JP2002276070A - Frame-retardant panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a panel having superior frame-retardancy and weather resistance with its weight permitting easy mooting on an outer wall of a general housing with nails or machine screws without requiring additional work for removing existing outer wall materials or the reinforcement of columns. SOLUTION: The panel comprises a panel molding containing, at least, a thermosetting resin, an inorganic filler and inorganic fibers, on the surface of which has a layer of a fire resistance paint material, and a laminated structure having a coating film laminated thereon. The layer of the fire resistant paint material and the coating film laminated thereon have respectively thickness 10 μm or more.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel having excellent fire protection.

[0002]

2. Description of the Related Art Conventionally, in the case of a wooden frame structure in a general house, its outer wall surface is generally finished with wood or mortar whose surface has been painted by spraying. In this case, a curing period of the mortar and a drying period of the paint are necessary, and therefore, this construction method is called a wet construction method.
Also, prefabricated construction methods such as nailing plywood and panels to studs, nailing ceramic siding boards to the outside, hooking tiles etc. on horizontal rails, and houses using a construction called two-by-four construction are also common. The construction method is called a dry construction method.

In the above-mentioned wet construction method, for example, when the outer wall surface is painted by spraying, there is a problem not only that the coating solution is scattered to neighboring houses or an environmental load is increased due to the evaporation of the organic solvent in the coating solution. In addition, there is a problem that the exterior wall surface obtained by the paint finish deteriorates in color tone and surface resin layer in about 10 years, and the appearance of the exterior wall surface deteriorates, so that repainting is required. Further, the construction method in which bricks, tiles, and the like are stacked or pasted via a mortar still has a problem that a long construction period is required for curing.

On the other hand, in the dry construction method, when ceramic siding boards, tiles, and the like as disclosed in Japanese Patent Application Laid-Open No. 5-209454 are used, their weight per unit area is heavy, and the It must be designed to withstand large weights. In particular, in the case of houses with wooden frame structures, the renovation (renovation) of the so-called second-hand house after 10 years is attempted without repainting, and ceramic siding boards and tiles are used. In this case, the design strength of existing external wall materials and columns is exceeded, and in many cases, these heavy ceramic siding boards and tiles cannot be used. Even if the house itself is renovated using ceramic siding boards or the tiles, it is necessary to remove existing outer wall materials and strengthen columns to prevent the design load of existing outer wall materials and columns from being exceeded. It often requires construction, which is extremely inconvenient for renovation work.

[0005] In the construction of ceramic siding materials,
Usually, a large flat panel of 3 × 6 (about 90 cm × about 180 cm) plates is fixed with nails, so it is necessary for the installer to carry heavy panels and position them on the wall. The burden is heavy. Therefore, in recent years, lightweight siding materials such as metal siding have been developed as lightweight outer wall materials. This is a structure in which embossed irregularities are formed on the surface of a thin metal plate made of aluminum or the like constituting the surface layer and the inner layer is made of urethane foam or the like, and a method of attaching this to an existing outer wall surface by nailing is adopted (for example, And JP-A-63-125770.

However, the uneven shape of the aluminum surface often lacks high-grade appearance due to excessive glossiness. In addition, since aluminum has a melting point of 660 ° C., there is a problem in terms of fire protection when an open flame comes into sharp contact with the outer wall surface due to fire or the like. Japanese Patent Application Laid-Open No. 7-217059 discloses a light-weight outer wall material which is formed into a panel using a thermoplastic resin as a main raw material. However, there is a problem that thermoplastic resin siding materials have poor fire protection properties and cannot be used as outer wall materials in areas designated as fire protection areas.

[0007]

SUMMARY OF THE INVENTION The present invention does not require separate work such as removal of existing outer wall materials and reinforcement of columns, and has a weight that can be easily attached to the outer wall of a general house with nails or screws. It is another object of the present invention to provide a panel having excellent fire resistance and a panel having excellent weather resistance.

[0008]

Means for Solving the Problems In view of the above situation, the present inventors have conducted intensive studies to solve the above problems, and as a result, completed the present invention. That is, the present invention
(1) A fire-retardant coating material having a laminated structure in which a layer made of a fire-retardant coating material and a coating film are laminated on the layer on the surface of a panel molded body containing at least a thermosetting resin, an inorganic filler and an inorganic fiber. And (2) the thermosetting resin is a phenolic resin, and the inorganic fillers are aluminum hydroxide and kaolin clay. The panel according to (1), which is a mixture with
(3) The panel according to (1) or (2), wherein the layer made of the fire protection coating material contains a fire protection component in an amount of 3 wt% or more and 60 wt% or less, and (4) the coating film is made of a weather-resistant paint. (1), (2) characterized in that it is a formed film
Or the panel according to (3).

