JP3054475B2 - Composite board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite board which is useful as a material for an outer wall and a partition in buildings and structures, and which is lightweight and has fire resistance, sound insulation and mechanical strength.

[0002]

2. Description of the Related Art In general, heat-resistant composite plates for outer walls are disclosed in Japanese Utility Model Laid-Open Nos. 57-185535, 58-1538, 63-15444 and 63-2544. No. -18230 is known.

[0003]

However, these composite plates have major drawbacks in the following points. That is, in the above-mentioned composite plate, the nonwoven fabric is a thin nonwoven fabric such as glass fiber, and the phenol foam leaks to the opposite surface, the so-called non-combustible substrate and the bonding surface, so that the function of the adhesive cannot be sufficiently exhibited. there were.

In the above-mentioned composite board, a lightweight aggregate is laid finely, and this is integrated with a non-combustible base material using phenol foam.
Although this is a configuration for improving the fire resistance, the adhesive strength of the phenol foam itself as the core material is not so strong, and there is a disadvantage that the phenol foam as the core material peels off from the non-combustible substrate.

[0005] The composite board described above is for architectural use in which a non-combustible sheet impregnated with sodium borate and phenol foam are integrally fixed, and a non-combustible impermeable layer is integrally fixed on the non-combustible sheet via an adhesive. It is a board. However, in this case, impregnation of the phenol foam raw material into the nonwoven fabric is liable to occur only on the surface, and the reaction of an alkali and an acid impedes the foam formation, resulting in a decrease in adhesive strength.

Further, the composite plate has a structure in which the face material and the phenol foam containing the aggregate are integrated, and since the fusion of the face material and the core material is utilized, the adhesive strength is uneasy. was there. Furthermore, the composite board shown in the above (1) does not have a reliable adhesive layer for the integration of the phenol foam and the face material, and furthermore, does not add any special consideration to the integration of the phenol foam and the separation layer. However, it has a disadvantage of lacking sound insulation properties despite its light weight.

[0007]

According to the present invention, in order to eliminate such a drawback, a separation layer having a special function and an adhesive layer are interposed between a non-combustible base material and a core material so that the adhesiveness, heat resistance, and the like can be improved. Sound insulation,
The present invention proposes a composite board that can improve the mechanical strength and pass a fire resistance 1 hour test.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the composite plate according to the present invention will be described below in detail with reference to the drawings. That is, FIG. 1 is a perspective view showing a typical example of a composite board P according to the present invention, wherein 1 is a non-combustible base material, 2 is a core material, and 3 is an inorganic lightweight aggregate, which is coarsely or finely filled as necessary. 4 is a back surface material, 5 is a separation layer, 7 is an adhesive layer, and P is a composite plate.

More specifically, as the non-combustible substrate 1,
For example, surface treated steel sheet, galvalume steel sheet, galfan steel
Sheet, enameled steel sheet, fluororesin coated steel sheet, clad steel
A plate, a stainless plate, a titanium plate, a copper plate or the like is press-formed or roll-formed . Core material 2 is phenol foam alone or inorganic lightweight aggregate 3 in foam
The mixture is used as the main body 2a, and the separation layer 5 is integrated with the main body 2a.
It is a configuration that has been converted.

The inorganic lightweight aggregate 3 is useful for enhancing the compressive strength, fire resistance and soundproofing, and specific examples thereof include pearlite grains, glass beads, shirasu balloons, calcium silicate grains, and talc grains. Etc., and the particle size is about 1 to 20 mmφ. The addition rate is a structure in which the packing is densely packed, sparse, unevenly distributed, or an unusually mixed state. Of course, the gap between the inorganic lightweight aggregates 3 is filled with the main body 2a such as phenol foam.

The backing material 4 is made of one or more of the same material as the non-combustible substrate 1 or kraft paper, paper, aluminum foil, plastic sheet, nonwoven fabric, or the like. Of course, a sheet material obtained by laminating aluminum foil on kraft paper is also included.

As shown in FIG. 2, the separation layer 5 mainly has a function of dispersing condensed water and steam to the outside during the formation of phenol foam, a function of absorbing water, a function of releasing, a function of a surface material, and a control of a phenol foam reaction system. It uses a nonwoven fabric having a function, a reinforcing function, a sound insulation function, a fireproof and incombustible layer forming function, and an anchoring function. Preferred materials for the nonwoven fabric include one of polyester-based, nylon-based, carbon fiber, and aramid fibers. In particular, the void and thickness of the non-woven fabric are the above-mentioned functions, and among the above-mentioned functions, the escape of condensed water during the phenol foam reaction, the prevention of a decrease in adhesiveness due to the condensed water, and the control (adjustment) of the reaction state make it possible to optimize It controls during the penetration of the nonwoven into the cure and helps to further strengthen the integration of the nonwoven with the phenolic foam.

Reference numeral 6 denotes a lead fine powder having a particle size of about 5 to 100 microns, which is mixed with one fiber 5a constituting the nonwoven fabric as shown in FIGS. It is made into a long fiber by adhesion or the like, and one fiber 5a
When the resin content is 100 in terms of the bulk ratio, the ratio is about 10 to 50, and is selected from the viewpoint of fiber formation and weight.

The adhesive layer 7 physically and chemically bonds the non-combustible substrate 1 and the separation layer 5 integrally. Examples of the adhesive include an elastomer type epoxy resin, a urethane resin, a phenol resin, and the like. An isocyanate, for example, an emulsion type such as methylene diisocyanate (abbreviated as MDI), a hot-melt type, or a modified isocyanate thereof, for example, one of urethane-modified, buret-modified isocyanate, and isocyanurate-modified isocyanate is used.

