JPH042095B2 - - Google Patents
Info
- Publication number
- JPH042095B2 JPH042095B2 JP59017949A JP1794984A JPH042095B2 JP H042095 B2 JPH042095 B2 JP H042095B2 JP 59017949 A JP59017949 A JP 59017949A JP 1794984 A JP1794984 A JP 1794984A JP H042095 B2 JPH042095 B2 JP H042095B2
- Authority
- JP
- Japan
- Prior art keywords
- phenolic resin
- flexible sheet
- resin foam
- foam
- voids
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
Landscapes
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
Description
【発明の詳細な説明】
（技術分野）
本発明は、断熱性、耐熱性、防火性にすぐれる
建築用板材に関し、特にフエノール樹脂発泡体
を、芯材とし、硬質表面材、裏面材などを積層一
体化した硬質積層板に関する。Detailed Description of the Invention (Technical Field) The present invention relates to architectural board materials that have excellent heat insulation, heat resistance, and fire resistance, and in particular, to a material using a phenolic resin foam as a core material, a hard surface material, a back surface material, etc. This invention relates to a rigid laminated board that is laminated into one piece.
また自己発泡硬化性レゾール型フエノール樹脂
を連続的に硬質表面材上に供給し、発泡させ、発
泡体上に可撓性シートを供給して、これらを積層
一体化させる、フエノール樹脂発泡体を芯材とす
る積層板の製造技術分野に属する。 In addition, a self-foaming hardening resol type phenolic resin is continuously supplied onto a hard surface material, foamed, a flexible sheet is supplied onto the foam, and the phenolic resin foam is laminated and integrated. It belongs to the field of manufacturing technology for laminates used as materials.
（背 景）
近年建築物などの断熱性向上の要求から種々の
断熱材が使用され始めてきており、その用途、目
的に応じて使いわけられている。特に高断熱性が
要求され、かつ硬質の板材として通常の建築板と
同様に使用される態様のものとして断熱性が大き
く、硬度もある硬質合成樹脂発泡体を芯材とし、
その表裏両面に適宜面材を積層一体化した積層板
があるが、特に耐火性にすぐれたものとして、フ
エノール樹脂発泡体を使用した積層板が注目を集
めている。(Background) In recent years, various types of heat insulating materials have begun to be used in response to demands for improved heat insulation properties in buildings, and are used differently depending on their use and purpose. In particular, the core material is a hard synthetic resin foam that requires high heat insulation properties and is used as a hard board in the same way as ordinary building boards, and has high heat insulation properties and hardness.
There are laminates in which appropriate face materials are laminated and integrated on both the front and back sides, but laminates using phenolic resin foam are attracting attention as they have particularly excellent fire resistance.
フエノール樹脂発泡体自体特に断熱性、耐熱性
にすぐれており、他の断熱性にすぐれた空隙を有
する硬質板や金属箔などの可撓性シート面材との
組み合せによる積層板は特に耐熱性の断熱建築板
としてその使途が期待されている。しかしながら
この種の積層板は通常液状の自己発泡硬化性レゾ
ール型フエノール樹脂発泡体混合液を硬質板上に
供給し、発泡させて、他面材を発泡体の上に供給
し、該発泡体の自己接着力により接着させ、積層
一体形成させるものであるが、発泡体原料が液状
であるため硬質板が空隙を有するものであると、
原料液が浸み込んでしまい、発泡体が凹凸になつ
たり、発泡体中に数多くのボイドが生じたりする
問題が生じる。このためこの種の積層板を得るに
はこのような通常の方法はとることができず、あ
らかじめ別途に製造した発泡体と硬質板とを接着
剤で貼り合せることが行われたが、通常の方法と
比較して極めて製造工程が増加しコストアツプに
なる欠点があり、また発泡体中に残存している水
分が接着剤被膜と金属箔などの不透性のために外
部に排出されず、発泡体内部で膨張して凹凸が生
じたりそり返つたりする品質上の欠点もあつた。 Phenol resin foam itself has particularly excellent heat insulation and heat resistance, and laminates made by combining it with other flexible sheet facing materials such as hard plates and metal foils that have voids that have excellent heat insulation properties are particularly heat resistant. It is expected that it will be used as a heat insulating building board. However, in this type of laminate, a liquid self-foaming hardening resol type phenolic resin foam mixture is usually supplied onto a rigid plate, foamed, and the other surface material is supplied onto the foam. The foam material is adhered by self-adhesive force to form an integral layer, but since the foam raw material is liquid, the hard plate has voids.
