JP3377355B2 - Rock wool board - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to fireproof building materials such as exterior wall materials, eaves ceiling materials, bathroom ceiling materials, bathroom wall materials, interior base materials, interior wall materials, flooring materials, and eaves ceiling materials. The present invention relates to a rock wool board used as a ceiling material for entrance porch.

[0002]

2. Description of the Related Art A rock wool board is disclosed in Japanese Patent Laid-Open No. 50-15.
As disclosed in Japanese Patent No. 812, etc., it is produced by wet-papermaking a slurry to which rock wool and starch serving as a binder are added. When the rock wool board is used as a building material, strength as a board is required, and therefore, the rock wool board is partially filled with a columnar member such as metal or resin for reinforcement (for example, Japanese Patent Application No. 6-557 filed by the applicant
No. 23).

[0003]

However, there is a problem in that even if the rock wool board is partially reinforced, the overall strength, especially the water resistance strength when absorbing water, cannot be increased. Also, when rock wool board is used as a building material facing outdoors, it is necessary to obtain fireproof structure certification or fireproof structure certification, but the current rockwool board has not reached this level.

The present invention has been made in view of the above points, and an object of the present invention is to provide a rockwool board having high strength when absorbing water and high fireproof performance.

[0005]

The rockwool board according to the present invention is a rockwool board formed mainly of rockwool, wherein the starch is 3 to 8% by weight, the phenol resin is 5 to 15% by weight, and the hydroxylated product is hydroxylated. It contains aluminum in an amount of 20 to 40% by weight and has a specific gravity of 0.4 to 0.
It is characterized by being 6.

In the present invention, a melamine resin can be contained together with the phenol resin. In this case, the total content of phenol resin and melamine resin is 5
It is preferable that the blending ratio of the phenol resin and the melamine resin is 99: 1 to 25:75 by weight. Further, in the present invention, a silane coupling agent may be contained.

[0007]

DETAILED DESCRIPTION OF THE INVENTION An embodiment of the invention of claim 1 will be described. First, when preparing a slurry in which rock wool and starch are mixed, aluminum hydroxide is added and mixed. And by wet papermaking a slurry, to produce a wet board which is contained in de Npun aluminum hydroxide. Next, the wet board is impregnated with the phenol resin by spraying an aqueous solution of the phenol resin on the surface of the wet board while sucking the wet board from the back surface. Next, the starch is gelatinized and the wet board is dried, and then the phenol resin is cured to obtain a rock wool board. Further, if necessary, an acrylic resin-based paint or the like is applied to the surface at a coating amount of about 100 g / m ² , whereby the material can be finished as a building material.

In the present invention, the starch content is 3 to 8% by weight, the phenol resin content is 5 to 15% by weight, and the aluminum hydroxide content is 20 to 40% by weight.
A rock wool board is manufactured. The content of the starch is adjusted by adjusting the concentration of the starch in the slurry, and the content of the aluminum hydroxide is adjusted by adjusting the content of the aluminum hydroxide in the slurry. Can be carried out by adjusting the solution concentration of the phenol resin aqueous solution to be sprayed.

In the present invention, the bending strength and compressive strength of the rock wool board at the time of absorbing water are improved by impregnating and solidifying the rock wool board with a phenol resin. When the content of the phenol resin in the rock wool board is less than 5% by weight, the effect of improving the strength at the time of absorbing water by containing the phenol resin cannot be sufficiently obtained. On the contrary, if the content of the phenol resin exceeds 15% by weight, the fireproof property of the rock wool board is lowered, which is not preferable.

Rock wool is nonflammable in the rock wool board, but if phenol resin or starch is added, fire resistance is lowered. Therefore, in the present invention,
Rockwool board contains aluminum hydroxide,
The latent heat of vaporization caused by the dehydration of aluminum hydroxide when the high temperature acts on the rock wool board is used to improve the fire protection performance. If the content of aluminum hydroxide in the rock wool board is less than 20% by weight, it is not possible to sufficiently obtain the effect of enhancing fire prevention performance by incorporating aluminum hydroxide. Conversely 4
If it exceeds 0% by weight, it becomes difficult to produce a slurry, and 40% by weight is the upper limit in production.

