JP2005131820A - Phenol resin foam laminated panel and its manufacturing method - Google Patents

Phenol resin foam laminated panel and its manufacturing method Download PDF

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JP2005131820A
JP2005131820A JP2003367748A JP2003367748A JP2005131820A JP 2005131820 A JP2005131820 A JP 2005131820A JP 2003367748 A JP2003367748 A JP 2003367748A JP 2003367748 A JP2003367748 A JP 2003367748A JP 2005131820 A JP2005131820 A JP 2005131820A
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phenol resin
resin foam
nonwoven fabric
foam laminate
caco
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Takatoshi Kuwajima
貴敏 桑島
Hiroo Takahashi
浩雄 高橋
Toshiyuki Kato
俊幸 加藤
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Nitto Boseki Co Ltd
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Nitto Boseki Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a phenol resin foam laminated panel constituted so that the corrosion of the metal being in contact with the phenol resin foam laminated panel is prevented and design properties are enhanced. <P>SOLUTION: The phenol resin foam laminated panel 1 is constituted by laminating a nonwoven fabric 3 containing a mixture of CaCO<SB>3</SB>, a white metal oxide and an adhesive on both sides or one side of a phenol resin foam 2. The corrosion resistance of a metal is enhanced by CaCO<SB>3</SB>functioning as a neutralizing agent and the outer surface of the phenol resin foam laminated panel 1 is made to look like white so as to be susceptible to desired coloration. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

本発明は、フェノール樹脂発泡体積層板及びフェノール樹脂発泡体積層板の製造方法に関する。   The present invention relates to a phenol resin foam laminate and a method for producing a phenol resin foam laminate.

従来、フェノール樹脂発泡体の両面又は片面に、面材としての合成繊維不織布が接着剤層無く貼り合わされて成るフェノール樹脂発泡体積層板が知られている（例えば、特許文献１参照）。
ＷＯ１９９９−０３４９７５ Conventionally, a phenol resin foam laminate is known in which a synthetic fiber nonwoven fabric as a face material is bonded to both sides or one side of a phenol resin foam without an adhesive layer (see, for example, Patent Document 1).
WO1999-034975

しかしながら、上記フェノール樹脂発泡体積層板にあっては、通気性のある不織布を通してフェノール樹脂が滲み出し、例えば鉄等の金属と接触すると、当該金属が錆びてしまう腐食の問題がある。また、フェノール樹脂の原色であるピンク色が不織布を透過して見えてしまい、意匠的に問題がある。   However, the phenol resin foam laminate has a problem of corrosion in which the phenol resin oozes out through a breathable nonwoven fabric and comes into contact with a metal such as iron, for example. In addition, the pink color that is the primary color of the phenolic resin is seen through the nonwoven fabric, which is problematic in design.

本発明は、このような課題を解決するために成されたものであり、フェノール樹脂発泡体積層板に接する金属の腐食が防止されると共に、意匠性が向上されるフェノール樹脂発泡体積層板及びフェノール樹脂発泡体積層板の製造方法を提供することを目的とする。   The present invention has been made in order to solve such a problem, and the phenol resin foam laminate in which the corrosion of the metal in contact with the phenol resin foam laminate is prevented and the design is improved. It aims at providing the manufacturing method of a phenol resin foam laminated board.

本発明によるフェノール樹脂発泡体積層板は、フェノール樹脂発泡体の両面又は片面に、ＣａＣＯ３と白色の金属酸化物と接着剤の混合物を含む不織布が積層されて成る。 The phenol resin foam laminate according to the present invention is formed by laminating a nonwoven fabric containing a mixture of CaCO 3 , a white metal oxide and an adhesive on both sides or one side of a phenol resin foam.

このようなフェノール樹脂発泡体積層板によれば、ＣａＣＯ３が中和剤として機能し金属の耐腐食性が向上されると共に、白色の金属酸化物がフェノール樹脂の原色を隠蔽しフェノール樹脂発泡体積層板の外面が白色に見えると共に所望の着色が可能とされる。 According to such a phenolic resin foam laminate, CaCO 3 functions as a neutralizing agent to improve the corrosion resistance of the metal, and the white metal oxide conceals the primary color of the phenolic resin and the phenolic resin foam. The outer surface of the laminate appears white and the desired coloration is possible.

