preferably, during the manufacturing process of the film
layers such as the printed layer 220, the grain layer 230, or the
hard coating layer 240, a fireproof material may also be added to
the film layers such that the film layers have the fireproof
effects simultaneously. Material of the above fireproof material is
such as a mixture of organic and inorganic material which has a
phosphorus-containing compound, a halogen compound, an azo
compound, a carbonate compound, a hydroxide, a metal oxide, or any
combination thereof. In detail, the carbonate compound includes
calcium carbonate (CaCO.sub.3). The hydroxide includes aluminum
hydroxide (Al(OH).sub.2), magnesium hydroxide (Mg(OH).sub.2). The
metal oxide includes antimony oxide, tin oxide, molybdenum oxide,
or zirconium oxide, etc. In addition, the metal oxide may be used
with the halogen compound. Specifically, the halogen compound may
avoid the production of free radicals during a combustion process.
Calcium carbonate or the azo compound may respectively produce
flame-retardant gases (such as carbon dioxide or nitrogen) during
combustion so as to dilute the oxygen concentration in the air. It
is easy for the hydroxide to generate water molecules during
combustion and thus having an endothermic effect. Antimony oxide
together with the halogen-containing compound may dilute flammable
gases and produce a flame-retardant layer during the combustion
process.
[0028] The adhesive layer 210 adheres between the fireproof layer
120 and the printed layer 220. In other words, the decoration film
200 may adhere to the fireproof building substrate 110 through the
adhesive layer 210. The adhesive layer 210 may be hot melt
adhesive, UV-curable adhesive, photo-curable adhesive, or
electron-curable adhesive. The adhesive layer 210 is selected from,
for example, at least one material of polyacrylate,
polymethacrylate, polystyrene, polycarbonate, polyurethane,
polyester, polyamide, epoxy resin, ethylene vinylacetate copolymer
(EVA), or thermoplastic elastomer, or copolymers, mixtures, or
composites thereof.
[0029] The decoration film 200 is transferred to the fireproof
building substrate 100 through a high-pressure transfer molding
process. First, a heating and softening procedure is performed to
the decoration film 200. Next, the decoration film 200 is made to
contact with the fireproof building substrate 100, and a
pressurizing procedure is performed. Then, a high-pressure vacuum
molding process is performed to the decoration film 200 and the
fireproof building substrate 100, such that the decoration film 200
is transferred to the fireproof building substrate 100.
[0030] Next, please refer to FIG. 3. A stripping procedure is
performed such that the release layer 250 and the membrane 260 are
released from the surface of the hard coating layer 240, and the
hard coating layer 240 is located at the outermost side of the
decorated multilayer 200a (including the printed layer 220, the
grain layer 230, and the hard coating layer 240). Thus, the
manufacturing of the decorated fireproof building substrate 10a is
completed.
[0031] Please refer to FIG. 3 again. The decorated fireproof
building substrate 10a includes the fireproof building substrate
100 and the decorated multilayer 200a. The fireproof building
substrate 100 includes the substrate 110 and the fireproof layer
120, wherein the fireproof layer 120 covers the surface of the
substrate 110. The decorated multilayer 200a includes the printed
layer 220, the grain layer 230, and the hard coating layer 240
which are disposed on the fireproof building substrate 100
subsequently, wherein the hard coating layer 240 is located at the
outermost side of the decorated multilayer 200a. In addition, the
decorated multilayer 200a further includes the adhesive layer 210,
wherein the adhesive layer 210 adheres between the fireproof layer
120 and the printed layer 220. The patterned surface 230b of the
grain layer 230 faces the printed layer 220 so as to form a
decorative effect of which the texture structure is toward the
inside of the decorated fireproof building substrate 10a. Since no
membrane 260 and no release layer 250 are disposed in the decorated
fireproof building substrate 10a of the embodiment, and thus it is
helpful to pass a fireproof test. In detail, the membrane 260 and
the release layer 250 are substantially composed of material of
lower ignition point (such as organic material). In the
manufacturing process of the embodiment, the decorated multilayer
200a is kept on the fireproof building substrate 100, and the
membrane 260 and the release layer 250 are removed instead of being
kept on the fireproof building substrate 100. Accordingly, the
decorated fireproof building substrate 10a may have the beautiful
decorative effect and the good fireproof effects.
[0032] FIG. 4 to FIG. 5 are schematic flow diagrams of
manufacturing a decorated fireproof building substrate of another
embodiment of the invention. The manufacturing flow in the
embodiment of FIG. 4 to FIG. 5 is similar to the manufacturing flow
in the embodiment of FIG. 1 to FIG. 3, wherein the same or similar
reference numerals are used for the same or similar components, and
the same part of the description of the technical content is not
reiterated. The differences between the two embodiments are
described in the following. First, the procedures as shown in FIG.
