JP2002273743A - Method for manufacturing metal sandwich panel or metal siding high in fireproofness - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a metal sandwich panel or metal siding high in fireproofness without posing the problem caused by an increase in the viscosity of a resin compound to which a curing agent is added with the elapse of time or the delay of foaming curing. SOLUTION: The resin compound, which is prepared by mixing a foam stabilizer, a foaming agent and a fire retardant having no curing action with respect to a resole type phenol resin with the resole type phenol resin, and a curing agent, which is prepared by adding a fire retardant having curing action with respect to the resole type phenol resin to a curing agent, are guided to a mixing head by separate pipings to be mixed under stirring and the obtained mixed resin is discharged to a region demarcated by a metal surface plate to be foamed and cured to form phenol resin foam. At this time, as the fire retardant added to the curing agent, boric acid is used and, if the mixing ratio of boric acid to the curing agent is set to 1/0.1-1/5, the phenol resin foam can be manufactured further efficiently.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a metal panel or a metal siding excellent in fire resistance, in which a metal plate is used as an image material and a foam is filled therein, with high productivity.

[0002]

2. Description of the Related Art Conventionally used metal sandwich panels and metal sidings include those using urethane foam, nullate foam or phenol foam. As such a metal sandwich panel or metal siding, it is necessary to produce a fire-retardant product with high productivity, and a resole-type phenol foam has recently been used as a foam resin satisfying such conditions. . Also, if necessary, resole type phenol foam,
A small amount of inorganic flame retardant aluminum hydroxide, magnesium hydroxide, boric acid, phosphorus flame retardant, organic flame retardant chlorine flame retardant, bromine flame retardant, etc. is added to assist the fire protection.

[0003] In these, a resin compound obtained by adding a foam stabilizer, a foaming agent, and a flame retardant to a resole type phenol resin is stored in a temperature-controlled tank, and a curing compound stored in the temperature-controlled tank is also used. The agent is introduced into a mixing head equipped with a stirrer through a separate pipe with the resin compound and mixed with stirring, filled into a metal plate pre-formed into a groove, and then bonded with a metal plate or paper pasted with aluminum foil. After the lid is placed, it is led to a heating press and heated to foam and harden to produce a metal sandwich panel or metal siding.

[0004]

In recent years, there has been a demand for further improvement in fire prevention performance due to changes in fire prevention standards.
In this case, a method is known in which a large amount of a flame retardant such as aluminum hydroxide or boric acid is added to enhance fire resistance. However, a large amount of flame retardants such as aluminum hydroxide and boric acid are added to the resole type phenolic resin used for conventional metal sandwich panels and metal siding to produce a resin compound, which is led to the mixing head by piping and foam hardening. As time passes, the resole resin compound reacts and cures due to boric acid added as a flame retardant, and the viscosity rises, preventing it from flowing through the pipes, or curing with the mixing head over time as well. Even when the mixture is extruded after stirring with the agent, problems such as delayed foaming and curing may occur, and it may be difficult to stably manufacture the composition.

The present invention has been devised in order to solve such a problem, and it has been found that a resin compound added with a curing agent causes a problem due to an increase in viscosity over time and a delay in foam hardening. It is an object of the present invention to provide a method for producing a metal sandwich panel or metal siding without the need.

[0006]

SUMMARY OF THE INVENTION In order to achieve the object, a method for producing a metal sandwich panel or a metal siding having high fire resistance according to the present invention includes a foaming agent, a foaming agent and a resol-type phenol added to a resol-type phenolic resin. A resin compound containing a flame retardant that has no curing effect on the resin and a curing agent containing a flame retardant that has a curing effect on the resole type phenol resin added to the mixing agent are guided to the mixing head through separate pipes and stirred. The phenolic resin foam is formed by mixing and discharging the mixed resin into a region defined by the metal face plate and foaming and hardening the mixed resin. In this case, if boric acid is used as a flame retardant to be added to the curing agent, and the mixing weight ratio with respect to the curing agent is 1 / 0.1 to 1/5, the production can be performed more efficiently.

[0007]

In the manufacturing method according to the present invention, the mixed resin discharged from the mixing head into the area defined by the metal face plates 1 and 2 is foamed and cured to form a resin foam 3,
It is sandwiched and used as the core material of the panel (see FIG. 1).