This causes problems such as the raw material liquid seeping into the foam, making the foam uneven, and creating many voids in the foam. For this reason, it was not possible to use the usual method to obtain this type of laminate, and instead a foam material and a hard board, which had been manufactured separately, were bonded together with adhesive. Compared to the conventional method, the production process is significantly increased and the cost is increased.Also, the moisture remaining in the foam cannot be discharged to the outside due to the adhesive coating and the impermeability of the metal foil. There was also a quality defect in that it expanded inside the body, causing unevenness and warping.
（目 的）
本発明は、このような欠点を解消し、そり返り
や凹凸の発生がない安定した品質の断熱積層板を
提供すること、及び通常の液状原料供給方式によ
る積層板の製造方法によつても高品質の断熱積層
板が容易に得られることを目的とする。(Purpose) The present invention eliminates such drawbacks and provides a heat-insulating laminate of stable quality without warpage or unevenness, and a method for manufacturing a laminate using a normal liquid raw material supply method. It is an object of the present invention to easily obtain a high-quality heat-insulating laminate.
（構 成）
本発明は、空隙を有する硬質板、多数の小孔を
有する可撓性シート、レゾール型フエノール樹脂
発泡体、金属箔を含む可撓性シートが順次積層一
体化してなるフエノール樹脂発泡体積層板であ
る。(Structure) The present invention is a phenolic resin foam formed by sequentially laminating and integrating a hard plate having voids, a flexible sheet having many small holes, a resol type phenolic resin foam, and a flexible sheet containing metal foil. It is a laminated board.
空隙を有する硬質板上に多数の小孔を有する可
撓性シートを供給し、該可撓性シート上に自己発
泡硬化性レゾール型フエノール樹脂発泡体混合液
を供給し、発泡させ、更に裏面材となる金属箔を
含む可撓性シートを発泡体上に供給し、空隙を有
する硬質板、多数の小孔を有する可撓性シート、
レゾール型フエノール樹脂発泡体、金属箔を含む
可撓性シートを積層一体成形することを特徴とす
るフエノール樹脂発泡体積層板の製造方法であ
る。 A flexible sheet having a large number of small holes is provided on a hard plate having voids, a self-foaming curable resol type phenolic resin foam mixture is supplied onto the flexible sheet, and the mixture is foamed. A flexible sheet containing metal foil is supplied onto the foam, and a hard plate with voids, a flexible sheet with many small holes,
This is a method for manufacturing a phenolic resin foam laminate, which comprises integrally laminating and molding a flexible sheet containing a resol type phenolic resin foam and a metal foil.
以下図面実施例に従つて説明するが、本発明は
この実施態様に限定されるものではない。 The present invention will be described below with reference to drawing examples, but the present invention is not limited to these embodiments.
第１図に示すごとく、空隙を多数有する硬質板
１をコンベアーライン上に連続的に進行させ、該
硬質板１上に孔径0.01〜3.0mm、孔数200000個／
m2以下の孔あき面材２をおき、該孔あき面材２上
に自己発泡硬化性レゾール型フエノール樹脂発泡
体混合液３を供給、発泡させ、面材４を発泡体１
２上に供給し、ダブルコンベアー９，９′内にて
一定厚さに制御しながら発泡、硬化させ、フエノ
ール樹脂発泡体積層板を連続的に製造する。 As shown in FIG. 1, a hard plate 1 having many voids is continuously advanced on a conveyor line, and 200,000 holes/holes with a diameter of 0.01 to 3.0 mm are formed on the hard plate 1.
A perforated face material 2 with a size of less than m 2 is placed, and a self-foaming hardening resol type phenolic resin foam mixture 3 is supplied and foamed on the perforated face material 2, and the face material 4 is replaced with the foam 1.
2, and is foamed and cured in double conveyors 9, 9' while controlling the thickness to a constant value, thereby continuously manufacturing a phenolic resin foam laminate.