Further, starch acts as a binder for binding rock wool, but if the content of starch in the rock wool board is less than 3% by weight, the strength of the rock wool board becomes insufficient, and conversely 8 If it exceeds 5% by weight, fire resistance is lowered, which is not preferable. Further, in the present invention, the rock wool board is manufactured so that the specific gravity (apparent specific gravity) is 0.4 to 0.6. To adjust the specific gravity of rock wool board, in the process of manufacturing rock wool board, spray the phenol resin on the wet board and press it while controlling the thickness, or the phenol resin cures at the drying stage after spraying the phenol resin. It can be performed by adjusting the degree of compression by pressing while controlling the thickness before starting. If the specific gravity of the rock wool board is less than 0.4, the fireproof performance will be poor, which is not preferable. The specific gravity increase by the press is 0.6, and therefore the specific gravity is 0.6. The thickness of the rock wool board is preferably in the range of 13 to 20 mm, and it is preferable that the weight of the board does not exceed 10 kg / m ² from the viewpoint of workability and prevention of dropping by nailing.

Next, an embodiment of the invention according to claims 2 to 4 will be described. First in the same manner as described above, by rock wool and starch and slurry wet papermaking and blended with aluminum hydroxide to produce a wet board which is contained in de Npun aluminum hydroxide. Next, the wet board is impregnated with the phenol resin and the melamine resin by spraying a mixed aqueous solution of the phenol resin and the melamine resin onto the surface of the wet board while sucking the wet board from the back surface. Thereafter, the starch is gelatinized and dried, and the phenol resin and melamine resin are further cured to obtain a rock wool board. The impregnation / curing of the phenol resin and the melamine resin may be performed after preparing a wet board to gelatinize the starch and drying the starch.

By impregnating the melamine resin in addition to the phenol resin in this way, the starch is reacted with the melamine resin to insolubilize it, and the phenol resin and the melamine resin are reacted with each other to make the binding portion of rock wool water resistant and absorb water. In this case, the bending strength and compressive strength of the rock wool board can be further increased. The phenol resin and the melamine resin are preferably contained in the rock wool board so that the total amount thereof is 5 to 20% by weight of the rock wool board. If the content is less than 5% by weight, the effect of improving the strength when absorbing water cannot be sufficiently obtained. On the other hand, if the content exceeds 20% by weight, the fire resistance of the rockwool board decreases, which is not preferable. The mixing ratio of phenol resin and melamine resin is 9 by weight.
It is preferably in the range of 9: 1 to 25:75. Even if the melamine resin is 0, there is no practical problem in strength when absorbing water, but when the melamine resin is blended in a proportion of 1% by weight or more, the residual phenol content of the phenol resin reacts with the melamine resin to eliminate the phenol odor. be able to. If the proportion of the melamine resin exceeds 75% by weight, on the contrary, a formaldehyde odor is generated due to the residual formaldehyde of the melamine resin, which is not preferable.

The other constitution is the same as that of the first aspect of the present invention, but by mixing a silane coupling agent such as an aminosilane coupling agent, the bond between the rock wool and the phenol resin is strengthened and the strength at the time of water absorption is improved. The effect of improvement can be enhanced. The silane coupling agent is preferably contained in the rock wool board in the range of 0.03 to 0.10% by weight. In the above-mentioned rock wool board manufacturing process, the gelatinization condition is 170 to 24.
0 ° C, 90% RH or more, 40 to 80 minutes, drying condition is 10
5 to 200 ° C., 0.5 hours to 2 hours, curing conditions are 160
It is preferably in the range of to 200 ° C for 20 to 120 minutes.