ここで、上記不織布としては、具体的には、合成繊維不織布又は無機繊維不織布又は天然繊維不織布等が挙げられるが、特に、上記作用を効果的に奏する不織布としては、合成繊維不織布の一つであるスパンボンド不織布又は無機繊維不織布の一つであるガラス繊維不織布が挙げられる。   Here, specific examples of the non-woven fabric include a synthetic fiber non-woven fabric, an inorganic fiber non-woven fabric, a natural fiber non-woven fabric, and the like. The glass fiber nonwoven fabric which is one of a certain spunbond nonwoven fabric or an inorganic fiber nonwoven fabric is mentioned.

また、上記作用を効果的に奏する白色の金属酸化物としては、具体的には、ＴｉＯ２又はＺｎＯが挙げられる。 Specific examples of the white metal oxide that effectively exhibits the above action include TiO 2 and ZnO.

また、本発明によるフェノール樹脂発泡体積層板の製造方法は、ＣａＣＯ３と白色の金属酸化物と接着剤の混合物を不織布面に塗工して無機物塗工不織布である面材を製造し、この面材を連続的に走行させると共に、この走行する面材の上又は上下の間に発泡フェノール樹脂組成物を供給して発泡硬化させることで、当該発泡硬化したフェノール樹脂発泡体の両面又は片面に面材が連続的に一体に積層されたフェノール樹脂発泡体積層板を得ることを特徴としている。 In addition, the method for producing a phenolic resin foam laminate according to the present invention produces a face material which is an inorganic material coated nonwoven fabric by coating a nonwoven fabric surface with a mixture of CaCO 3 , a white metal oxide and an adhesive. While continuously running the face material, by supplying a foamed phenol resin composition between the top and bottom of the running face material and foaming and curing it, both sides or one side of the foam cured phenol resin foam It is characterized by obtaining a phenolic resin foam laminate in which face materials are continuously and integrally laminated.

このようなフェノール樹脂発泡体積層板の製造方法によれば、ＣａＣＯ３と白色の金属酸化物と接着剤の混合物を不織布面に塗工した不織布が、フェノール樹脂発泡体の両面又は片面に連続的に一体に積層されるため、上述した作用を奏するフェノール樹脂発泡体積層板が簡易に得られる。 According to such a method for producing a phenol resin foam laminate, a nonwoven fabric obtained by applying a mixture of CaCO 3 , a white metal oxide, and an adhesive to the nonwoven fabric surface is continuous on both sides or one side of the phenol resin foam. Therefore, the phenol resin foam laminate having the above-described effects can be easily obtained.

このように本発明によるフェノール樹脂発泡体積層板によれば、ＣａＣＯ３により金属の耐腐食性が向上され、フェノール樹脂発泡体積層板に接する金属の腐食を防止することが可能になると共に、白色の金属酸化物によりフェノール樹脂発泡体積層板の外面が白色に見えると共に所望の着色が可能とされ、意匠性を向上することが可能となる。また、本発明によるフェノール樹脂発泡体積層板の製造方法によれば、上記フェノール樹脂発泡体積層板の効果に加えて、フェノール樹脂発泡体積層板が簡易に得られるため、製造コストを低減することが可能となる。 Thus, according to the phenol resin foam laminate according to the present invention, the corrosion resistance of the metal is improved by CaCO 3 , it is possible to prevent the corrosion of the metal in contact with the phenol resin foam laminate, With this metal oxide, the outer surface of the phenol resin foam laminate appears white and desired coloration is possible, and the design can be improved. Moreover, according to the manufacturing method of the phenol resin foam laminated board by this invention, in addition to the effect of the said phenol resin foam laminated board, since a phenol resin foam laminated board is obtained easily, manufacturing cost is reduced. Is possible.

以下、本発明によるフェノール樹脂発泡体積層板及びフェノール樹脂発泡体積層板の製造方法の好適な実施形態について図１及び図２を参照しながら説明する。図１は、本発明の実施形態に係るフェノール樹脂発泡体積層板を模式的に示す断面図、図２は、図１のフェノール樹脂発泡体積層板を製造する装置を示す概略構成図であり、本実施形態のフェノール樹脂発泡体積層板は、例えば各種建築材料として好適に用いられるものである。   Hereinafter, a preferred embodiment of a phenol resin foam laminate and a method for producing a phenol resin foam laminate according to the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a cross-sectional view schematically showing a phenol resin foam laminate according to an embodiment of the present invention. FIG. 2 is a schematic configuration diagram showing an apparatus for producing the phenol resin foam laminate of FIG. The phenol resin foam laminate of this embodiment is suitably used as various building materials, for example.