適正温度の空隙を多数有する硬質板１上に孔径
0.01〜3.0mm、孔数200000個／m2以下の孔あき面
材２をおき、面材には面材のシワ防止等を考慮し
適正なテンシヨンをかける。該孔あき面材２上に
レゾール型フエノール樹脂初期縮合物と界面活性
剤を適正比率に混合した液５、発泡剤６、硬化剤
７を適正比に定量ポンプで混合機８に送給し、回
転数1000〜10000rpmの混合機で連続的に撹拌混
合し、吐出口より吐出され、混合液３上に面材４
をのせる。吐出された混合液３は直ちに泡化して
クリーム状となり、縮合反応により反応熱及びオ
ーブン（図示せず）による熱などによりさらに泡
化及び硬化が進行し、ダブルコンベアー９，９′
により一定厚味の積層板が出来る。 The hole diameter is placed on a hard plate 1 that has many voids at the appropriate temperature.
A perforated face material 2 with a diameter of 0.01 to 3.0 mm and a number of holes of 200,000 holes/m 2 or less is placed, and an appropriate tension is applied to the face material in consideration of wrinkle prevention of the face material. On the perforated surface material 2, a liquid 5 in which a resol-type phenolic resin initial condensate and a surfactant are mixed in an appropriate ratio, a foaming agent 6, and a hardening agent 7 are fed in an appropriate ratio to a mixer 8 using a metering pump, Continuously stir and mix with a mixer with a rotation speed of 1000 to 10000 rpm, and the mixture is discharged from the discharge port, and the surface material 4 is deposited on the mixed liquid 3.
put on. The discharged mixed liquid 3 immediately foams and becomes creamy, and further foams and hardens due to the reaction heat due to the condensation reaction and the heat from an oven (not shown), and is transferred to the double conveyors 9, 9'.
This produces a laminate with a constant thickness.
本発明に使用する孔あき面材２は、クラフト
紙、Ｋライナー紙、アスフアルトルーフイング
紙、石綿紙、ガラス不織布、不燃紙、各種不織布
などの紙及び紙とポリエチレンの積層面材が使用
出来る。孔は円形、楕円形、多角形等の形状で孔
径は、0.01〜0.3mm好ましくは0.05〜1.0mm、孔数
は、200000個／m2以下好ましくは、10〜500個／
m2が良い。孔径が0.01mm未満の場合、レゾール型
フエノール樹脂の浸み出しがなく、硬質板と発泡
体を接着させることが出来ない。又、孔径が3.0
mmより大きくなると、フエノール樹脂の浸み出し
が大きくなり、外観上大きな問題となるので好ま
しくない。又、孔径、孔数は、面材の中央部、端
部で異なつていても良く、混合液の粘度、反応性
などにより変える。孔あき面材の孔径と数は、自
己発泡硬化性レゾール型フエノール樹脂発泡体の
反応性、硬質板と発泡体の接着力の必要性（必要
強度）により任意に選定することができる。 As the perforated facing material 2 used in the present invention, paper such as kraft paper, K-liner paper, asphalt roofing paper, asbestos paper, glass nonwoven fabric, noncombustible paper, various nonwoven fabrics, and laminated facing material of paper and polyethylene can be used. The pores are circular, oval, polygonal, etc. in shape, the pore diameter is 0.01 to 0.3 mm, preferably 0.05 to 1.0 mm, and the number of pores is 200,000 or less/ m2 , preferably 10 to 500/
m2 is good. If the pore diameter is less than 0.01 mm, the resol type phenolic resin will not seep out and the hard board and the foam cannot be bonded together. Also, the pore diameter is 3.0
If it is larger than mm, the phenolic resin will seep out to a large extent, which will cause a big problem in terms of appearance, which is not preferable. Further, the pore diameter and the number of pores may be different between the center and the ends of the face material, and are changed depending on the viscosity, reactivity, etc. of the liquid mixture. The diameter and number of holes in the perforated face material can be arbitrarily selected depending on the reactivity of the self-foaming hardening resol type phenolic resin foam and the need for adhesive strength (required strength) between the hard plate and the foam.
画材４は、クラフト紙、Ｋライナー紙、アスフ
アルトルーフイング紙、石綿紙、不燃紙などの
紙、接着剤、金属箔の積層面材などが使用でき
る。 As the art material 4, paper such as kraft paper, K-liner paper, asphalt roofing paper, asbestos paper, and noncombustible paper, adhesive, laminated surface material of metal foil, etc. can be used.
