JPS6046014B2 - How to manufacture fireproof panels - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a fire-resistant panel that is excellent in heat insulation, fire prevention, and safety, and is easy to manufacture.

Recently, there has been a strong demand for thermal insulation properties for internal and external wall materials of buildings, and materials that are safe and easy to manufacture, such as those that do not require adhesives to integrate the core material and the facing material, have become stronger. Structural panels have been desired. Therefore, for example, panels using phenol foam (hereinafter simply referred to as foam) as a core material are also on the market. However, the foam alone did not pass the semi-flammability test, and the adhesive strength between the face material and the foam was also poor. That is, the reason why the above test cannot be passed is because the cracks reach the back surface, although the passing criteria values of smoke generation coefficient, afterflame, and temperature/time area are satisfied. That is, when the foam and the flat kraft paper are integrally formed, the kraft paper burns and is exposed as the back side of the foam, and cracks in the foam appear as cracks in the panel. In addition, in order to manufacture foam from raw materials, phenolic resin, curing agent (acid curing agent), foaming agent, and foam stabilizer are mixed, reacted, and foamed. The resulting condensation water is combined with the water contained in the resol-type phenolic resin, curing agent, and blowing agent. Approximately 30% (by weight) of the total raw material water is released outside the foam during foaming, and this cools the bonding surface between the foam and the facing material. At the same time, the reaction was inhibited and the adhesive strength was greatly reduced. Furthermore, since the flat face material comes into contact with the entire surface of the foam raw material almost simultaneously when the foam is foamed, condensed water (and this reaction takes place at high temperatures) is generated, and the evaporated water vapor cannot escape to the outside and the face material The disadvantage is that the adhesive is trapped between the foam raw materials during the reaction, forming a board between the foam and the facing material, and the reaction on the foam surface during the reaction is cooled and hardened, further reducing the adhesion. It was hot. In order to eliminate these drawbacks, the present invention uses asbestos paper, which is water-absorbing and has a rougher surface than kraft paper, as a surface material, and has a corrugated cross section. A single-sided corrugated base material made of asbestos fibers (hereinafter simply referred to as the base material) prevents cracks in the foam from appearing on the panel surface, and
The contact area between the foam and the base material is increased by making contact with the wavy surface, and condensation water is easily absorbed and water, water vapor, etc. can easily escape between the foam raw material and the base material, and the area between the contact surfaces is increased. The presence of moisture is significantly reduced to strengthen the adhesive strength, and water and steam are led out through cardboard-like ventilation channels to more effectively demonstrate the self-adhesive properties of the foam raw material. This paper proposes a method for manufacturing a fireproof panel that has sufficient moisture control and heat insulation functions.

The manufacturing method of the fireproof panel according to the present invention will be explained in detail below with reference to the drawings.

FIG. 1 is a vertical cross-sectional view showing one embodiment of a fireproof panel according to the present invention, and 1 is a foam that includes a core material, a heat insulating material, a fireproof material,
and act as an adhesive. That is, the foam 1 is a resol type phenolic resin, which is a raw material that is fireproof and heat resistant, foams through a chemical reaction, and exhibits self-adhesive properties, and has a viscosity of 1000 to 20000C.
pS/20°C, and contains three or four components of an organic acid as a curing agent, such as balatoluenesulfonic acid, a chlorofluorocarbon gas, such as Freon 11 or Freon 11, as a foaming agent, and silicone as a foam stabilizer. The mixture is fed into a mixer all at once at a predetermined ratio, mixed and foamed to form a foam with a density of 30-40k, 91d1 and a thickness of 10-40mm.
Tf$L foam with mold temperature 50-1000C, line speed 5-20rn. It is formed using Im1n.
Note that Form 1 has traditionally had low mechanical strength and
It is said to be fragile. 2 is a single-sided corrugated hole made of asbestos fiber (hereinafter simply referred to as the base material) that is fixed integrally to the surface of the form 1 as shown in Figure 1, or to the front and back sides as shown in Figure 2. It functions as a decorative material, a heat insulating material, a fireproof material, a hygroscopic material, a moisture absorbing material, a moisture control material, a reinforcing material, an adhesion reinforcing layer, and a ventilation layer.

The structure is a base material consisting of a corrugated core 2a and a decorative surface material 2b as shown in FIG. 3a, or a base material formed in two layers as shown in FIG. 3b. To explain further, the base material 2 is made from a single piece of asbestos fiber, or a composition made of asbestos fiber as the main component mixed with an appropriate amount of bulbs and resin (for solidification). The surface is rough due to asbestos.
As a result, when this sheet-like material is formed with a curved longitudinal section like the core 2a, the fiber structure is forced to curve on each curved surface of the core 2a, Partial peeling occurs on the surface, the thickness becomes thinner, the contact area with the foam raw material increases, and the reaction of the foam raw material and steam condensation water during foaming are formed by the decorative surface 2b and the core 2a. Even if the core 2a absorbs a large amount of condensed water and moisture due to the ventilation action of the ventilation channel, even if the core 2a absorbs water and moisture, Since moisture can be prevented from being present on the surface of the core 2a, deterioration in adhesive properties will not occur. Furthermore, the base material itself, such as a honeycomb structure, has several times higher strength and can be lighter in weight than a simple sheet-like material. Reference numeral 3 denotes the backing material, which is composed of a hard base material and one flexible base material, and as shown in FIG. be.