1 are performed, by which the fireproof building substrate 100 is
provided.
[0033] Next, please first refer to FIG. 4. A decoration film 200'
is adhered to the fireproof building substrate 100. The decoration
film 200' is transferred to the fireproof building substrate 100
through, for example, the high-pressure transfer molding process.
The decoration film 200' includes the adhesive layer 210, a printed
layer 220', a hard coating layer 240', a release layer 250', and
the membrane 260 which are subsequently adhered to each other. The
structure of the decoration film 200' is similar to the structure
of the decoration film 200 in FIG. 2, wherein the differences
therebetween are that the release layer 250' of the decoration film
200' has a patterned surface 250a, and the patterned surface 250a
has a texture structure thereon. In addition, the hard coating
layer 240' which contacts with the patterned surface 250a of the
release layer 250' also has another patterned surface 240a, wherein
the patterned surface 240a also has the texture structure thereon.
In detail, in the embodiment, the release layer 250' with the
texture structure is formed on the membrane 260, and then the hard
coating layer 240' is formed on the release layer 250'.
Accordingly, the patterned surface 240a of the hard coating layer
240' and the patterned surface 250a of the release layer 250' are
adhered to each other, and thus the patterned surface 240a has
another texture structure.
[0034] Next, please refer to FIG. 5. The stripping procedure is
performed such that the release layer 250' and the membrane 260 are
released from the surface of the hard coating layer 240', and the
patterned surface 240a of the hard coating layer 240' is located at
the outermost side of the decorated multilayer 200b (including the
printed layer 220' and the hard coating layer 240'). Thus, the
manufacturing of the decorated fireproof building substrate 10b is
completed.
[0035] Please refer to FIG. 5 again. The decorated fireproof
building substrate 10b includes the fireproof building substrate
100 and the decorated multilayer 200b. The fireproof building
substrate 100 includes the substrate 110 and the fireproof layer
120, wherein the fireproof layer 120 covers the surface of the
substrate 110. The decorated multilayer 200b includes the printed
layer 220' and the hard coating layer 240' which are disposed on
the fireproof building substrate 100 subsequently, wherein the
patterned surface 240a of the hard coating layer 240' is located at
the outermost side of the decorated multilayer 200b so as to form a
decorative effect of which the texture structure is toward the
outside of the decorated fireproof building substrate 10b.
Furthermore, the decorated multilayer 200b further includes the
adhesive layer 210, wherein the adhesive layer 210 adheres between
the fireproof layer 120 and the printed layer 220'. Since no
membrane 260 and no release layer 250' are disposed in the
decorated fireproof building substrate 10b of the embodiment, and
thus it is helpful to pass the fireproof test. In detail, the
membrane 260 and the release layer 250' are substantially composed
of the material of lower ignition point (such as organic material).
In the manufacturing process of the embodiment, the decorated
multilayer 200b is kept on the fireproof building substrate 100,
and the membrane 260 and the release layer 250' are removed instead
of being kept on the fireproof building substrate 100. Accordingly,
the decorated fireproof building substrate 10b may have the
beautiful decorative effect and the good fireproof effects.
[0036] The Fireproof Test of the Decorated Fireproof Building
Substrate
[0037] The substrate of the decorated fireproof building substrate
of the invention is such as the calcium silicate board. Material of
the fireproof layer is such as the resin containing inorganic
material, for example, a coating material added with substances
having the flame-resistant effect. The decorated multilayer is
adhered to the fireproof layer, and the structure thereof id shown
in FIG. 3. A CNS flame resistant test is performed on the
above-mentioned decorated fireproof building substrate, wherein the
heating temperature is 720.degree. C. to 730.degree. C., and the
heating time is 20 minutes.
[0038] According to the above, the decorated fireproof building
substrate of the invention is disposed with the decorated
multilayer so as to provide the good decorative effects. The
decorated fireproof building substrate above is disposed with the
fireproof layer so as to provide the fireproof effects. Moreover,
no release layer and no membrane are disposed on the decorated
multilayer and thus it is difficult to burn due to high
temperature. Accordingly, the fireproof effects of the decorated
fireproof building substrate may be effectively enhanced.
[0039] It will be apparent to those skilled in the art that various
modifications and variations can be made to the structure of the
disclosed embodiments without departing from the scope or spirit of
the invention. In view of the foregoing, it is intended that the
disclosure cover modifications and variations of this specification
provided they fall within the scope of the following claims and
their equivalents.
* * * * *