According to the present invention, a layer made of a fire-resistant coating material and a coating film made of a highly durable paint are laminated on the outermost surface of a panel molded product containing a thermosetting resin, an inorganic filler and an inorganic fiber. This is based on the finding that excellent fire protection performance is exhibited.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail. The panel molded article of the present invention contains at least a thermosetting resin, an inorganic filler and an inorganic fiber. In the present invention, the panel molded body is obtained by molding a molding resin composition containing at least a thermosetting resin, an inorganic filler and an inorganic fiber. It refers to a molded body that is not formed. Further, in the present invention, a panel obtained by forming a layer made of a fire-retardant coating material on the surface of the molded article and further laminating a coating film on the layer is referred to as a panel.

The thermosetting resin used in the present invention includes phenol resins, unsaturated polyester resins, urea resins, epoxy resins, alkyd resins, melamine resins, urethane resins, silicon resins and mixtures thereof. Among them, a phenol resin and an unsaturated polyester resin are preferable because they exhibit good moldability, and phenol resins are particularly preferable because they have excellent flame retardancy. As a phenolic resin, even a resol-based phenolic resin,
Novolak-based phenolic resins may be used, and these resins may be added with an acid catalyst for resol-type phenolic resins and a basic catalyst for novolak-type phenolic resins for the purpose of increasing the degree of polymerization as necessary. Is also good. In the present invention, the use of a resol-based phenol resin that is liquid at room temperature without a catalyst is preferable from the viewpoint of ease of molding and productivity.

In the present invention, the content of the thermosetting resin is
10w from the viewpoint of panel durability and moldability during molding
t% or more is preferable, and 60 wt% from the viewpoint of fire protection.
Or less, more preferably 15 wt% or more,
0 wt% or less. When a phenol resin is used as the thermosetting resin, the content can be increased to 80 wt% because the resin has excellent fire resistance. The panel of the present invention needs to contain an inorganic filler. As inorganic fillers, aluminum hydroxide, kaolin clay, calcium hydroxide, magnesium hydroxide, dawsonite, calcium aluminate, calcium zinc borate, talc, microballoon, barium sulfide,
Silicic anhydride, diatomaceous earth, glass powder, mica, magnesium carbonate, antimony trioxide, zonotolite, tobermorite, wollastonite, silica sand, gypsum and the like can be mentioned. Among them, aluminum hydroxide and kaolin clay are preferred because they exhibit an endothermic effect in the range of 200 to 600 ° C. and have an effect of inhibiting a combustion reaction during panel combustion.

Although aluminum hydroxide and kaolin clay may be used alone, it is preferable to use a mixture of aluminum hydroxide and kaolin clay because the effect of inhibiting the combustion reaction becomes more remarkable. The mixing ratio of aluminum hydroxide and kaolin clay is preferably in the range of 1: 9 to 9: 1 by mass, more preferably 1: 5.
To 5: 1, particularly preferably 1: 3 to 3: 1. The content of the inorganic filler in the panel is preferably 30 wt% or more and 80 wt% or less, more preferably 40 w%.
It is not less than t% and not more than 70 wt%.

The panel of the present invention needs to contain inorganic fibers. Inorganic fibers are glass fibers, metal fibers,
Refers to mineral fibers and the like, and these can be used alone or in combination. Among them, glass fiber is preferable because it has high strength and is advantageous in cost. E-glass, C-glass, T-glass, AR-glass, and D-glass may be used as the type of glass fiber, but E-glass is preferred from the viewpoint of cost and the like. The inorganic fiber preferably has a fiber diameter of about 3 to 30 μm, more preferably 6 to 15 μm. The fiber length of the inorganic fibers is preferably 0.1 mm or more from the viewpoint of the strength of the molded product.

[0015] From the viewpoint of fluidity of the panel molding resin composition containing at least inorganic fiber, thermosetting resin and inorganic filler, which is used in the production of the panel molded article of the present invention,
00 mm or less, more preferably 3 to 30 mm
It is. The content of the inorganic fibers in the panel is preferably 3 wt% or more from the viewpoint of the strength of the panel, and from the viewpoint of fluidity when mixed with the thermosetting resin and the inorganic filler.
0 wt% or less is preferable. More preferably, it is 5 wt% or more and 20 wt% or less.