本発明に使用する硬質板１は、空隙が多数存在
する硬質板で、木毛セメント板、孔あき石こう
板、ガラス繊維成形板、岩綿成形板、各種吸音板
などが使用出来る。 The hard board 1 used in the present invention is a hard board with many voids, and wood wool cement boards, perforated gypsum boards, glass fiber molded boards, rock wool molded boards, various sound absorbing boards, etc. can be used.
本発明に使用するレゾール型フエノール樹脂発
泡体は、ホルムアルデヒド類／フエノール類のモ
ル比が1.0〜2.5好ましくは1.2〜2.0で含水率が５
〜35％好ましくは10〜25％のレゾール型フエノー
ル樹脂および界面活性剤、発泡剤、酸性硬化剤、
添加剤等から生成する。ホルムアルデヒド類とし
ては、ホルムアルデヒド、パラホルムアルデヒ
ド、ポリオキシメチレン等があり単独又は併用で
使用する。フエノール類としては、フエノール、
ｏ−クレゾール、ｍ−クレゾール、ｐ−クレゾー
ル、3.5キシレノール、ナフトール等があり単独
又は併用で使用する。界面活性剤としては非イオ
ン系界面活性剤、シリコーン系界面活性剤等があ
り単独又は併用で使用できる。発泡剤としてはハ
ロゲン化炭化水素類が使用できる。例えば、ジク
ロロジフルオロメタン、トリクロロモノフルオロ
メタン、メチレンジクロロメタン、モノクロロジ
フルオロメタン、トリクロロトリフルオロエタ
ン、ジクロロテトラフルオロエタンなどがあり単
独又は併用で使用できる。酸性硬化剤としては、
無機酸と有機酸が使用できる。 The resol type phenolic resin foam used in the present invention has a formaldehyde/phenol molar ratio of 1.0 to 2.5, preferably 1.2 to 2.0, and a water content of 5.
~35% preferably 10-25% resol type phenolic resin and surfactant, blowing agent, acidic curing agent,
Generated from additives, etc. Formaldehydes include formaldehyde, paraformaldehyde, polyoxymethylene, etc., and may be used alone or in combination. As phenols, phenol,
There are o-cresol, m-cresol, p-cresol, 3.5 xylenol, naphthol, etc., and they can be used alone or in combination. Examples of the surfactant include nonionic surfactants and silicone surfactants, which can be used alone or in combination. Halogenated hydrocarbons can be used as blowing agents. Examples include dichlorodifluoromethane, trichloromonofluoromethane, methylene dichloromethane, monochlorodifluoromethane, trichlorotrifluoroethane, and dichlorotetrafluoroethane, which can be used alone or in combination. As an acidic curing agent,
Inorganic and organic acids can be used.
（作用、効果） 本発明によると下記の作用、効果を奏する。(action, effect) According to the present invention, the following actions and effects are achieved.
(1) 空隙を有する硬質板上に小孔を有する可撓性
シートをおき、この上に発泡体形成混合液を吐
出するから、混合液は直接硬質板の空隙内に浸
み込むことがなく、可撓性シート上で増粘し、
シート表面に展延した流動体がシートの小孔か
ら硬質板の空隙内にくい込むのでレゾール型フ
エノール樹脂の発泡硬化時の自己接着力によつ
て、硬質板も接着一体化される。(1) A flexible sheet with small holes is placed on a hard plate with voids, and the foam-forming mixed liquid is discharged onto this, so the mixed liquid does not directly seep into the voids of the hard plate. , thickened on a flexible sheet,
The fluid spread on the sheet surface sinks into the voids of the hard plate through the small pores of the sheet, so that the hard plate is also bonded and integrated by the self-adhesive force of the resol type phenolic resin when it is foamed and cured.
(2) 小孔の数、径の設定によつて、発泡体と硬質
板の接着強さを自由に調整することができる。(2) By setting the number and diameter of small holes, the adhesive strength between the foam and the hard plate can be adjusted freely.
(3) 裏面材と同種の面材を硬質板と発泡体との間
に設けることができ、しかも発泡体と面材との
接着が良いから積層板のそり変形がない。(3) A facing material of the same type as the backing material can be provided between the hard plate and the foam, and since the adhesive between the foam and the facing material is good, there is no warping of the laminate.
