JP2001227251A - Door - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a wooden door avoiding warping arid twisting over a long period and having excellent fire resistance. SOLUTION: Carbon fibers are laid in a line and integrated together between a surface decorating member 5 and a core 8. The carbon fibers are bundled into a hardened sheet 6 using a thermosetting resin as a matrix. Further, the hardened sheet is formed into three layers comprising a porous sheet, a resin- impregnated carbon fiber sheet, and another porous sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a door in a house or the like, and particularly to a door of a harsh environment where it is exposed to rainwater and sunlight, and which is hardly warped or twisted for a long period of time and has excellent fire protection performance. .

[0002]

2. Description of the Related Art Entrance doors, which are also referred to as the faces of houses, have not only been designed but also have been provided with functions such as heat insulation and fire prevention. Wood is a material having functions such as ease of processing, warmth, high heat insulation performance and fire protection performance according to its thickness, and has been widely used for entrance doors and the like. However,
Due to the effects of moisture and heat on wood, irregularities such as warpage and twisting occur, and doors using this may cause problems such as drafts and light leakage, and the insulation performance of the house may not be sufficiently maintained . In order to solve these problems, measures have been taken to reduce the influence of moisture by adopting a frame structure, integrating the frames, and painting at the stage of the members. Nevertheless, it was still difficult to control warpage and twist.

[0003] Therefore, a composite specification in which a rigid metal sheet, for example, an aluminum sheet or the like is laid between the surface material and the core material of the door on the front and back to suppress warping and twisting has been studied and commercialized. However, combining flammable materials such as wood or wood with metal materials such as aluminum has the effect of suppressing warpage and twisting, but not only makes processing difficult, but also causes separation during disposal. It is difficult and it is difficult to say that it leads to an increase in waste and is environmentally favorable. In addition, doors using aluminum sheets not only burn surface materials in the event of a fire, but also melt the aluminum and lose the balance between the front and back, causing warpage, accompanying flame penetration, and burning to the non-fire side. There is fear.

[0004]

SUMMARY OF THE INVENTION In view of the above-mentioned problems, the present invention makes it possible to easily process and dispose of wood in the same manner as in wood processing, and to prevent warpage over a long period of time even in an entrance where the use environment is severe. An object of the present invention is to provide a wooden door which is less likely to be twisted and has excellent fire prevention performance.

[0005]

To solve the above-mentioned problems, the present invention has the following constitution. The door of the present invention has solved the above-mentioned problem by arranging and integrating carbon fibers between a core material and a surface decorative material and integrating them.

The present inventors have disclosed in Japanese Patent Application Nos. 8-93566 and 8-93567 and 10-224143 a material having carbon fibers for reinforcing wood. Have been found to be able to solve, and have been disclosed. Specifically, a linear material such as a unidirectionally oriented sheet or roving is used for the carbon fiber to form a cured sheet using a thermosetting resin as a matrix, and further, to improve the adhesion with a core material and a surface decorative material. , A porous sheet, a resin-impregnated carbon fiber sheet, and a porous sheet.

The carbon fiber used in the present invention is not particularly limited, but the nitrogen content obtained from the polyacrylonitrile fiber is 0.1 to 15% by weight, and the tensile strength is 2,500 to 2,500.
A carbon fiber having a modulus of 7000 MPa and an elastic modulus of 150 to 700 GPa is preferable. Particularly, a tensile strength of 3500 MPa or more having a nitrogen content of 3 to 10% by weight and a tensile strength of 200 to 350 are preferred.
Carbon fibers having an elastic modulus of GPa and a diameter of 5 to 9 microns are preferred because they have good adhesion to the matrix resin. Furthermore,
The molar ratio of oxygen / carbon on the surface of the carbon fiber is from 0.1 / 1 to 0.1.
The ratio is preferably 3/1, and even more preferably, the molar ratio is set to 0.15 / 1 to 0.25 / 1 to further improve the adhesion.