In the present invention, in addition to the above-mentioned components, a flame retardant, an ultraviolet absorber, an internal mold release agent, a thickener, etc. are added in order to impart further flame retardancy, weather resistance, mold releasability during molding and the like. May be added to the resin composition for panel molding, and it is particularly recommended to add an internal mold release agent to improve moldability. The content of the internal release agent in the panel is preferably 0.1 wt% or more and 10 wt% or less, more preferably 1 wt% or more and 5 wt% or less. Examples of the internal release agent include aliphatic hydrocarbon-based ones, higher aliphatic alcohol-based ones, fatty acid amide-based ones, metal soap-based ones, and phosphoric acid-based ones. Hydrophilic alcohols are preferred because of their high mold release effect.

The panel molded article of the present invention has on its surface a layer made of a fire-resistant coating material and a laminate having a structure in which a coating film is laminated on the layer. Here, the surface of the panel molded body refers to the outermost surface of the front surface of the panel, or the outermost surface of both the front and back surfaces of the panel. That is, the panel of the present invention is obtained by laminating a layer made of a fire-resistant coating material on the surface of a panel molded body obtained by molding the above-mentioned resin composition for panel molding, and further laminating a coating film on the layer. It can be obtained by

The layer composed of the fire-resistant coating material refers to a layer formed by coating the fire-resistant coating material on the surface of the panel molded body and then drying it. In the present invention, the fireproof coating material refers to a coating material containing a fireproof component that suppresses the amount of heat generated when the panel is burned. Examples of the fire protection component include ammonium polyphosphate, antimony trioxide, zirconium oxide, barium metaborate, melamine, pentaerythritol, zinc borate, phosphate, polyphosphate, tricresyl phosphate and the like.

Among these fireproof coating materials, the foamable fireproof coating material containing ammonium polyphosphate is suitably used for the panel of the present invention because it exhibits excellent fireproof properties. The amount of the fire protection component in the coating material is determined based on the value of 3
The amount is preferably not less than wt% and not more than 60 wt%, more preferably not less than 5 wt% and not more than 40 wt%. In addition, in the fire-resistant coating material, acrylic silicone resin, urethane resin, silicon resin,
A fluorine resin, an epoxy resin, an inorganic filler, and the like are included.

In the present invention, the thickness of the layer made of the fireproof coating material needs to be at least 10 μm, preferably at least 30 μm, more preferably at least 50 μm. If the thickness is less than 10 μm, it is difficult to form a uniform coating film,
The fire protection performance of the panel is reduced. The upper limit of the thickness is 500 μm or less, preferably 300 μm or less, in order to achieve uniform coating. The layer made of the fireproof coating material can be formed to a desired thickness by adjusting the solid content and the amount of the fireproof coating material.

In the present invention, the total calorific value was measured using a cone calorimeter III device manufactured by Toyo Seiki Co., Ltd.
Determined in accordance with the combustion test conducted based on the "Fire Protection Performance Test / Evaluation Work Method Manual" edited by the Japan Building Research Institute.
Further, the panel of the present invention has a coating film on the layer made of the fire-resistant coating material. This coating film has an effect as a protective layer for protecting the underlying layer made of the fire-resistant coating material from external impacts and the like. Examples of the coating film exhibiting such an effect include those obtained by dispersing an inorganic or organic pigment in a solvent and applying and drying the same, coating with an inorganic glass, clear lacquer, and the like.

Further, it is preferable to use a weather-resistant paint as a paint for forming the coating film, because the coating film can not only protect the layer made of the fire-resistant coating material but also has a weather resistance. . Examples of the weather-resistant paint include acrylic paints, urethane paints, acrylic silicone paints, silicone paints, and fluororesin paints. Acrylic silicone paints are preferred in terms of cost. In the present invention, the thickness of the coating film needs to be 10 μm or more, preferably 30 μm or more, and more preferably 50 μm or more. If the thickness is less than 10 μm, it is difficult to form a uniform coating film, and the protection performance and weather resistance for the layer made of the fire-resistant coating material are reduced. The upper limit of the thickness is 500 μm or less, and preferably 300 μm or less. The layers having these thicknesses can be formed by adjusting the solid content and the amount of the coating.