(4) 不透性の金属箔などの断熱性が大きい面材が
使用できるから、断熱性、難燃性のすぐれるフ
エノール樹脂発泡体との積層板は特に耐火性に
すぐれ、準不燃材料試験に合格する。(4) Since it is possible to use surface materials with high heat insulation properties such as impermeable metal foils, laminates with phenolic resin foam, which has excellent heat insulation properties and flame retardance, have particularly excellent fire resistance, and have passed the quasi-noncombustible material test. pass.
(5) フエノール樹脂発泡体中に残存する水は面材
の小孔、硬質板の空隙から外部に排出されるか
ら、積層板の経時安定性が良い。(5) The water remaining in the phenolic resin foam is discharged to the outside through the small holes in the face material and the voids in the hard plate, so the laminate has good stability over time.
第１図は本発明の方法を実施するのに適する装
置の概念図、第２図は本発明のフエノール樹脂発
泡体積層板の断面図である。
１……硬質板、２……孔あき面材、３……混合
液、４……面材、５……レゾール型フエノール樹
脂初期縮合物と界面活性剤の混合液、６……発泡
剤、７……硬化剤、８……混合機、９……ダブル
コンベアー、１０……フエノール樹脂発泡体積層
板、１１……カツター。
FIG. 1 is a conceptual diagram of an apparatus suitable for carrying out the method of the present invention, and FIG. 2 is a cross-sectional view of the phenolic resin foam laminate of the present invention. 1... Hard plate, 2... Perforated face material, 3... Mixed liquid, 4... Face material, 5... Mixed liquid of resol type phenolic resin initial condensate and surfactant, 6... Foaming agent, 7...Curing agent, 8...Mixer, 9...Double conveyor, 10...Phenol resin foam laminate, 11...Cutter.
Claims (1)
撓性シート、レゾール型フエノール樹脂発泡体、
金属箔を含む可撓性シートが順次積層一体化して
なるフエノール樹脂発泡体積層板。 ２ 空隙を有する硬質板上に多数の小孔を有する
可撓性シートを供給し、該可撓性シート上に自己
発泡硬化性レゾール型フエノール樹脂発泡体混合
液を供給し、発泡させ、更に裏面材となる金属箔
を含む可撓性シートを発泡体上に供給し、空隙を
有する硬質板、多数の小孔を有する可撓性シー
ト、レゾール型フエノール樹脂発泡体、金属箔を
含む可撓性シートを積層一体成形することを特徴
とするフエノール樹脂発泡体積層板の製造方法。[Claims] 1. A hard plate having voids, a flexible sheet having many small holes, a resol type phenolic resin foam,
A phenolic resin foam laminate made by sequentially laminating and integrating flexible sheets containing metal foil. 2. A flexible sheet having a large number of small holes is provided on a hard plate having voids, a self-foaming curable resol type phenolic resin foam mixture is supplied onto the flexible sheet, and the mixture is foamed. A flexible sheet containing metal foil is supplied onto the foam, and a rigid plate with voids, a flexible sheet with many small holes, a resol type phenolic resin foam, and a flexible sheet containing metal foil are produced. A method for manufacturing a phenolic resin foam laminate, which comprises integrally laminating sheets and integrally molding them.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59017949A JPS60162638A (en) | 1984-02-03 | 1984-02-03 | Phenol resin foam laminated board and manufacture thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP59017949A JPS60162638A (en) | 1984-02-03 | 1984-02-03 | Phenol resin foam laminated board and manufacture thereof |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS60162638A JPS60162638A (en) | 1985-08-24 |
| JPH042095B2 true JPH042095B2 (en) | 1992-01-16 |
Family
ID=11958015
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP59017949A Granted JPS60162638A (en) | 1984-02-03 | 1984-02-03 | Phenol resin foam laminated board and manufacture thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS60162638A (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS62184813A (en) * | 1986-02-12 | 1987-08-13 | Okamura Seisakusho:Kk | Manufacture of foam molded body covered by air-permeable skin material |
| JP2020006659A (en) * | 2018-07-12 | 2020-01-16 | 株式会社庄内工業 | Sandwich panel and method for manufacturing sandwich panel |
-
1984
- 1984-02-03 JP JP59017949A patent/JPS60162638A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS60162638A (en) | 1985-08-24 |
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