A fiber bundle (strand) composed of carbon fibers having a fiber diameter of 5 to 9 microns and a constitution number of 1,000 to 300,000 is bundled by a desired amount or widened in a sheet form for use. Is desirable, but not particularly limited to this.

The form of the carbon fiber is preferably a linear material such as a unidirectionally oriented sheet or roving for achieving the object of the present invention to suppress the warpage. Is also good.

The matrix resin for carbon fibers used in the present invention is a thermosetting resin such as a phenol resin, a resorcinol resin, a phenol-resorcinol co-condensation resin, an epoxy resin, and a polyester resin. From the viewpoint of heat resistance and fire resistance, the phenol resin is used. And a resorcinol resin or a phenol-resorcinol cocondensation resin.

These phenol or resorcinol resins include phenol, cresol, xylenol,
Phenols or oligomers having one phenolic hydroxyl group such as ethylphenol and chlorophenol, and phenols having two or more phenolic hydroxyl groups such as resorcinol, hydroquinone and catechol, and phenols such as formaldehyde, paraformaldehyde, furfural, benzaldehyde and trioxane Aldehydes and phenols / aldehydes = 2/1 to 1 /
3, preferably a phenol-formaldehyde initial condensation resin obtained by methylolation in the presence of an alkali catalyst such as sodium hydroxide, potassium hydroxide, or ammonia in a molar ratio of 5/4 to 2/5, This initial condensed resin is impregnated, coated or immersed in the carbon fiber, and dried to be used as a matrix resin.

The curing agent is a known phenolic resin such as formaldehyde, paraformaldehyde, acetaldehyde, furfural, trioxane, or a resorcinol resin, and is used as a curing agent to be mixed with the resin to form a paste or a liquid. It is preferable to use an organic acid such as paratoluenesulfonic acid, benzenesulfonic acid, or phenolsulfonic acid as a curing catalyst.

The porous sheet used in the present invention includes a thin plate obtained by slicing wood such as cedar, hinoki and Japanese oak, non-woven fabric, paper, woven fabric and the like made of pulp, glass fiber, carbon fiber, synthetic fiber and the like. These are coated with the phenol-formaldehyde initial condensation resin,
Although a resin composite porous sheet obtained by impregnation, immersion, and drying can be used, a resin composite porous sheet that does not decrease tensile strength or adhesive strength is suitable.

The cured sheet is obtained by heating and pressing a sheet-like carbon fiber having the phenol-formaldehydes initial condensation resin as a matrix by using a hot press or the like. When it is made into a layered structure and heated and pressed to form an integrated product, not only is it easy to handle, but the adhesiveness of the adhesive for bonding the core material or surface material and the porous sheet is improved from the cured sheet of carbon fiber alone, preferable.

Hereinafter, the present invention will be described in detail with reference to embodiments.

Embodiment 1 FIG. 1 shows an embodiment of the present invention. The height is 2200 mm and the width is 900 m.
m, a front view of a door having a thickness of 45 mm, and FIG. 2 is a sectional view of a vertical frame portion thereof. The vertical frame 2 has a fiber characteristic of carbon fiber diameter of 7 microns and a number of fibers of 12,000 between a core material 8 made of laminated wood having a width of 120 mm and a thickness of 35 mm and a surface decorative material 5 made of a wooden veneer having a thickness of 4 mm. Book, tensile modulus 2360GP
a, basis weight 300g / m ² carbon fiber roving, molar ratio 4
Prepreg impregnated and dried with a phenol-formaldehyde precondensed resin of / 5% by weight at a resin amount of 55% by weight and a basis weight of 50%
g / m ² of pulp paper sandwiched between the phenol-formaldehyde initial condensation resin and a phenol resin impregnated paper impregnated and dried at a resin amount of 40% by weight, and heated and pressed at a temperature of 140 ° C., a pressure of 0.8 MPa and a time of 5 minutes. The carbon fiber cured sheet 6 having a thickness of 0.6 mm integrally molded under the conditions is adhered with a resorcinol-based adhesive and arranged and laid. After the vertical frame 2 is assembled with another member such as the end plate 3, the surface is finished by applying an acrylic urethane resin-based paint.

