JP2003205579A - Heat-resistant panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat-resistant panel which imparts both adhesive properties and ease of separation because of its sufficient adhesive strength when used as a facing and ease of separating an aluminum foil when released from the panel. <P>SOLUTION: In the heat-resistant panel constituted of a nonwoven fabric of a synthetic fiber, an adhesive and an aluminum foil laminated, in that order, on one side or both sides of a phenol resin foam layer, the average fiber diameter of the nonwoven fabric of a synthetic fiber is 10 to 50 μm and the weight of an amount applied of the fabric is 20 to 100 g/m<SP>2</SP>and further, the average apparent density of the fabric is 0.1 to 0.3 g/cm<SP>3</SP>. The adhesive is made of a vinyl acetate emulsion and its applied amount is 20 to 120 g/m<SP>2</SP>in terms of a solid content. <P>COPYRIGHT: (C)2003,JPO

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat-resistant panel excellent in flame retardancy and heat insulation which is widely used for building materials and the like, and particularly relates to a phenol resin foam layer. The present invention relates to a heat-resistant panel formed by laminating face materials having heat resistance, flame retardancy and the like on one or both surfaces. 2. Description of the Related Art Conventionally, heat-resistant panels, heat-insulating panels, and flame-retardant heat-insulating panels used for building materials such as ceiling boards are generally provided on one side or both sides of a foamed resin such as phenolic resin foam. And a heat-resistant, flame-retardant face material and the like are integrally adhered and laminated. Aluminum foil is used as a face material having heat resistance, flame retardancy, and the like, and a vinyl acetate emulsion-based adhesive is used as an adhesive having low cost and excellent workability. However, when a metal surface material such as aluminum foil is simply bonded using a vinyl acetate emulsion-based adhesive, the metal surface material peels off during handling or the like and cannot be used practically. There have been many proposals for improvement. [0003] Such heat-resistant panels and heat-insulating panels are disclosed in, for example, JP-A-1-168411 (first known technique), JP-A-1-188572 (second known technique), and JP-A-6-235256. Gazette (third known technology)
Panels having various configurations are known as exemplified in the above. The above-mentioned first publicly known technique is configured such that an adhesive such as a vinyl acetate resin is applied in advance to the surface of the face material when integrally forming the face material made of phenol resin foam and aluminum foil or the like. This is a technique relating to a phenolic resin foam laminate having excellent adhesion. [0004] The above-mentioned second known technique is a vinyl acetate emulsion-based adhesive in which aluminum oxide is previously added to the surface of a phenolic resin foam and a surface material made of a metal plate such as an aluminum plate. This is a technique relating to a phenolic resin foam laminate having excellent adhesiveness constituted by applying an agent. According to the third known technique, when integrally forming a phenolic resin foam and a face material made of a thin metal plate such as an aluminum plate, a vent groove having a substantially concave cross section bonded with an adhesive such as a vinyl acetate emulsion is used. This is a technique relating to a phenolic resin foam laminate having excellent adhesiveness, which is formed through a nonwoven fabric formed at a constant pitch. However, in the prior arts shown in the above-mentioned first to third prior arts, a metal face material is attached and laminated on one or both sides of a phenol resin foam to form an integrated structure. In this case, a strong adhesive force is provided by various devices. However, there is a problem that a composite plate of a synthetic resin foam such as a phenol resin foam and a metal plate becomes an industrial waste when discarded. As a recent situation, awareness of environmental protection has increased, and disposal of scrap materials at construction sites and waste materials at the time of dismantling houses has become a social problem. If only the metal plate can be separated, the subsequent processing is also easy. In addition, the demand for recycling is increasing, and among metals, aluminum is particularly high in recyclability, and if it can be separated, it can be reused as a resource. In addition, in the prior art, in order to compensate for the lack of adhesion between the phenolic resin foam and the metal surface material, which is generally called,