An example of the hard base material is one of a metal plate, a calcium silicate plate, and a gypsum board. The flexible base material is one that is integrally adhered to the back surface of the foam 1 as shown in FIG. An example of the flexible base material is one of paper, asbestos paper, synthetic resin film, aluminum foil, or a laminate of one or more of these. In particular, the flexible base material improves ease of supply in the manufacturing process, moisture resistance, radiation properties, and cosmetic properties of the finished surface, so-called aesthetics. Of course, the main functions are moisture resistance and sand/f-tsuchi structure to provide toughness. Next, one embodiment of the fireproof panel according to the present invention will be described.

As a foam raw material, an unfoamed resol type phenolic resin raw material is discharged onto the center core 2a surface of the base material 2 (total thickness 5 Tr0n), and a mold material (not shown) and a hard base material 3 (color steel plate ) and a flexible sheet substrate (aluminum foil laminated with kraft paper) are laminated. Next, fireproof panels having cross sections as shown in FIGS. 1, 4, and 5 were manufactured using a molding machine, for example, a cure oven. In the conventional example, polyurethane foam was formed in the same manner as the panel shown in FIG. In addition, the heat resistance is class 2 flame retardant (quasi-noncombustible material) as specified in Japanese Industrial Standards JIS-A-1321.
It was evaluated by surface test. Furthermore, mechanical strength such as bending strength, dimensional stability, moisture control properties, and other properties were determined using Japanese Industrial Standards, self-designed test methods, and visual inspection, and the results are shown in the table below. In addition, in the test, the base material was attached so that two sides were in contact with the flame. Further, the adhesion was measured by the test method shown in FIG.

That is, the base material 2 (the height of the core 2a is 2 mg, the pitch is 46
? ) in the direction of the arrow while maintaining the angle θ=900, and read the scale of the spring scale when L=10CTL. In addition, in Fig. 6, L is 10 cm
．． ．． W is 10C7n1H is 1㎪, θ=90, α is an acrylic plate with a through hole for hooking the hook of the central spring balance β,
One end of the base material 2 was cut with a cutter as shown in the figure, and the base material 2 was peeled off from the foam 1 by H = 1 cm, and the acrylic plate α was adhered to the peeled end of the base material 2 with vinyl tape. There are things. In (a), the difference in adhesive strength between foam 1 and base material 2 is due not only to physical bonding but also to the material of foam 1 (an escape route for water vapor during foaming) and the material of base material 2 (roughness), although the principle is not clear. This is thought to be due to the presence of a synergistic effect resulting from the fiber structure and the core structure of voids.

In particular, conventional kraft paper has a dense fiber structure, which not only makes it difficult for foam raw materials to penetrate, but also prevents the water vapor released during the foam reaction from escaping to the outside, causing the surface of the foam 1 during the reaction and foaming to tumble into the kraft paper. It is thought that this is because it accumulates between the back surfaces of the paper, which not only inhibits the reaction of Foam 1, but also reduces adhesiveness. (mouth)
(c) shows the presence or absence of shrinkage and deformation of the fireproof panel after 5 cycles of -20 to 80°C every 1 hour; (c) shows the base material 2
A mist of water was sprayed on the surface, and the shape was determined based on the state at that time and the shape after drying. What has been described above is only one embodiment of the present invention, and as shown in FIG. 2, a fireproof panel may also be provided in which the base material 2 is disposed on both sides of the foam 1. Further, the foam raw material can be discharged onto the back material 3, a so-called hard base material, or a flexible base material, and the base material 2 can be laminated thereon. As mentioned above, the fire-resistant panel according to the present invention has the feature that the base material prevents cracks that reach the back surface, which is one of the weak points of foam, and is a fire-resistant panel that can pass the semi-flammability test.

In addition, under normal conditions, the base material absorbs condensed water released during foam reaction foaming due to the core shape, coarse fiber structure, and efficient water absorption, ventilation, and moisture absorption effects of the curved core. It is absorbed by the base material without being stored between the materials as much as possible, and is released (ventilated) to the outside through the core and its cardboard-like voids to prevent a decrease in adhesive strength.
In addition, the adhesive strength between the foam and the base material is greatly strengthened due to the increased contact area, geometrical bonding, and synergistic effects of the materials. Furthermore, the substrate has the characteristic of protecting the brittle foam from impact due to the cushioning properties of the corrugated structure. Furthermore, since the base material serves as a humidity control material, a heat insulating material, and a gas outlet path, it has the characteristic of suppressing the deformation of the foam. In addition, because the base material is strong, even if there is a part of the foam that is missing in the contact area with the base material, it will not appear on the outside, and even if gas during foaming is accumulated between the foam and the base material, the appearance will not be visible. This feature improves the yield in practice.

[Brief explanation of the drawing]

1, 2, 4, and 5 are longitudinal sectional views showing a fireproof panel according to the present invention, and Figures 3A and b are single-sided asbestos fibers used in the fireproof panel according to the present invention. FIG. 6 is an explanatory view showing an example of a corrugated board-like base material, and FIG. 6 is a perspective view showing a test method for measuring adhesive strength. 1... Phenol foam, 2... Asbestos fiber corrugated base material, 3... Back material.

Claims (1)

[Scope of Claims] 1. An unfoamed resol type phenol foam raw material is discharged onto the central core surface of a single-sided corrugated board-like substrate made of asbestos fibers, and the foam is formed integrally through self-adhesion during formation. A method for producing a fireproof panel characterized by: 2 Discharge an unfoamed resol-type phenol foam raw material between the core surface and back surface material of a single-sided corrugated board-like base material made of asbestos fibers, and form these two members into one body through self-adhesive properties when forming the foam. A method for producing fireproof panels characterized by: