JP2005074681A - Manufacturing method for metal panel or board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a metal panel excellent in fire resistance by sprinkling a foamable resin composition FC, wherein the ratio of a resin compound RC to a curing agent CA is stabilized by suppressing the thickening of resin compound RC, over a face material (FP). <P>SOLUTION: A fire retardant having no curing action with respect to a resole type phenol resin is mixed with the resole type phenol resin along with a foam stabilizer and a foaming agent to prepare the resin compound RC and this resin compound RC is fed into a premixing head 30. After the resin compound RC is kneaded with a fire retardant showing action for curing the resole type phenol resin in the premixing head 30, the kneaded mixture of the resin compound RC and the fire retardant FR is immediately fed out to the mixing head 50 to be mixed with the curing agent CA under stirring and the obtained foamable resin composition FC is sprinkled over the recessed parts of one face material FP. Subsequently, the other face material BP is superposed on the face material FP and the foamable resin composition FC is foamed and cured. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a metal panel or a metal board excellent in fire resistance with high productivity without causing fluctuations in manufacturing conditions.

  For building materials such as wall materials and ceiling materials, metal panels or metal boards (hereinafter collectively referred to as metal panels) in which resin foams such as urethane, nurate and phenol are filled between face materials are used. Metal panels are building materials that take advantage of lightness, but resol type phenolic resins have begun to be used in resin foams to improve fire resistance. In order to improve fire resistance, a small amount of inorganic flame retardants such as aluminum hydroxide, magnesium hydroxide, boric acid and phosphate, and organic flame retardants such as chlorine and bromine may be added to the resol type phenol resin.

  A resin compound in which a foam stabilizer, a foaming agent, a flame retardant, etc., is blended with a resol type phenolic resin is stored in a tank having a temperature control function, and is sent out from the tank when manufacturing a metal panel. The resin compound of the resol type phenol resin is sent to a mixing head with a stirrer through a pipe and stirred and mixed with a curing agent sent from another tank. After the resin mixture is distributed in the concave portion of the face material that has been molded into a groove shape in advance and covered with the other face material, it is introduced into a heating press and heated to be cured by foaming. A sandwiched metal panel is produced.

  In building material applications, the fire performance required for metal panels has become even higher with changes in fire protection standards. In order to improve the fire prevention performance, a large amount of a flame retardant such as aluminum hydroxide or boric acid may be added. However, when a resin compound is prepared by adding a large amount of a flame retardant such as aluminum hydroxide or boric acid to a resol type phenolic resin used in a resin foam of a metal panel, the resol type phenolic resin is converted by the added boric acid. The resin cures and the viscosity of the resin compound increases as the time from compounding elapses.

The increase in the viscosity of the resin compound hinders the flow of the resin compound inside the pipe from the tank to the mixing head, and causes the pipe to be blocked. Even if the pipe does not become clogged, the flow resistance of the resin compound increases and the ratio of the resin compound kneaded in the mixing head: the curing agent varies, so the performance of the resulting metal panel is not stable. Even after the resin compound is agitated and mixed with the curing agent by the mixing head and discharged onto the face material, the foam curing is delayed. As a result, it becomes difficult to stably manufacture a metal panel having a certain quality.
Therefore, the present inventors have proposed a method in which boric acid, which has a curing action on a resol type phenolic resin, is blended in a curing agent, and the resin compound and the curing agent are sent to the face material immediately after stirring and mixing with a mixing head. (Patent Document 1).
JP 2002-273743 A

  The proposed method can form a resin foam containing a larger amount of boric acid (a flame retardant) than the conventional method. As a result of further investigation and research on the behavior until each component contained in the resin foam is foamed and cured, the present inventors have added a flame retardant exhibiting a curing action to the resol type phenol resin and immediately after mixing the resin compound. When the prepared foamable resin composition is sprayed on the faceplate, the curing of the resol-type phenolic resin due to the flame retardant formulation is suppressed, and the resin compound and the curing agent at a predetermined ratio are faced under stable conditions. We found that it can be sent out to the material.