FIG. 2 is a conceptual diagram of an apparatus used in the present invention.
The resin compound is stored in a tank 4 whose temperature can be adjusted, and is mixed from a pipe 5 through a pump 6 through a mixing head 7.
It is led to. The pipe 5 used preferably has a pipe diameter of 20 mm or more, though it depends on the amount of resin compound flowing in the pipe. The pump 6 for pressure-feeding the compound is preferably a gear pump or a snake pump for high viscosity. However, when the flame retardant of the compound is an inorganic flame retardant, a gear pump is preferable because a gear is worn since the gear is worn.

[0009] The curing agent compound is also stored in a tank 8 whose temperature can be adjusted, and is guided from a pipe 9 to a mixing head 7 via a pump 10. Since the conventional curing agent has a lower viscosity than the resol type phenolic resin compound, the diameter of the pipe used is 10 mm or less, and the pump used a diaphragm pump for low viscosity. Since the viscosity of the hardening agent compound used is increased by adding boric acid or the like, the pipe 9 used is preferably a pipe diameter of 10 mm or more. Since the inorganic flame retardant such as boric acid is added, the pump 10 is also required to be high. A snake pump for viscosity is preferred.

The stirring by the mixing head 7 is performed by the stirrer 1
Although it is performed by one motor 12, since the viscosity of each compound to be mixed and stirred becomes higher than before,
It is necessary to increase the output of the motor 12, and it is necessary to increase the size of the mixing head 7.

The metal face plates 1 and 2 have a thickness of 0.2 to
A 2.0 mm metal plate is used. Specifically, there are various surface-treated steel sheets, zinc-aluminized steel sheets, Cu-plated steel sheets, aluminum-plated steel sheets, aluminum sheets, painted aluminum sheets, and the like. Although a flat metal plate is generally used, a metal plate with improved appearance and strength can be used by embossing or bending with a roll forming machine or the like. Further, the metal face plate 2 may be paper in which aluminum foil is bonded in place of the metal plate.

The phenolic resin foam is produced from a resol-type phenolic resin or a novolak-type phenolic resin, and the resin used in the production method of the present invention is a resol-type phenolic resin. The resole phenolic resin compound is obtained by reacting phenol and formalin under an alkaline catalyst, and then adding a foaming agent, a foam stabilizer, and a flame retardant that has no curing action to the resole phenolic resin. Adjust by adding. Depending on the required fire protection performance, increase or decrease the flame retardant as needed in the resin compound.

The foaming agent to be added includes volatile petroleum oils such as petroleum ether, naphtha, pentane and hexane; low-boiling hydrocarbons such as methylene chloride, carbon tetrachloride, trichloroethane, fluorotrichloromethane and trifluorotrichloromethane. It is. Foam stabilizers to be added are polyoxyethylene nonylphenyl ether, polyoxyethylene lauryl ether, polyoxyethylene solibitan stearate,
Nonionic surfactants such as polyoxyethylene castor oil fatty acid ester and polyoxyethylene dimethyl silicon.

The flame retardant added to the resin compound mainly composed of the resole type phenol resin has no hardening effect on the resole type phenol resin, and tris (tribromoneopentyl) is used as the organic flame retardant. ) Phosphate, tetrabromobisphenol A, triphenyl phosphate, and inorganic flame retardants such as aluminum phosphate, ammonium phosphate, aluminum hydroxide, magnesium hydroxide, gypsum and the like.

The resole type phenol foam is obtained by adding a curing agent such as an organic sulfonic acid such as phenol sulfonic acid, paratoluene sulfonic acid, xylene sulfonic acid or benzene sulfonic acid to the prepared resol resin compound and a resol type phenol resin. On the other hand, it is manufactured by adding a curing agent compound mixed with a flame retardant having a curing effect and foam-curing. Boric acid is used as a flame retardant having a curing effect on the resole type phenol resin. The amount of flame retardant added to the curing agent is adjusted as required depending on the required fire protection performance.

The resin compound used in the method for producing a highly fire-resistant metal sandwich panel or metal siding of the present invention has a curing action on a resol type phenolic resin, a foam stabilizer, a foaming agent, and a resol type phenolic resin. It is made by mixing a flame retardant without the compound. In addition, the curing agent compound is obtained by adding a flame retardant having a curing action to a resol type phenol resin to a curing agent such as an organic sulfonic acid such as phenolsulfonic acid, paratoluenesulfonic acid, xylenesulfonic acid, and benzenesulfonic acid. It is made. As the flame retardant having a curing action on the resole type phenol resin, boric acid is preferred, and the mixing weight ratio of the curing agent and boric acid is preferably in the range of 1 / 0.1 to 1/5. The amount of boric acid is more preferably 0.5 or more in order to exert the fire protection effect, and is more preferably 2 or less in order to stably pump the piping.

[0017]

Examples The workability of boric acid as a flame retardant having a hardening action on a resole type phenol resin was compared with the case where boric acid was added to a resin compound (Example) and the case where boric acid was added to a hardener compound (Comparative Example). We investigated how the foam hardening time changes. Example 4 100 parts by weight of a resol type phenol resin having a viscosity of 900 mPas (25 ° C.), 4 parts by weight of methylene chloride as a blowing agent,
3 parts by weight of a silicone-based nonionic surfactant as a foam stabilizer and 40 parts by weight of aluminum hydroxide as a flame retardant were added and mixed to prepare a resin compound. Further, a curing agent compound was prepared by adding 40 parts by weight of boric acid to 25 parts by weight of the curing agent phenolsulfonic acid.

The prepared resin compound and curing agent compound were stored in separate tanks capable of adjusting the temperature, respectively, and each compound was guided to a mixing head having a stirrer through a pipe using separate snake pumps, followed by stirring and mixing. . The mixed resin compound was discharged and filled into a mold controlled at 70 ° C., and the time required for the foam to foam and harden was measured.

The piping diameter of the resole resin compound is 30
mm, and the pipe diameter of the curing agent compound was 20 mm.
The target amount of resin compound to be introduced into the mixing head is 14 kg / m so that the mixing ratio of the resole type phenolic resin and the curing agent compound becomes 140 parts / 65 parts.
In, the target amount of the curing agent compound introduced into the mixing head was 6.5 kg / min, and the rotation speed of the pump was adjusted immediately after the mixture was put into the tank. The measurement of the viscosity of the phenolic resin compound, the measurement of the discharge amount, and the measurement of the foam hardening time of the foam were performed immediately after the compound was prepared and put in a tank and 24 hours later.

Comparative Example A comparative example was implemented by a method according to a conventional manufacturing method. 100 parts by weight of a resole type phenol resin having a viscosity of 900 mPas (25 ° C.), 4 parts by weight of methylene chloride as a foaming agent, 4 parts by weight of a silicone-based nonionic surfactant as a foam stabilizer, and 40 parts of aluminum hydroxide as a flame retardant By weight, 40 parts by weight of boric acid were added and mixed to prepare a resin compound. Further, the curing agent used was phenolsulfonic acid alone. The prepared resin compound and curing agent are stored in a tank that can control the temperature.The resole resin compound is passed through a pipe using a snake pump, and the curing agent is guided to a mixing head with a stirrer through a pipe using a diaphragm pump, and mixed and stirred. The mixture was discharged and charged into a mold controlled at 70 ° C., and the time required for the foam to foam and harden was measured.

The pipe diameter of the resole resin compound is 30
mm, and the piping diameter of the curing agent was 10 mm. The mixing ratio of the resole type phenol resin and the curing agent compound is 180
So that the target amount of the resin compound to be introduced into the mixing head is 18 kg / min, and the target amount of the curing agent compound to be introduced into the mixing head is 2.5 kg / min, so that the amount becomes 2.5 parts / 25 parts. The rotation speed of the pump was adjusted. The measurement of the viscosity of the phenolic resin compound, the measurement of the discharge amount, and the measurement of the foam hardening time of the foam were performed immediately after the compound was prepared and put in a tank and 24 hours later.

As a result of measuring the viscosity of the resol resin compound produced in the example, it was 9000 mPas.
The amounts of the resol resin compound and the curing agent compound introduced into the mixing head immediately after being put into the tank were 14 kg / min and 6.5 kg /, respectively.
min, the pump rotation speed is 65 rpm
m and 30 rpm, and the time until the foaming and curing of the foam was completed was 2 minutes and 10 seconds.

After 24 hours, the same measurement was repeated. As a result, the viscosity of the resol resin compound in the tank prepared in the example was measured. As a result, it was 9200 mPas. Also, when the number of rotations of the pump was the same and the amounts of the resol resin compound and the curing agent compound introduced into the mixing head were measured, they were 13.9 k each.
g / min and 6.5 kg / min, which were almost the same as the target amount. The time until the foam hardening of the foam was completed was also 2 minutes and 15 seconds, and there was almost no change from immediately after the adjustment.

The viscosity of the resol resin compound prepared in the comparative example was measured and found to be 11,000 mPas. The amounts of the resol resin compound and the curing agent compound of the comparative example introduced into the mixing head immediately after being put into the tank were 18 kg / min and 2.5 k, respectively.
g / min, the pump rotation speed is 85r
pm and 24 rpm, and the time until the foam hardening of the foam was completed was 2 minutes and 20 seconds.

When the same measurement was repeated 24 hours later, the viscosity of the resol resin compound in the tank prepared in the comparative example was measured. As a result, the viscosity was 24000 mPas, which was a large increase. The amounts of the resol resin compound and the curing agent compound introduced into the mixing head were measured at the same rotation speed of the pump, and were 8.9 kg / min and 2.5 kg / min, respectively.
As a result, the amount of the resol resin compound introduced into the mixing head was greatly reduced. Target introduction amount 18 kg / m
In order to increase the rotation speed to in, the rotation speed of the snake pump of the resol resin compound was increased. At this time, when the mixing ratio of the resol-type phenolic resin compound and the curing agent was set to a predetermined ratio of 180 parts / 25 parts and the time until the completion of the foaming and curing of the foam was measured, the time was significantly longer in 5 minutes and 20 seconds. Was.

The method of the present invention is characterized in that boric acid as a flame retardant having a curing effect on a resol type phenol resin is added to a curing agent (Example), and the boric acid is produced by a conventional production method. Table 1 shows the experimental results when the compound was added to the resole-type phenolic resin compound according to (Comparative Example).
Are shown together.

[0027]

[0028]

As described above, according to the method for producing a metal sandwich panel or metal siding of the present invention, instead of adding a flame retardant having a curing action to a resol type phenol resin to a resol resin compound, By adding the compound in the curing agent compound, it becomes possible to stably produce a highly fire-resistant metal sandwich panel or metal siding even after a lapse of time after preparing the resol resin compound and the curing agent compound.

[Brief description of the drawings]

FIG. 1 Cross-sectional structure of a metal sandwich panel

FIG. 2 is a conceptual diagram of a mixed resin compound preparation and discharge device.

[Explanation of symbols]

1, 2: metal face plate, 3: resin foam,
4, 8: tank 5, 9: piping, 7: mixing head, 1
1: stirrer, 12: motor

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04F 13/12 E04F 13/12 A // B29K 61:04 B29K 61:04 105: 22 105: 22 B29L 31 : 10 B29L 31:10 F-term (reference) 2E110 AA02 BA03 BA12 GA24Z GA28Z GA32X GA33W GA33X GB02W GB02X GB06W GB06X GB11Z GB49Z GB63X 4F074 AA60 AC20 AC33 AG10 BA45 BB03 BB06 BC01 BC05 CA23 CC04Y CC22X AB32 AB04 AD08 AG20 AH48 EA01 EB01 EB11 EB22 EB24 EE02 EE12 EE22 EE28 EF01 EF02 EF27 EK13 EK17 EK24 EL03 EL17 EW06 EW15 4J002 CC041 CH052 CP182 DE076 DE146 DG056 DH046 EA007 EA56 EB0 EB67 FD67 EB67 FD0

Claims (2)

[Claims] 1. A resin compound in which a resol type phenol resin is mixed with a foam stabilizer, a foaming agent, and a flame retardant having no hardening effect on the resol type phenol resin, and a hardening agent having a hardening effect on the resol type phenol resin. A hardener compound with a certain flame retardant added is introduced into a mixing head through separate pipes and mixed by stirring, and the mixed resin is discharged into an area defined by a metal face plate and foam-hardened to form a phenol resin foam. A method for producing a metal sandwich panel or metal siding having high fire resistance. 2. The flame retardant added to the curing agent is boric acid, and the mixing weight ratio to the curing agent is from 1 / 0.1 to 1/5.
The method for producing a metal sandwich panel or metal siding having high fire resistance according to claim 1, wherein