In order to confirm that these layers are formed on the molded panel of the present invention, the panel is cut perpendicularly to the surface thereof and observed with an electron microscope at a magnification of 500 to 1,000. In addition, the thickness of the layer made of the fire protection coating material and the thickness of the coating film laminated on the layer is defined as the minimum value of the measured values at 10 points randomly selected by observation with an electron microscope.
At this time, if it is difficult to distinguish between the layer made of the fire protection coating material and the coating film laminated thereon, the element contained only in the layer made of the fire protection coating material is replaced with EPMA (Electron P).
The boundary between the two layers is determined by measuring the distribution of elements contained only in the layer made of the fire-protection coating material in the cross section, with detection by a probe microanalyzer. For example, when a foamable fire-resistant coating material containing ammonium polyphosphate is applied to the surface of the panel molded body and dried, and then an acrylic silicon-based weather-resistant coating material is applied thereon, the distribution of phosphorus is measured by EPMA. Thereby, the boundary between the layer made of the fire-resistant coating material and the coating film can be determined, and the thickness can be determined by observing the boundary with an electron microscope at 500 to 1000 times.

The panel in the present invention refers to a flat plate having a flat surface, a panel having a design molded on the surface with a molding resin composition for a panel, or a panel-shaped molded article decorated by painting. The panel obtained by the present invention can be used as a building material such as an outer wall material, an inner wall material, a flooring material, a roofing material, a ceiling material, etc., but because of its durability, fire resistance, and design, it is particularly suitable as an outer wall material for reforming. It is suitable. For this reason, it is preferable that the panel structure be devised so that the panel can be more easily constructed and made robust.

If the thickness of the panel is too small, the shape retention and strength of the panel after combustion become remarkable, so it is recommended that the average thickness of the panel be 1 mm or more and 5 mm or less. In addition, from the viewpoint of workability, the size of one panel is set to 0.
The thickness is preferably ² m ² or more and 1 m ² or less, and the weight of one panel is preferably 0.5 kg or more and 6 kg or less, and it is also recommended to have a fitting structure at the upper, lower, left and right portions of the panel. Here, the fitting structure refers to a structure in which a part of a panel is provided with a projection and a part of another panel is provided with a recess, and the two panels are fitted with the projection and the recess so that the panels can be added together.

As a method of manufacturing the panel of the present invention, a mold having an intended panel shape and capable of being separated vertically is prepared, and the required amount of the above-mentioned molding resin composition is injected into the mold and heated. The molded panel is manufactured by a normal press molding method or an injection molding method in which the mold is opened and a target panel molded body is taken out. At this time, in order to include a sheet base made of inorganic fibers, a panel formed body containing the sheet can be obtained by setting the sheet base on a mold, then charging the raw materials, and applying heat and pressure. .

Next, a method for forming a layer made of a fire-resistant coating material on the surface of the panel molded product and a coating film to be laminated on the layer will be described. First, the panel molded body is sprayed with a fire-resistant coating material dispersed in a solvent such as water, alcohol, and toluene.The panel molded body is immersed in a fire-resistant coating material dispersed in a solvent such as water, alcohol, and toluene, or Water, alcohol, water, alcohol, etc. are applied to the panel molded body by a method such as brushing a fire-resistant coating material dispersed in a solvent such as toluene on the panel molded body.
A fire protection coating material dispersed in a solvent such as toluene is applied, and then dried by hot air or air drying to form a layer made of the fire protection coating material. Thereafter, a paint for forming a protective layer, a weather-resistant paint, and the like are further applied on the layer made of the fire-resistant coating material by the same method to form a coating film, whereby the panel of the present invention can be obtained.

Hereinafter, the present invention will be described with reference to examples.

[0029]

Example 1 25.0 parts by mass of a resole phenolic resin (BRL-240 manufactured by Showa Polymer Co., Ltd.), calcium hydroxide as a thickener (special grade reagent manufactured by Kanto Chemical Co., Ltd.)
0.3 parts by mass, 1.0 part by mass of zinc stearate (first grade reagent, manufactured by Kanto Chemical Co., Ltd.) as an internal release agent, aluminum hydroxide (Heidilite H32, manufactured by Showa Denko KK) 4
7.5 parts by mass, kaolin clay (ENGELHARD ASP
-400P) 17.5 parts by mass, 10.0 parts by mass of glass fiber having a fiber length of 3 mm (CS-3SK, manufactured by Nitto Boseki Co., Ltd.) was mixed with an omni mixer (OM-5, manufactured by Chiyoda Giken Kogyo Co., Ltd.) for about 1 part. The mixture was stirred for minutes to obtain a molding resin composition. 1
The resin composition for molding was quickly charged into a steel mold having a surface chromium plating finish mounted on a pressure press heated to 80 ° C., and the mold was closed and heated and pressed (1.17 × 10 ⁷ Pa). However, a panel molded body having the same shape as the inner shape of the mold was obtained. The average thickness is 2mm and the mass per unit area is 5kg
/ M ² .