Embodiment 2 FIG. 3 shows another embodiment of the present invention, in which the height is 2200 mm and the width is 90 mm.
FIG. 4 is a front view of a door having a thickness of 0 mm and a thickness of 45 mm, and FIG. The door is composed of a vertical frame 2 or the like made of hardwood LVL, and a core 8 having a thickness of 35 mm in which drill glue is embedded and a surface decorative material 5 made of a wooden veneer having a thickness of 4 mm. The above-mentioned cured carbon fiber sheet 6 is adhered with a resorcinol-based adhesive and is arranged and laid.
After being attached, an acrylic urethane resin-based paint is applied and finished.

The cured carbon fiber sheet 6 suppresses the warpage of the door by utilizing the properties of carbon fiber having a high tensile strength and a high elastic modulus. It can also be used. The adhesive is
In addition to the above resorcinol adhesives, phenolic adhesives, aqueous vinyl urethane adhesives, epoxy adhesives, rubber adhesives, etc. can be used, but can be cured at room temperature,
A resorcinol adhesive excellent in heat resistance and fire resistance is suitable.

As the core material 8, in addition to the laminated material, particle board, MDF, honeycomb material, synthetic resin foam, calcium silicate, ALC, rock wool, and the like can be appropriately selected and used.

The veneer used as the surface decorative material 5 is directly printed or transferred onto the surface of veneer, laminated veneer, MDF, plywood or the like, which is processed into a plate shape from various woods such as oak, oak, maple, or the like. Wood veneer veneers coated with resin can be used.

Embodiment 3 FIG. 5 shows another embodiment of the present invention, in which the height is 2200 mm and the width is 90 mm.
FIG. 6 is a sectional view of a vertical frame portion of a door having a thickness of 0 mm and a thickness of 45 mm. The vertical frame 2 has a carbon fiber cured sheet 6 as a resorcinol-based adhesive between a core material made of laminated wood having a width of 120 mm and a thickness of 32 mm and a surface decorative material 5 made of a wooden veneer having a thickness of 4 mm. After laminating and adhering four sheets, it is further adhered with a resorcinol-based adhesive and arranged and laid. After being assembled with other members such as the end plate 3, the surface is coated with an acrylic urethane resin paint. It is finished.

Embodiment 4 FIG. 7 shows another embodiment of the present invention, in which the height is 2200 mm and the width is 90 mm.
FIG. 8 is a front view of a door having a thickness of 0 mm and a thickness of 45 mm, and FIG. The door is cored to a vertical frame 2 or the like with an LVL made of hardwood, and a core material 8 having a thickness of 32 mm in which drill glued wood is embedded and a surface decorative material 5 made of a wooden veneer having a thickness of 4 mm. The above-mentioned carbon fiber cured sheet 6 is laminated and bonded with a resorcinol-based adhesive, and then laminated and laid in a resorcinol-based adhesive.
After being attached, an acrylic urethane resin-based paint is applied and finished.

Comparative Example 1 In Example 1, the core material of the vertical frame was a laminated material having a thickness of 37 mm, and a wood surface material having a thickness of 4 mm was adhered to the front and back thereof with a resorcinol-based adhesive. did.

Comparative Example 2 In Example 2, an aluminum plate having a thickness of 0.6 mm was bonded with a water-based vinyl urethane-based adhesive instead of the carbon fiber cured sheet to form a door.

Performance evaluation Warpage test: The obtained door was irradiated with 12 infrared irradiation lamps at a distance of 1 m from the lamp surface for 3 hours in a windless state.
The heat was radiated for one hour, and after this cycle was repeated six times, the warpage (height in the height direction) of the door was measured. At this time, the surface of the door was at about 80 ° C. Fire resistance test: The door was heated along the heating curve of JIS A 1304, and the time required for the flame to burn out to the non-heating side was measured.

The results are shown in the table.

[Table 1]

The door in which the carbon fibers were laid was arranged not only to prevent warpage but also to have high fire resistance.
Although the degree of warpage depends on the amount of carbon fibers, there is no difference in fire resistance performance, and the configuration is appropriately selected from cost and performance. In addition, in the door using an aluminum plate, although the occurrence of warpage can be suppressed, in the fire resistance test, the aluminum plate on the heating side melts, the core material shrinks by heating, and the non-heating side aluminum plate expands due to heat conduction. , Warpage was observed. The reason why there is no difference in fire resistance performance between Examples 1 and 3 and Comparative Example 1 is that carbon fibers are not laid and arranged on the head plate portion.

[0028]

As described above, the door according to the present invention has a high tensile elasticity in which the stress of the wooden material drying and shrinking due to heat from one side such as the sun is laid between the core material and the surface material. The structure is relaxed by the carbon fiber having the modulus, and the structure is less warped. In addition, carbon fiber is a carbide baked at a high temperature of 1500 ° C. or more, and such a carbide has a high thermal diffusivity and has a property of hardly transmitting heat to the back surface,
The carbide blocks the flame against fire. Therefore, it has a high fire resistance even with heating up to 800 to 900 ° C. like a fire door, and has a high effect of blocking a flame.

Further, even if a laminated material which is susceptible to warping due to the influence of humidity and temperature is used for the core material, the carbon fiber sheet using the thermosetting raw resin as a matrix can block such an effect. it can. In addition, since warpage is suppressed, problems such as cracking, peeling of the surface material, and cracking of the coating film are suppressed.

The door of the present invention can be used for a long period of time as a door for a harsh environment, and it is difficult to open or close the door due to leakage of light, draft, or the like. Problems such as impaired appearance are suppressed.
Furthermore, the carbon fiber can be cut in the same manner as wood, and there is no need to separate and discard it as a combustible material at the time of disposal, so that the door is environmentally friendly. in addition,
Since carbon fibers have high conductivity, an effect of shielding electromagnetic waves can be obtained by orthogonally or randomly arranged carbon fibers.

[Brief description of the drawings]

FIG. 1 is a front view of a door according to a first embodiment.

FIG. 2 shows a partial cross-sectional view along line AA in FIG.

FIG. 3 is a front view of a door according to a second embodiment.

FIG. 4 is a partial cross-sectional view taken along line AA in FIG.

FIG. 5 is a front view of a door according to a third embodiment.

FIG. 6 shows a partial cross-sectional view along the line AA in FIG. 5;

FIG. 7 is a front view of a door according to a fourth embodiment.

FIG. 8 is a partial cross-sectional view taken along a line AA in FIG. 7;

FIG. 9 is a schematic cross-sectional view of a carbon fiber cured sheet used in Examples.

FIG. 10 is a schematic cross-sectional view of a carbon fiber cured sheet used in Examples.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Door 2 Vertical frame 3 End plate 4 Decorative member 5 Surface decorative material 6 Carbon fiber cured sheet 7 Carbon fiber 8 Core material 9 Resin-cured impregnated paper 10 Matrix resin

Claims (4)

[Claims] 1. A door characterized in that carbon fibers are arranged and integrated between a surface decorative material and a core material. 2. The carbon fiber according to claim 1, wherein the carbon fiber is a linear material such as a unidirectionally oriented sheet or roving.
The mentioned door. 3. The carbon fiber according to claim 1, wherein the carbon fiber is a cured sheet having a thermosetting resin as a matrix.
Alternatively, the door according to claim 2. 4. The cured sheet has a three-layer structure of a porous sheet, a resin-impregnated carbon fiber sheet, and a porous sheet,
The door according to claim 3, wherein these are formed by heating and pressing.