JPH0333086B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) This invention relates to an apparatus that uses a composite heat source to continuously manufacture fire-resistant panels made of an inorganic fire-resistant heat insulating material and a novolac-type powdered phenolic resin with high efficiency. It is something.

(Prior Art) In the past, polyurethane foam was often used as a heat insulating material for the backing and core materials of architectural panels. Polyurethane foam has a liquid raw material and a low foaming temperature, so it is easy to use and handle, and the foam curing time is short, allowing for speed-up. It has been used because it is less likely to rust on equipment and products because it is not used.

However, polyurethane foam has drawbacks such as melting and igniting at low temperatures, emitting very high smoke when burned, and the generated gas containing a large amount of harmful hydrogen cyanide. It has been strongly pointed out that using it as a backing material or core material poses a great danger to the human body.

Compared to polyurethane foam, phenol foam has self-extinguishing properties by simply carbonizing its surface even when exposed to flame, has significantly lower calorific value and smoke generation, and does not emit harmful gases, making it the most heat-resistant plastic foam. It is known that there is.

In particular, since the solid or powdered resin obtained by condensing novolak-type phenols and aldehydes is foamed by heating, it does not contain free acids like resol-type resins and can be used for construction without damaging equipment or products. It is suitable as a backing material for panels for
Until now, continuous foam molding was thought to be impossible due to the need for foaming at high temperatures and long curing times, small closed cells, and poor raw material storage stability.

The present applicant previously filed Japanese Patent Application No. 59-146103.
- In Publication No. 25810, a novolak-type phenolic resin uniformly supplied as a powder is used as a backing material for architectural panels, and a foam with a uniform cell structure is molded in a short time by using both external and internal heating. I suggested that.

On the other hand, one of the inventors of the present invention disclosed in Japanese Patent Publication No. 56-30175 that a fireproof insulation panel is continuously manufactured by supplying a fireproof insulation material to a gutter-like member formed from a long strip-shaped metal plate. proposed a method.

(Problem to be solved by the invention) When using a fireproof insulation material, due to its low thermal conductivity, it takes time and high temperature to melt and solidify the resin in the center of the thickness of the panel. However, it has not been put to practical use because the surface treatment material for the metal plate deteriorates due to softening or melting.

Therefore, the present invention proposes an apparatus for continuously manufacturing long panels with excellent fire resistance and heat insulation properties using a composite heat source.

(Means and effects for solving the problem) The present invention first irradiates infrared rays to the backing material made of a mixture of a fireproof heat insulating material and phenol powder in the atmosphere inside the furnace due to the generation of hot air. After melting the phenol powder and obtaining a state in which the microwave effect can be fully exerted, microwave irradiation is performed to melt and solidify the backing material from the inside while avoiding the rise in temperature of the iron plate due to the heat source. It is.

The present invention will be explained in detail below with reference to the drawings.

In FIG. 1, a metal hoop material 1 is a long metal material wound around a coil 2, which is transported in the longitudinal direction by a transfer roll 3, patterned by an embossing roll 4, and shaped into a predetermined gutter by a forming roll 5. It is molded into a shaped cross section.

Next, a liquid adhesive is sprayed by an adhesive applicator 6 (Fig. 2), and a heat insulating and fireproof material (for example, rock wool, glass fiber), an inorganic aggregate (perlite, shirasu balloon, etc.) and a novolac are sprayed by an adhesive applicator 6 (Fig. 2). A mixture of mold powder and phenolic resin is supplied by dropping (Figure 3).

Inorganic aggregate is used to reduce the weight of product panels, and its amount should be 30 to 40 parts per 100 parts of rock wool.

Novolak type phenolic resin is added to improve nonflammability, and it also provides bending strength and self-adhesive properties, so it is recommended to use 10 to 20 parts per 100 parts of rock wool.

The mixed and adjusted backing material 8 is placed in the gutter-like hoop 1.
and compressed and transferred by compression roll 9 (fourth
Figure) Next, the back paper 10 is continuously supplied under pressure,
It is sent into the furnace by the transfer roll 11. Depending on the material of the backing paper, it may be attached to the backing material after being irradiated with microwaves, as will be described later.

In the heating and foaming steps in the present invention, first, the material 12 is introduced into a heating furnace provided with an infrared ray 17. Here, the powdered resin is melted by infrared rays, compressed and solidified in the microwave irradiation zone 13, and the stability of the product is ensured at the furnace atmosphere temperature in the soaking zone 14.
It is cut into a predetermined length using a cutting machine 15.

The heating by infrared rays is preferably far infrared rays, but external ultraviolet rays, electron beams, etc. are of course also applicable.

Moreover, if the elongated hoop material is preheated and introduced into the heating furnace 12, the temperature rise to the foaming temperature of the phenol resin can be accelerated.