  The present invention has been completed on the basis of such knowledge, and even if a large amount of a flame retardant is blended with a resol type phenolic resin for improving fire resistance, the production conditions are unstable due to thickening of the resin compound. The objective is to produce a metal panel with high fire resistance and high productivity.

  The method for producing a metal panel or board of the present invention adjusts a resin compound in which a flame retardant having no curing action on a resol type phenolic resin is mixed with a foam stabilizer and a foaming agent together with the resol type phenolic resin, and premixes the resin compound. The foamable resin composition obtained after being fed into the head and kneaded with a flame retardant exhibiting the action of curing the resol type phenolic resin, and then immediately sending the resin compound and flame retardant kneaded material to the mixing head and stirring and mixing with the curing agent It is characterized in that the foamed resin composition is foamed and cured after the product is distributed in the concave portion of one face material and the other face material is overlapped.

  Examples of the flame retardant previously mixed with the resol type phenol resin include aluminum hydroxide, magnesium hydroxide, dihydrate gypsum, tris (tribromoneopentyl) phosphate, tetrabromobisphenol A, triphenyl phosphate, and the like. Examples of the flame retardant mixed in the resin compound immediately before being sent to the mixing head include boric acid and borax.

  In this invention, the flame retardant mix | blended with a resin compound is divided into the flame retardant which does not have a hardening effect with respect to a resol type phenol resin, and the flame retardant with a hardening effect. A flame retardant having no curing action is blended in advance with a resol type phenolic resin to adjust the resin compound, and a flame retardant having a curing action is blended with the resin compound immediately before the resin compound is stirred and mixed with the curing agent.

  Since the heterogeneous flame retardant is mixed with the resol type phenol resin in two stages, the ratio of the total flame retardant in the resin foam can be increased, and the fire resistance of the manufactured metal panel is improved. In addition, since a flame retardant having a curing action is added to the resin compound separately from the curing agent just before mixing the resin compound and the curing agent, there are few restrictions on the amount of flame retardant that can be added, and a large amount of difficulty. A flame retardant can be blended into a resin compound. In addition, the resin compound has a small increase in viscosity even after a long period of time after adjustment, and a foamable resin composition having a target composition can be obtained under stable conditions, and the quality of the metal panel is also stabilized.

In the present invention, for example, a foamable resin composition prepared by the apparatus shown in FIG. 1 is fed onto a face plate to produce a metal panel.
The resin compound RC, which is the main component of the foamable resin composition FC, is stored in a tank 10 having a temperature adjusting function, and is appropriately stirred by a stirrer 11. A resin compound pipe 12 is opened at the bottom of the tank 10, and the other end of the pipe 12 faces the premixing head 30. A pump 13 for sending the resin compound RC from the tank 10 to the premixing head 30 is incorporated in the middle of the pipe 12.

The phenolic resin foam is manufactured from a resol type or novolac type phenolic resin. In the present invention, a resol type phenolic resin having excellent fire resistance is used, and a curing action is exerted on a foaming agent, a foam stabilizer, and a resol type phenolic resin. Resin compound RC is prepared by adding a flame retardant or the like not exhibiting the above. The amount of flame retardant added is increased or decreased according to the required fire resistance.
Low-boiling hydrocarbons such as petroleum ether, naphtha, pentane, hexane and other volatile petroleums, methylene chloride, carbon tetrachloride, trichloroethane, fluorotrichloromethane, trifluorotrichloromethane, etc. There is.

  The flame retardant added to the resin compound RC mainly composed of a resol type phenol resin is a flame retardant that does not exhibit a curing action on the resol type phenol resin, such as tris (tribromoneopentyl) phosphate, tetrabromobisphenol A. , Organic flame retardants such as triphenyl phosphate, and inorganic flame retardants such as aluminum hydroxide, magnesium hydroxide, and dihydrate gypsum.

  The flame retardant FR that exhibits a curing action on the resol type phenolic resin is accommodated in a hopper 20 having a temperature adjusting function. A feeder 21 having a weighing function is provided at the bottom of the hopper 20, and a predetermined amount of the flame retardant FR is sent to the premixing head 30 through the feeder 21 through the feeder 21.

  Examples of the flame retardant FR include boric acid and borax. Since the flame retardant FR is mixed with the resin compound RC just before the foamable resin composition FC is sent to the face material FP, the kneaded product of the resin compound RC and the flame retardant FR with an uncured resol type phenolic resin is premixing head. Thus, the pipe 35 is not blocked by the kneaded material. As a result, the mixing ratio of the flame retardant FR to the resin compound RC can be increased, and the fire resistance of the resulting metal panel is improved.

  The mixing ratio of the resin compound RC: the flame retardant FR is generally 10: 1 to 10:10 in consideration of the fact that a flame retardant that does not exhibit a curing action with respect to the resol type phenol resin is preliminarily blended in the resin compound RC. (Mass ratio). When higher fire resistance is required, the amount of the flame retardant FR is increased to 10: 3 or more. However, in order to stably feed the kneaded material in the pipe 35, the flame retardant FR is added to 10: 7 or less. It is preferable to suppress the ratio.

The pipes 12 and 22 face the open upper portion of the premixing head 30. In the premixing head 30, a stirrer 32 is disposed inside an outer jacket 31 that receives a resin compound RC and a flame retardant FR falling from the pipes 12 and 22, and an output shaft of the motor 33 is connected to the stirrer 32. ing. The stirrer 32 preferably has a screw shape that promotes the dropping of the resin compound RC and the flame retardant FR and promotes the stirring and mixing in the outer jacket 31.
A tray 34 is disposed below the premixing head 30, and a pipe 35 extends from the tray 34 to the mixing head 50. A pump 36 is provided in the middle of the pipe 35, and a kneaded product of the resin compound RC and the flame retardant FR is sent out from the tray 34 to the mixing head 50 by the pump 36.

Curing agent CA is fed into mixing head 50 through another piping system. The curing agent CA is accommodated in a tank 40 having a temperature adjusting function, and a curing agent pipe 42 is opened at the bottom of the tank 40. The other end of the pipe 42 faces the open top of the mixing head 50, and the curing agent CA is sent from the tank 40 to the mixing head 50 by the pump 43. As the curing agent CA, an organic sulfonic acid such as phenolsulfonic acid, paratoluenesulfonic acid, xylenesulfonic acid, benzenesulfonic acid or the like, or an aqueous solution in which two or more kinds are mixed is used.
The mixing head 50 includes a stirrer 52 that is driven by a motor 51, and a foaming resin composition FC is prepared by stirring and mixing a curing agent CA with a kneaded product of a resin compound RC and a flame retardant FR. A nozzle 53 that sends out the foamable resin composition FC toward the face material FP is attached to the bottom of the mixing head 50.

  As the face material FP, a metal plate, foil, woven fabric, non-woven fabric, paper, film, or the like is used. Examples of the metal plate include an iron plate, a galvanized steel plate, an Al plated steel plate, a Zn—Al plated steel plate, a Zn—Al—Mg plated steel plate, an aluminum plate, a copper plate, another metal or alloy plate, and a painted plate. The same kind of material can be used for the metal foil. Examples of the woven fabric and non-woven fabric include organic fibers such as polyester, nylon, vinylon, cotton, and wool, inorganic fibers such as glass, rock wool, ceramic fibers, and metal fibers, or a cloth in which various fibers are mixed. Paste western paper made from pulp, Japanese paper made from Kozo, Mitsuma, Gambi, special paper with other fiber mixed paper, polyester, nylon, vinylon, polyethylene, polypropylene, etc. Combined laminate film, vapor deposition film, etc. can also be used for the face material FP.

After a predetermined amount of foamable resin composition FC is sprayed on the face material FP, the other face material BP is overlapped, and both end portions in the width direction of the face materials FP and BP are engaged with each other, and then the whole is pressurized and heated. Thus, when the foamable resin composition FC is foamed and cured, a metal panel (FIG. 2) in which the resin foam RF is sandwiched between the face materials FP and BP is manufactured.
Although it is possible to manufacture a metal panel by a batch method using cut plates for the face materials FP and BP, if a long strip material is used for the face materials FP and BP, a metal panel can be manufactured with high productivity. For example, in a production line that uses steel strips for face materials FP and BP, a continuous amount of foaming is applied to the concave portions of the formed face material FP by continuously bending the both ends of the steel strip in the width direction by roll bending. After spraying the resin composition FC, it is overlapped with the other steel strip and meshed with each other at both ends in the plate width direction, then passed through a double conveyor placed in the heating furnace, and foamed resin under pressure and heating The composition FC is foam-cured.

Viscosity (20 ° C.): 600 mPas resol type phenolic resin: 54 parts by mass methylene chloride (foaming agent): 3 parts by mass, silicone-based nonionic surfactant (foam stabilizer): 3 parts by mass, aluminum hydroxide (flame retardant) ): 40 parts by mass were blended to prepare Resin Compound RC.
Boronic acid as a flame retardant FR having a curing action on a resol-type phenol resin and a 75% aqueous solution of phenolsulfonic acid as a curing agent CA were separately prepared.

  Resin compound RC was placed in tank 10, flame retardant FR was placed in hopper 20, and curing agent CA was placed in tank 40. The resin compound RC is continuously fed from the tank 10 through the pipe 12 having a diameter of 30 mm to the premixing head 30 using the pump 13, and a predetermined amount of the flame retardant FR is put into the premixing head 30 from the hopper 20 by the measuring feeder 21. . The target amounts to be introduced into the premixing head 20 were set to resin compound RC: 10 kg / min and flame retardant FR: 4 kg / min so that the mass ratio of resin compound RC: flame retardant FR was 10: 4.

After the resin compound RC and the flame retardant FR were kneaded by the premixing head 30, the kneaded material was immediately discharged to the receiving tray 34 and further fed to the mixing head 50 by the pump 36. Resin compound RC and flame retardant FR kneaded material: Curing agent CA kneaded product: resin compound RC and flame retardant FR kneaded material: 14 kg / kg so that the mass ratio of the curing agent CA is 14: 1.5. Min, curing agent CA: 1.5 kg / min.
The kneaded material was mixed with the curing agent CA fed from the tank 40 via the pipe 42, and then discharged and filled as a foamable resin composition FC into the face material FP held at 70 ° C. and bent at both ends.

  The resin compound RC had a viscosity (20 ° C.) of 9000 mPas and was sent to the premixing head 30 without adding the flame retardant FR, so that the piping 12 was not blocked. When the introduction amounts into the premixing head 30 were the resin compound RC: 10 kg / min and the flame retardant FR: 4 kg / min, the rotation speeds of the pump 13 and the feeder 21 were 65 rpm and 30 rpm, respectively. The rotational speed of the pump 36 required for sending the resin compound RC and flame retardant FR kneaded material at a flow rate of 14 kg / min is 14 rpm, and the rotational speed of the pump 43 required for sending the curing agent CA at a flow rate of 1.5 kg / min. Was 14 rpm. After the curing agent CA was blended in the kneaded product of the resin compound RC and the flame retardant FR, the time required for the foamable resin composition FC to cure was 2 minutes 30 seconds.

  When 24 hours had passed since the preparation of the resin compound RC, the viscosity of the resin compound RC in the tank 10 was measured and found to be 9200 mPas, which was almost the same as that immediately after the adjustment. The pumps 13 and 43 and the feeder 21 were driven at the same number of revolutions, and the amount introduced into the mixing head 50 was measured. As a result, 13.9 kg / min of the kneaded product of the resin compound RC and the flame retardant FR was 1. It was 5 kg / min, and it was found that the introduction amount did not vary substantially. The time for completing foam curing of the foamable resin composition FC is also 2 minutes and 35 seconds, and the time for completing foam curing is substantially the same as that immediately after the adjustment.

  Immediately after the preparation of the resin compound RC and after 24 hours, there is no substantial variation in the viscosity of the resin compound RC, the amount introduced into the mixing head 50, and the foam curing time of the foamable resin composition FC. This means that compound RC, flame retardant FR, and curing agent CA can be kneaded, and metal panels with consistent quality can be manufactured under stable conditions. Moreover, even if a relatively large amount of flame retardant FR such as boric acid that exhibits a curing action on the resol type phenol resin is blended in a relatively large amount, a metal panel having excellent fire resistance can be produced without causing fluctuations in production conditions.