The average thickness of the obtained panel molded product is a digital caliper CD-15C manufactured by Mitutoyo.
P was randomly measured at 10 points, and the average value was obtained. A fire-resistant coating material (Goethe No. 9 manufactured by Goethe House Co., 27 wt.
% Containing) was diluted with water as a solvent so that the thickness of the dried coating film was 50 μm, and applied by spray coating.
Further, an acrylic silicon-based paint (Luffon Ceramic, manufactured by Suzuka Fine Co., Ltd.) was similarly applied thereon so that the thickness of the coating film after drying became 50 μm to obtain a panel for evaluation.

This panel was cut into a size of 10 cm × 10 cm, and a cone calorimeter III of Toyo Seiki Co., Ltd.
Using the device, the combustion test was performed three times based on the “Fireproof Performance Test and Evaluation Business Method” edited by the Japan Building Research Institute. The total calorific value was 2.1, 6.0, 4.1 MJ. / M ² . This panel was cut into a size of 10 cm × 10 cm, and a xenon-type accelerated weathering tester (Ci4000,
(Toyo Seiki Seisakusho), temperature 63 ° C, humidity 50%, 2
Irradiation for 4 hours, spraying water for 18 minutes every 2 hours, irradiation at 120 W / m ² (light source wavelength 300-400 nm)
When the test was performed for 00 hours, no abnormality was found in the appearance.

[0032]

Examples 2 to 5 Evaluation panels were prepared and tested in the same manner as in Example 1 except that the thickness of the layer made of the fireproof coating material and the thickness of the coating film were changed as shown in Table 1. Table 1 shows the results.

[0033]

Comparative Examples 1 and 2 Evaluation panels were prepared and tested in the same manner as in Example 1 except that the thickness of the layer made of the fireproof coating material or the thickness of the coating film was 10 μm or less. Table 1 shows the results. In Comparative Example 1, deterioration of the panel surface is observed after the weather resistance test. In the comparative example 2, the upper limit value of the total heat generation value is larger than that of the example.

[0034]

Comparative Examples 3 and 4 An evaluation panel was prepared and tested in the same manner as in Example 1 except that only one layer of a fire-resistant coating material or a layer of a coating film formed of an acrylic silicone paint was used. Was. Table 1 shows the results. In Comparative Example 3, deterioration of the panel surface is observed after the weather resistance test. In Comparative Example 4, the upper limit value of the total calorific value is larger than that of the embodiment.

[0035]

Comparative Example 5 A panel was prepared and tested in the same manner as in Example 1 except that the total amount of aluminum hydroxide and kaolin clay in the raw materials was changed to calcium carbonate. Table 1 shows the results. The upper limit of the total calorific value is larger than that of the embodiment.

[0036]

[Table 1]

[0037]

According to the present invention, it is possible to obtain a panel which is excellent in fire resistance, has no surface deterioration, and is excellent in weather resistance.

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2E001 DE01 FA04 GA12 GA42 HD11 HF12 2E162 CD04 EA18 4D075 CA18 CA32 DA06 DA23 DB46 DB47 DB48 DB49 DB50 DB52 DB54 DC02 EA07 EA10 EA19 EA43 EB16 EB22 EB33 EB38 EC01

Claims (4)

[Claims] 1. A fire-retardant laminate comprising a layer made of a fire-retardant coating material on a surface of a panel molded body containing at least a thermosetting resin, an inorganic filler and an inorganic fiber, and a coating film laminated on the layer. A panel, wherein the thickness of a layer made of a coating material and the thickness of a coating film laminated on the layer are each 10 μm or more. 2. The thermosetting resin is a phenol resin,
The panel according to claim 1, wherein the inorganic filler is a mixture of aluminum hydroxide and kaolin clay. 3. The layer made of a fire protection coating material contains 3 w of a fire protection component.
3. The panel according to claim 1, wherein the content is at least t% and at most 60 wt%. 4. The panel according to claim 1, wherein the coating film is a film formed from a weather-resistant paint.