[0015]

EXAMPLES Next, the present invention will be specifically described with reference to examples. (Examples 1 to 9 and Comparative Examples 1 to 8; Invention of Claim 1) A wet board was produced by making a slurry prepared by dispersing rock wool, starch and aluminum hydroxide in water. Next, 400m on the back of the wet board
The phenol resin was impregnated into the wet board by spraying an aqueous phenol resin solution on the surface of the wet board while sucking the solution under reduced pressure to mHg. Next, after compressing the wet board while controlling the thickness, 180
The starch is gelatinized under the conditions of ℃, 90% RH and 40 minutes, and dried under the conditions of 200 ℃ and 40 minutes.
A rock wool board was obtained by curing the phenol resin under the condition of 40 ° C for 40 minutes.

Here, adjustment of the concentration of starch in the slurry, adjustment of the blending amount of aluminum hydroxide in the slurry,
By adjusting the solution concentration of the phenol resin aqueous solution to be sprayed, the contents of starch, aluminum hydroxide, and phenol resin are as shown in Table 1, and the specific gravity (apparent specific gravity) shown in Table 1 is obtained due to the thickness regulation when compressing the wet board. I made a rock wool board.

With respect to each rock wool board produced as described above, the fireproof performance and the bending strength at the time of absorbing water were measured. The fireproof performance is the amount of heat given by the fireproof 30-minute combustion curve (fireproof second-class curve) (temperature × time area (℃ ・ mi
JIS) at the time when a heat quantity equivalent to n)) is given
The surface test specified in A 1321 was performed, and the back surface temperature of the rock wool board at that time was measured. When the back surface temperature is 200 ° C. or lower, “◎”, 200 to
Table 1 shows 260 ° C. as “◯” and 260 ° C. or higher as “x”.

Bending strength test when absorbing water is 30 mm wide ×
The rock wool board having a length of 200 mm was immersed in warm water at 60 ° C. for 24 hours, and the bending strength at the time of absorbing water was measured. And the bending strength is 10 kgf
/ Cm ² or less "×", 10～20Kgf / cm ² to "○", indicated 20 kgf / cm ² or more in Table 1 as "◎".

[0019]

[Table 1]

As can be seen from the results shown in Table 1, each of the examples has a good performance in both fire resistance and strength upon absorbing water. On the other hand, in Comparative Example 1 having a small specific gravity, the fire resistance was poor, and there was a limit to the increase in the specific gravity in the press, so that it was not possible to manufacture the one having a large specific gravity like Comparative Example 2. In Comparative Example 3 having a low starch content, the strength upon absorption of water was poor, and conversely, in Comparative Example 4 having a high starch content, the fire resistance was poor. Further, in Comparative Example 5 in which the content ratio of aluminum hydroxide is low, the fire resistance is deteriorated, and when the compounding amount of aluminum hydroxide in the slurry is high, the paper-forming property of the slurry is deteriorated. A product having a high aluminum hydroxide content could not be produced. In addition, Comparative Example 7 in which the content of the phenol resin is low
The material of Comparative Example 8 had poor strength upon absorption of water, and conversely, the material of Comparative Example 8 having a high content of phenol resin had poor fire resistance.

(Examples 10 to 12, Comparative Examples 9 and 10; Inventions of Claims 2 to 4) Rockwool, starch, aluminum hydroxide and other components (inorganic filler: silica, pearlite, silica sand) are treated with water. A wet board was prepared by dispersing the slurry to prepare a slurry and making the slurry into paper. Then Table 2
400mm by blending aminosilane mosquitoes Tsu coupling agent mixed resin solution was prepared, the back surface of the wet board with mixing a phenolic resin and melamine resin in a weight ratio of
The wet board was impregnated with the phenol resin and the melamine resin by spraying the mixed aqueous solution of the phenol resin and the melamine resin onto the surface of the wet board while sucking under reduced pressure to Hg. Next, after compressing the wet board while controlling the thickness, 180 ° C., 90% RH,
Gelatinize the starch under the condition of 40 minutes and 200 ° C.,
Rock wool board was obtained by drying under the condition of 40 minutes and further curing the phenol resin and melamine resin under the condition of 180 ° C. for 40 minutes.