Comparative example

Viscosity (20 ° C.): 600 mPas resol type phenolic resin: 54 parts by mass, methylene chloride: 3 parts by mass, silicone-based nonionic surfactant: 3 parts by mass, aluminum hydroxide: 40 parts by mass, boric acid: 40 parts by mass Resin compound RC was prepared by mixing. As the curing agent CA, a 75% aqueous solution of phenolsulfonic acid was prepared.
The resin compound RC was put into the tank 10, sent directly from the tank 10 to the mixing head 50, stirred and mixed with the curing agent CA from the tank 40, and discharged and filled into a mold maintained at 70 ° C. The target introduction amounts to the mixing head 50 were set to resin compound RC: 14 kg / min and curing agent CA: 1.5 kg / min so that the mass ratio of resin compound RC: curing agent CA was 14: 1.5. .

  The resin compound RC immediately after preparation had a viscosity (20 ° C.) of 13000 mPas. Assuming that the introduction amount into the mixing head 50 is resin compound RC: 14 kg / min and curing agent CA: 1.5 kg / min, the rotational speeds of the pumps 13 and 43 were 90 rpm and 14 rpm, respectively, immediately after the preparation of the resin compound RC. . The time until foaming and curing of the foamable resin composition FC was completed was 2 minutes and 40 seconds.

  When 24 hours have elapsed from the preparation, the resin compound RC has thickened to 28000 mPas, and when the pumps 13 and 43 are driven at the same rotational speed, the amount of the curing agent CA fed into the mixing head 50 does not change, but the resin The amount of compound RC introduced was greatly reduced to 8.7 kg / min. The number of revolutions of the pump 13 was increased to increase the introduction amount of the resin compound RC, but the target introduction amount of 14 kg / min was not reached even at the maximum capacity of the pump 13 of 140 rpm. Further, when the mixing ratio of the resin compound RC: curing agent CA was set to 14: 1.5 and the time until foaming and curing of the foamable resin composition FC was completed was measured as 5 minutes and 50 seconds, the foam curing reaction. Was longer and foaming was not complete.

  As described above, the flame retardant FR exhibiting a curing action on the resol type phenolic resin is added to the resin compound RC with the premixing head 30 disposed immediately before the mixing head 50, thereby being excellent in fire prevention performance. Metal panels can be manufactured under stable conditions. Since the obtained metal panel can contain a large amount of flame retardant, it is used as a building material that sufficiently satisfies the revised fire prevention standards.

Schematic diagram of an apparatus used in the manufacture of metal panels according to the present invention Cross section of the manufactured metal panel

Explanation of symbols

10: Resin compound tank 11: Stirrer 12: Resin compound pipe 20: Hopper 21: Feeder 22: Flame retardant pipe 30: Premixing head 31: Mantle 32: Stir bar 33: Motor 34: Sauce plate 35: Pipe 36 : Pump 40: Tank 42: Pipe for curing agent 43: Pump 50: Mixing head 51: Motor 52: Stirrer 53: Nozzle
RC: Resin compound FR: Flame retardant CA: Curing agent FC: Foamable resin composition
FP, BP: Face material RF: Resin foam

Claims (3)

 Resole phenolic resin is cured with a flame retardant that does not have a curing action, foam stabilizer and foaming agent and mixed with resole phenolic resin, and the resin compound is sent to the premixing head to cure the resole phenolic resin. After kneading with the flame retardant exhibiting, the resin compound and the flame retardant kneaded material are immediately sent to the mixing head and stirred and mixed with the curing agent, and the resulting foamable resin composition is distributed in the recess of one face material, A method for producing a metal panel or board, wherein the foamable resin composition is foam-cured after superposing the other face material.  One or two flame retardants premixed in the resol type phenolic resin are selected from aluminum hydroxide, magnesium hydroxide, dihydrate gypsum, tris (tribromoneopentyl) phosphate, tetrabromobisphenol A, triphenyl phosphate The production method according to claim 1, wherein the production method is a seed or more.  The production method according to claim 1, wherein the flame retardant mixed in the resin compound immediately before being sent to the mixing head is one or two selected from boric acid and borax.

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