In the microwave irradiation zone 13, as shown in FIG. 6, a desired number of microwave oscillators 18 and waveguides 19 are installed, but they can also be installed on both the upper and lower sides of a long hoop material.

The heating furnace 12 in the present invention is preferably provided with a hot air generating device 20 at 150° C. to 200° C., and an infrared irradiation device 17 is preferably provided in contact with the transfer roll 11 .

FIG. 4 and FIG. 5 are schematic diagrams showing the functions of the compression roll and the transfer roll in the present invention. The compression roll provides a compression ratio of approximately 50% to the backing material.

In the present invention, the phenolic resin mixed into the backing material is made into a gelatinous liquid using far infrared rays, so rock wool and pearlite are uniformly stabilized by the liquid resin. Furthermore, liquid resin has good absorption of microwaves and is advantageous in that internal heating can be carried out quickly, and internal heating occurs and foaming starts from the inside. Microwaves of 915MHz and 2450MHz are commonly used, but are not particularly limited.

After the resin is foamed by internal heating, it is covered with paper on the back, and then in the soaking zone 14,
After being heated by infrared rays, it is transferred to a take-up roll 15,
A cutting machine 16 cuts it into a regular length to form a product panel.

FIG. 7 is a side view of the product, and FIG. 8 is a cutaway perspective view of the product. The product panel has a convex portion 25 and a concave portion 26, and is used for bonding.

FIG. 9 is a side view showing another example of the present invention.
That is, according to this example, the back surface material of the panel consists of an organic heat insulating layer made of phenol foam and an inorganic noncombustible heat insulating layer made of rock wool.

According to the inventor's experiments, 40 parts of perlite was added to 100 parts of rock wool in a metal hoop shaped like a gutter.
When layer 22 is a mixture of 20 parts of novolak-type powdered phenolic resin and layer 23 of novolak-type powdered phenolic resin is formed, and the phenolic resin is melted by far-infrared heating and subsequently irradiated with microwaves, the phenolic resin is mixed with 20 parts of novolak-type powdered phenolic resin. It was confirmed that by completely foaming the resin, soaking it and cooling it, an extremely excellent heat insulating layer and non-combustible heat insulating layer were formed. (FIG. 9a) When far-infrared heating and microwave irradiation are performed from above and below the metal hoop material, the time required for melting and foaming is shortened.

FIG. 9b shows a cross section of a panel in which the rock wool 22 is sandwiched between the phenol foam 23, and FIG. 9c shows the phenol foam 23.
3 shows an example in which the raw wool 22 is constructed.
According to the present invention, a composite layer can be formed regardless of the thickness of the layers, so the layer structure can be selected depending on the application.

(Effects of the Invention) With the above-described configuration, the present invention enables consistent continuous production of uniform, stable, and high-quality panels using a composite heat source mainly consisting of microwaves. Furthermore, by employing the phenolic resin powder novolac resin, there is a great industrial effect in that fireproof and heat-insulating panels can be manufactured continuously with high efficiency, without any problems of corrosion of metal plates or the generation of toxic gases.

[Brief explanation of the drawing]

The figures show an example of an embodiment of the present invention, in which Fig. 1 is a schematic side view of the whole, Fig. 2 is an explanatory drawing of spraying liquid adhesive, Fig. 3 is an explanatory drawing of insulating and fireproofing material being dropped and supplied, Fig. 4 is an explanatory diagram of the process of compression with a compression roll, Fig. 5 is an explanatory diagram of the transfer roll, Fig. 6 is a partial side view of infrared rays and microwave irradiation, Fig. 7 is a side view of the product, Fig. 8 9 is a cutaway perspective view of the product, and FIGS. 9a, 9b, and 9c are side views of other examples of the present invention. 1: Metal hoop material, 2: Hoop material coil, 3:
Transfer roll, 4: Enibos roll, 5: Molding machine,
6: liquid adhesive applicator, 7: fireproof insulation material supply device, 8: fireproof insulation material, 9: compression roll, 10,
10': Back paper, 11: Transfer roll, 15: Take-up roll, 16: Cutting machine, 17: Infrared rays or ultraviolet rays, 18: Microwave oscillator, 19: Waveguide, 2
0: Hot air generator, 21: Product, 22: Rock wool, 23: Phenol foam.

Claims (1)

[Claims] 1. An infrared heating furnace equipped with an infrared radiator and a microwave irradiation furnace equipped with a microwave oscillator in contact with a transfer roll that transfers a trough-like hoop containing a mixture of novolak-type powdered phenolic resin and fireproof insulation material. A furnace and a soaking furnace are connected and sealed, a heating furnace having a hot air generator is installed, and the transfer roll for transferring the trough-shaped hoop is connected to the infrared heating furnace and the soaking furnace. A heating device for a fireproof panel, characterized in that it is installed in a microwave irradiation furnace and a soaking furnace.