Since the composition and application method of the adhesive are devised, or a specially shaped member is used, there are problems that the process becomes complicated and the cost may be increased. SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems at the time of disposing of a conventional panel, and has a sufficient adhesive strength as a surface material, and separates aluminum foil during sorting. It has excellent heat resistance, flame retardancy, and heat insulation, which can provide both adhesiveness and ease of separation, which is easy, and can provide products at a low cost with a simple manufacturing process. Panels are provided. [0007] A heat-resistant panel according to the present invention is a fundamental improvement of the above-mentioned conventional problems. That is, the present invention relates to a heat-resistant panel comprising a laminated plate formed by sequentially laminating a synthetic fiber nonwoven fabric, an adhesive, and an aluminum foil on one or both surfaces of a phenolic resin foam layer, wherein the average fiber diameter of the synthetic fiber nonwoven fabric is Is 10-5
0 μm, the basis weight is 20 to 100 g / m ² , the average apparent density is 0.1 to 0.3 g / cm ³ , the adhesive is a vinyl acetate emulsion adhesive, and the coating amount is 20 It is a heat-resistant panel characterized by being 〜120 g / m ² . [0008] The heat-resistant panel according to the present invention has both adhesiveness and releasability, which have sufficient adhesive strength as a surface material of the panel and easy separation of the aluminum foil upon separation. I can do it. In addition, since aluminum foil, which is easy to recycle, is used as the surface material having heat resistance, flame retardancy, etc., it is possible to use a vinyl acetate emulsion adhesive which is a low cost and excellent workability adhesive as it is. The manufacturing process is simple and products can be provided at low cost. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The structure of the heat-resistant panel according to the present invention will be specifically described as follows. That is, in the present invention, first, a phenol resin is foamed between specific synthetic fiber nonwoven fabrics to be integrally formed. This facilitates integral molding by continuous lamination with a foamed resin such as a phenolic resin foam, and mass production can be performed at low cost. [0010] A vinyl acetate emulsion-based adhesive is applied to one or both sides of the phenolic resin foam base plate on the phenolic resin base plate having the above-mentioned synthetic fiber non-woven fabric, and aluminum is placed on the adhesive layer. The heat-resistant panel of the present invention is manufactured by laminating a foil face material and integrally laminating the face material to the phenol resin foam layer via the adhesive layer. Hereinafter, the contents of the present invention will be described in more detail. The most different point of the present invention from the prior art is that the synthetic non-woven fabric used has a specific average fiber diameter, specific weight, and average apparent density. By using the synthetic fiber non-woven fabric, an appropriate adhesive strength is imparted when bonded to an aluminum foil via an adhesive, and at the same time, it functions as a buffer when the aluminum foil is peeled off. When a woven fabric is used, uniform adhesion is obtained, and it is difficult to obtain good results as in the present invention. In the present invention, the average fiber diameter of the synthetic fiber nonwoven fabric is 10 to 5
0 μm. Preferably it is 12 to 30 μm. If the average fiber diameter is less than 10 μm, the denseness is too high, and the effect of the adhesive applied thereon becomes insufficient, and the aluminum foil of the surface material is peeled off, making it difficult to withstand practical use. Conversely, if the average fiber diameter exceeds 50 μm, the phenol resin raw material serving as the core material during integral molding tends to exude, and the effect of the adhesive applied thereon also becomes insufficient. The basis weight of synthetic fiber non-woven fabric is 20 ~
100 g / m ² . Preferably it is in the range of 30 to 80 g / m ² . If the basis weight is less than 20 g / m ² , the phenol resin raw material is likely to exude, which is not preferable, and if the basis weight exceeds 100 g / m ² , it becomes expensive as a nonwoven fabric. It is not preferable from the viewpoint. The average apparent density (weight per unit area / average thickness) of the synthetic fiber nonwoven fabric is 0.1 to 0.3 g / cm.
³ If it is less than 0.1 g / cm ³ , the phenol resin raw material tends to exude, which is not preferable.
If it exceeds ³ g / cm ³ , the compactness is too high, and the effect of the adhesive applied thereon becomes insufficient, which is not preferable. The synthetic fiber non-woven fabric used in the present invention is a non-woven fabric made of a material such as polyester, polypropylene, or polyamide, and is not particularly limited. However, when economical (price) is required, a non-woven fabric made of polyester or polypropylene is preferably used. [0012] Nonwoven fabrics are classified into several types according to their production methods and the like. Generally, wet nonwoven fabrics, adhesive nonwoven fabrics, and non-woven fabrics are used depending on the method of forming the bond between fibers. Type, stitch bond type, self heat fusion (thermal bond) type, spunlace type, melt blown type, spun bond type, etc. In particular, spunbond nonwovens are mass-produced, with continuous processes from melt-drawing spinning to web formation and self-heat fusing, and do not require the use of a solvent and do not require immersion of an adhesive and require a process. It is suitable for the present invention because it is economical for reasons such as simplicity, and because the nonwoven fabric has high physical properties (such as tearing strength) for its low weight per unit area because the nonwoven fabric is composed of continuous long fibers. Can be used. The adhesive used in the present invention is a vinyl acetate emulsion-based adhesive having an appropriate adhesive strength. The vinyl acetate emulsion-based adhesive is an adhesive obtained by emulsion polymerization using vinyl acetate as a main component and water as a medium. Examples thereof include those specified in JIS K 6804 “vinyl acetate emulsion wood adhesive”. For example, epoxy adhesives other than vinyl acetate emulsion adhesives are suitable because the adhesive strength is too high, separation is impossible, and the adhesive layer after curing is too hard, and processing properties such as cutting are poor. Absent. It is also disadvantageous in terms of economy. The coating amount of the vinyl acetate emulsion-based adhesive is 20 to 120 g / m ² in terms of solid content after drying and curing. Preferably,
30 to 100 g / m ² . Adhesive application amount 20g /
When it is smaller than m ² , it is not preferable because the adhesive strength becomes insufficient, and when the amount of the adhesive applied exceeds 120 g / m ² , it becomes difficult to separate the aluminum foil on the surface, and also from the viewpoint of economy. Not preferred. There are no particular restrictions on the components of the aluminum foil used in the present invention, but JIS H 41
An aluminum foil specified by 60 "aluminum and aluminum alloy foil" is preferred. The same applies to the thickness of the aluminum foil, but the thickness is more preferably 12 to 50 μm in terms of strength during handling, ease of separation and separation, and economic efficiency. The phenol resin used as a raw material of the phenol resin foam of the present invention is not particularly limited, but a resol type phenol resin or the like is preferably used. According to the method for producing a phenolic resin foam of the present invention, a surfactant, a foaming agent, and a catalyst are added to a phenolic resin, mixed and continuously discharged onto a synthetic fiber nonwoven fabric running as a foamable composition. Further, a laminating method of producing a phenolic resin foam by coating the upper surface with a synthetic fiber nonwoven fabric and then completing the foaming and curing can be suitably used. In this case, the synthetic fiber nonwoven fabric and the foam are bonded by the adhesive force of the phenol resin itself, and there is no need to use an adhesive. Among the laminating methods, those employing the floss method as a method for continuously discharging the foamable composition are more preferable as the production method. Normally, when the foamable composition is discharged from a nozzle, the discharge liquid is discharged as a liquid, but the floss method is to discharge as a foam that has already foamed to some extent, and the uncured foamable composition is This has the effect of suppressing seepage from the face material. As the surfactant, a nonionic surfactant is usually used. For example, silicone-based surfactants such as polydimethylsiloxane, block copolymers of ethylene oxide and propylene oxide, alkylene oxides and nonylphenols, condensates of alkylphenols such as dodecylphenol, condensates of alkylene oxides and castor oil, Fatty acid esters such as polyoxyethylene fatty acid esters are used.
Difluoromethane (HFC32) as a foaming agent,
1,1,1,2-tetrafluoroethane (HFC134
a), HFCs such as 1,1-difluoroethane (HFC152a), 1-chloro-1,1 difluoroethane (HFC
HCFCs such as CFC142b) and hydrocarbons such as normal butane, isobutane, normal pentane, cyclopentane and isopentane are used. As the catalyst, an acidic compound such as an inorganic acid and an organic acid is used, and aromatic sulfonic acids such as toluenesulfonic acid, xylenesulfonic acid, and phenolsulfonic acid are preferably used. As a curing aid, resorcinol, cresol, o-methylolphenol, p-methylolphenol and the like can also be added. Further, the curing catalyst and the curing assistant may be used after being diluted with a solvent such as diethylene glycol. Example 1 and Comparative Examples 1 to 4 The present invention will be described in more detail with reference to Examples and Comparative Examples. In concretely implementing the heat resistant panel of the present invention, first, a spinning condition was adjusted using a polyethylene terephthalate resin as a raw material and a fiber diameter of 14.3 μm using a spunbond nonwoven fabric manufacturing apparatus. The web forming conditions were further adjusted to obtain a nonwoven fabric having a basis weight of 30 g / m ² and an average apparent density of 0.2 g / cm ³ . Also, the web forming conditions and thickness were adjusted with the same fiber diameter to obtain a nonwoven fabric having a basis weight of 10 g / m ² and an average apparent density of 0.2 g / cm ³ . Next, a phenol resin foam serving as an original plate is manufactured. At this time, except for a synthetic fiber nonwoven fabric,
All were manufactured by the following steps. As a phenol resin, a resol type phenol resin was synthesized, and after adjusting the moisture content, a surfactant was added. The phenolic resin, the foaming agent, and the acid catalyst are mixed by a mixer, continuously discharged onto the running synthetic fiber nonwoven fabric facing, and further coated with the same synthetic fiber nonwoven fabric facing. A continuous laminate was formed, and then the continuous laminate was sandwiched and passed between double conveyors set at a predetermined temperature, foamed and cured to obtain a phenol resin foam having a predetermined thickness. The obtained phenolic resin foam is cut into a predetermined length,
Heat treatment was performed at 5 ° C. for 3 hours to complete the curing. Note that isobutane was used as a foaming agent, and a mixture of organic toluenesulfonic acid, dihydric phenol, and a diluent was used as an acid catalyst. On the above-mentioned phenolic resin foam, various phenolic resin foam laminates having the composition shown in Table 1 and having different basis weights, adhesive types, and application amounts were obtained. The measurement of the adhesive strength was performed according to the following procedure. First, a specimen having a width of 5 cm and a length of 12 cm is cut out from the phenol resin foam laminate. Next, about 2 cm of the aluminum foil face material at the end in the length direction was peeled off, gripped with a paper clip, connected to a tensile tester, and turned downward in the vertical direction at a speed of about 1 cm / sec. The aluminum foil face material and the core material are peeled while keeping the peel angle at 45 degrees. The maximum value at that time was used as the measured value, the average of the measured values of the five test specimens was determined, and the value rounded to the nearest one was used as the adhesive strength (N / 5 cm
Width). Generally, the adhesive strength of the phenol resin foam to the synthetic fiber nonwoven fabric is 4 (N / 5 cm width) or more.
On the other hand, in general, the practically required adhesive strength of the surface material is 0.1.
(N / 5 cm width) or more. Adhesion strength is 0.1 (N /
If the width is less than 5 cm, the surface material may peel off during handling or transportation. Also, as the peeling part, unless it is peeling from the interface between the aluminum foil and the synthetic fiber nonwoven fabric,
It doesn't make sense to separate and recycle. That is, the adhesive strength required for the ease of separation of the aluminum foil is 0.1 to
4 (N / 5 cm width).
This is the interface between the aluminum foil and the synthetic fiber nonwoven fabric. The adhesive strength and the peeling point measured as described above were evaluated. The peeled portions are as follows. A: Peeling from the interface between the aluminum foil and the synthetic fiber nonwoven fabric B: Peeling from the interface between the synthetic fiber nonwoven fabric and the phenolic resin foam C: Peeling (breaking) at the base material of the phenolic resin foam The criteria for the comprehensive judgment on the ease of separation of the aluminum foil are as follows. A: The peeled portion is A and the adhesive strength is 0.1 (N / 5 cm
Width) or more and less than 4 (N / 5 cm width), excellent in ease of separation. X: The peeled part is other than A, and XX inferior in ease of separation; The peeled part is A, but the adhesive strength is 0. .1 (N /
Table 5 shows the results of evaluations of Examples and Comparative Examples in which the adhesive strength as a surface material was inferior. [Table 1] [Table 2] The heat-resistant panel according to the present invention has sufficient adhesive strength as a surface material of the panel and has an easy-to-separate aluminum foil at the time of separation. Can also be added. Moreover, heat resistance,
The easy-to-recycle aluminum foil is used as the face material with flame retardancy, etc., and the vinyl acetate emulsion adhesive, which is a low cost and excellent workability adhesive, can be used as it is, simplifying the manufacturing process. Products can be provided at low cost. Further, the heat-resistant panel according to the present invention is constituted by integrally laminating a non-flammable and highly moisture-proof soft face material of aluminum foil and a phenol resin foam having excellent heat resistance and heat insulation properties. It has the effect of maintaining heat resistance, flame retardancy and heat insulation even when heated to a very high temperature.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E04B 1/94 E04B 1/94 V E04C 2/26 E04C 2/26 VF term (Reference) 2E001 DD01 DE01 FA14 GA12 GA22 GA28 GA42 HB04 HD02 HD11 LA04 2E162 CB24 CD01 CD15 4F100 AB10C AB33C AK01B AK22G AK33A AK34 BA03 BA07 CA01 CA02 DG15B DJ01A EK06 GB07 JJ02 JJ03 JJ07 YY00B

Claims (1)

Claims: 1. A heat-resistant panel comprising a laminated plate formed by sequentially laminating a synthetic fiber nonwoven fabric, an adhesive, and an aluminum foil on one or both sides of a phenolic resin foam layer. The average fiber diameter of the fiber nonwoven fabric is 10 to 50 μm,
The basis weight is 20 to 100 g / m ² , the average apparent density is 0.1 to 0.3 g / cm ³ , the adhesive is a vinyl acetate emulsion adhesive, and the applied amount is 20 to 120 g in terms of solid content. / M ² .