Next, an example of a method for manufacturing a composite plate according to the present invention is shown in FIG. First, the non-combustible base material 1, for example, a color steel plate (thickness 0.35 mm) is sent from the feeding step A (for example, an uncoiler, a lifter) or the like to the adhesive applying step B, and the non-combustible base material 1 is heated to 20 to 80 ° C. Then , an adhesive A, specifically a urethane resin, as a specific example, is thinly applied to the back surface thereof by a roll coater, a spray gun, or the like C, and a separating layer 5, for example, a nonwoven fabric made of polyester fiber having a basis weight of 100 g / m ² (thickness: 100 g / m ^2). 0.2mm) contains fine powder of lead (10 microns).
What is provided is supplied to the position shown in FIG. 2 through the feeding step D, and the non-combustible base material 1 and the separation layer 5 are bonded . Next
The phenol foam stock solution is discharged from the discharger E onto the separation layer 5, and the backing material 4, for example, aluminum kraft paper is laminated thereon via the uncoiler F and fed to the curing oven G of a predetermined type. Or about 1 in badge
Curing is performed at 30 to 100 ° C. for up to 3 minutes, and then cut to a predetermined size by a cutter H and then sent to a packing step I.

The above is only one embodiment of the composite board according to the present invention, and as shown in FIG. 5, the foam is sandwiched by the core 2 in which the aggregate 3 is mixed large and small, or the separation layer 5. The composite plate P having the above-described structure, or the composite core P formed by integrally forming the formed core material 2 on the non-combustible base material 1 and the back surface material 4 via an adhesive can also be used.

Further, in FIG. 4, a production line in which a molding machine A is provided after the feeding step A can be used. Further, in order to manufacture the composite board P in which the back material 4 is also provided with the separation layer 5 and the adhesive layer as shown in FIG.
E must be provided separately.

The shape of the composite plate P is shown in FIG.
-(H), FIGS. 7 (a)-(h), FIGS. 8 (a)-(g),
The cross sections shown in FIGS. 9A to 9F and FIGS. 10A to 10F can also be used. In addition, the inorganic lightweight aggregate 3, the separation layer 5, the adhesive layer 7, and the like are omitted. Further, b is a packing material and is made of one of rubber, plastic, incombustible elastic body, and the like.

[0019]

As described above, according to the composite plate of the present invention, (1) the separation layer contains fine lead powder;
(2) Non-combustible base material and core material that can greatly improve sound insulation
Heat resistant, impregnating, reinforcing, and sound insulating
Separation layer is interposed, and separation layer is impregnated with adhesive and core material.
To improve mechanical strength and economics (cost)
(3) Impregnating the separation layer with both the adhesive and the core solution
Separates from non-combustible substrate as anchor effect occurs
The adhesion between the layer and the core is improved, and the non-combustible substrate and the core are improved.
Can facilitate the integration with, (4) air gap and the thickness of the nonwoven fabric, in order to water retention of the water of condensation occurring again the core material is cured, further core is controlled (adjusted) to cure during the penetration , Combination of separation layer, non-combustible base material, separation layer and core material
(5) Non-woven fabric with high heat resistance as separation layer
To further integrate the non-combustible substrate, the separation layer and the core material.
1 hour fire resistance test (JISA1304)
(6) The separation layer is more adhesive to the reaction system of the core material.
Control while passing between fibers at timing of improvement
(7) Thermal insulation is more than 4 times higher than ALC,
The amount and amount are 2/3 times or less.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an example of a composite plate according to the present invention.

FIG. 2 is an explanatory diagram extracting and showing a part of the composite board used in FIG. 1;

FIG. 3 is an explanatory diagram showing an enlarged view of a fiber of a separation layer.

FIG. 4 is an explanatory view showing an example of a process for manufacturing a composite plate according to the present invention.

FIG. 5 is a sectional view showing another embodiment of the composite plate according to the present invention.

FIG. 6 is a sectional view showing another embodiment of the composite plate according to the present invention.

FIG. 7 is an explanatory view showing another embodiment of the composite board according to the present invention.

FIG. 8 is an explanatory view showing another embodiment of the composite board according to the present invention.

FIG. 9 is an explanatory view showing another embodiment of the composite board according to the present invention.

FIG. 10 is an explanatory view showing another embodiment of the composite plate according to the present invention.

[Explanation of symbols]

 P Composite board 1 Non-combustible base material 2 Core material 2a Main body 3 Inorganic lightweight aggregate 4 Back material 5 Separation layer 6 Lead fine powder 7 Adhesive layer A Adhesive A Feeding process B Adhesive applying process C Roll coater, spray gun, etc. D Feeding process E Discharger F Uncoiler G Cure oven H Cutter I Packing process

──────────────────────────────────────────────────続 き Continued on front page (51) Int.Cl. ⁷ Identification code FI E04B 1/94 E04B 1/94 R

Claims (1)

(57) [Claims] 1. A composite plate in which a separation layer is interposed between a non-combustible base material and a phenol foam serving as a core, wherein the separation layer contains fine lead powder and has a heat-resistant thickness of 0.1 mm or more.
Formed of a non-woven fabric of synthetic resin fiber, and partially impregnated in the non-woven fabric
Non-combustible with the separation layer due to the adhesive of the component that reacts with the water
Adhere the substrate and further impregnate the nonwoven fabric with the core material
The separation layer and the core material are integrated by
A composite plate characterized by the following.