Here, adjustment of the concentration of starch in the slurry, adjustment of the blending amount of aluminum hydroxide in the slurry,
By adjusting the solution concentration of the phenol resin / melamine resin mixed aqueous solution to be sprayed and adjusting the blending amount of the silane coupling agent to the phenol resin / melamine resin mixed aqueous solution, starch, aluminum hydroxide, phenol resin,
A melamine resin, a silane coupling agent, and the like had the contents shown in Table 2, and the rock wool board having the specific gravity (apparent specific gravity) shown in Table 2 was produced due to the thickness regulation when compressing the wet board.

The rock wool board produced as described above was measured for bending strength in an air-dried state and in a state of absorbing hot water after being immersed in warm water of 60 ° C. for 24 hours. In addition, quasi-noncombustibility and noncombustibility were evaluated. The results are shown in Table 2.

[0024]

[Table 2]

As shown in Table 2, each of the examples had a high bending strength and a good fireproof performance. On the other hand, Comparative Example 9 containing no melamine resin had a phenol odor. Further, in Comparative Example 10 in which the silane coupling agent was not mixed, it was not possible to obtain the high bending strength at the time of water absorption as in the example in which the silane coupling agent was mixed.

[0026]

INDUSTRIAL APPLICABILITY As described above, according to the present invention, starch is added in the range of 3 to 3.
8% by weight, 5 to 15% by weight of phenolic resin, 20 to 40% by weight of aluminum hydroxide were contained and the specific gravity was set to 0.4 to 0.6.
It is possible to give rock wool board a high fireproofing performance under the conditions of not more than 10% by weight, phenol resin not more than 15 parts by weight, aluminum hydroxide not less than 20 parts by weight, and specific gravity not less than 0.4, starch 3% by weight or more, phenol resin 5
It is possible to impart a high strength upon absorption of water to the rock wool board under the condition of not less than wt%.

Further, since the melamine resin is contained together with the phenol resin, the strength at the time of absorbing water can be further enhanced. Moreover, since so as to contain a Shiranka Tsu coupling agent, in which the strength at the time of water absorption can be further enhanced.

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Masasuke Tsukamoto 1048, Kadoma, Kadoma, Osaka Prefecture Matsushita Electric Works, Ltd. (72) Sadao Yabu, 1048, Kadoma, Kadoma, Osaka Prefecture (72, Matsushita Electric Works, Ltd.) ) Inventor Masaru Kishimoto 1048 Kadoma, Kadoma City, Osaka Prefecture Matsushita Electric Works Co., Ltd. (56) References JP-A-4-12071 (JP, A) JP-A-5-186254 (JP, A) (58) Field (Int.Cl. ⁷ , DB name) C04B 38/00-38/10 C04B 30/00 C04B 32/00

Claims (4)

(57) [Claims] 1. A rockwool board formed mainly of rockwool containing 3 to 8% by weight of starch,
It contains 5 to 15% by weight of phenolic resin and 20 to 40% by weight of aluminum hydroxide, and has a specific gravity of 0.4 to
Rockwool board characterized by being 0.6. 2. The rock wool board according to claim 1, wherein a melamine resin is contained together with the phenol resin. 3. The phenol resin and the melamine resin are contained in a total amount of 5 to 20% by weight, and the mixing ratio of the phenol resin and the melamine resin is 99: 1 to 25: by weight.
It is 75, The rock wool board of Claim 2 characterized by the above-mentioned. 4. The rock wool board according to claim 2 or 3, which contains a silane coupling agent.