図１に示すように、フェノール樹脂発泡体積層板１は、フェノール樹脂発泡体２の両面に、ＣａＣＯ３と白色の金属酸化物と接着剤の混合物を含む不織布が面材３，３として積層されたものである。 As shown in FIG. 1, the phenolic resin foam laminate 1 is formed by laminating a nonwoven fabric containing a mixture of CaCO 3 , a white metal oxide and an adhesive on both sides of a phenolic resin foam 2 as face materials 3 and 3. It is a thing.

ここで、フェノール樹脂発泡体２は、発泡フェノール樹脂組成物を発泡硬化させたものである。面材３を構成する不織布は、フェノール樹脂発泡体２を保護するためのもので、合成繊維不織布又は無機繊維不織布又は例えばクラフト紙等の天然繊維不織布等が用いられるが、特に、合成繊維不織布の一つであるスパンボンド不織布又は無機繊維不織布の一つであるガラス繊維不織布を用いるのが好適である。   Here, the phenol resin foam 2 is obtained by foam-curing a foamed phenol resin composition. The nonwoven fabric constituting the face material 3 is for protecting the phenol resin foam 2, and synthetic fiber nonwoven fabric or inorganic fiber nonwoven fabric or natural fiber nonwoven fabric such as kraft paper is used. It is preferable to use a glass fiber nonwoven fabric which is one of spunbond nonwoven fabric or inorganic fiber nonwoven fabric.

ＣａＣＯ３は、金属の耐腐食性を向上させる中和剤として用いられている。白色の金属酸化物は、フェノール樹脂のピンク色の原色を隠蔽しフェノール樹脂発泡体積層板１の外面を白色に見せると共に所望の着色を可能とするためのもので、種々のものが用いられるが、特に、ＴｉＯ２又はＺｎＯを用いるのが好適である。 CaCO 3 is used as a neutralizing agent that improves the corrosion resistance of metals. The white metal oxide is used to conceal the pink primary color of the phenolic resin so that the outer surface of the phenolic resin foam laminate 1 is white and enables desired coloring, and various types are used. In particular, TiO 2 or ZnO is preferably used.

接着剤は、ＣａＣＯ３及び金属酸化物を不織布に接着するもので、種々のものが用いられるが、特に、アクリル樹脂又は尿素樹脂又はＰＶＡｃ（酢酸ビニル）又はＰＶＡ（ポリビニルアルコール）等のバインダー樹脂を用いるのが好適である。 Adhesives are those that adhere CaCO 3 and metal oxides to the nonwoven fabric, and various types are used. In particular, binder resins such as acrylic resins, urea resins, PVAc (vinyl acetate) or PVA (polyvinyl alcohol) are used. It is preferred to use.

このような構成を有するフェノール樹脂発泡体積層板１は、以下の製造方法により得られる。先ず、面材３を得るべく、ＣａＣＯ３粉末、白色の金属酸化物の粉末、バインダー樹脂（接着剤）を調合する。 The phenol resin foam laminate 1 having such a configuration is obtained by the following manufacturing method. First, in order to obtain the face material 3, CaCO 3 powder, white metal oxide powder, and binder resin (adhesive) are prepared.

ここで、バインダー樹脂が少ないとＣａＣＯ３や白色の金属酸化物の脱落が生じやすく、また、白色の金属酸化物が少ないと隠蔽性が低くなり、また、白色の金属酸化物が多いとコストが高くなるため、乾燥状態で、ＣａＣＯ３粉末：５０〜９４％、金属酸化物の粉末：１〜３０％、バインダー樹脂：５〜２０％として調合するのが特に好ましい。また、混合物の乾燥質量が、３０〜１００ｇ／ｍ２となるように調合するのが特に好ましい。 Here, if the binder resin is small, CaCO 3 and the white metal oxide are likely to fall off, and if the white metal oxide is small, the concealability is low, and if the white metal oxide is large, the cost is low. Since it becomes high, it is particularly preferable to prepare in a dry state as CaCO 3 powder: 50 to 94%, metal oxide powder: 1 to 30%, and binder resin: 5 to 20%. Moreover, it is especially preferable to prepare so that the dry mass of a mixture may be 30-100 g / m < 2 >.

そして、バインダー樹脂は、水系エマルジョン又は有機溶剤に溶解したものを用い、ＣａＣＯ３、白色の金属酸化物、バインダー樹脂の混合物を、不織布面に対してバーコータ又はロールコータ等の塗工機により塗工する。この場合、フェノール樹脂発泡体２に対面することになる不織布面又はこの不織布面の裏面又はこれらの両面に混合物を塗工する。そして、この混合物を塗工した不織布を乾燥させ、無機物塗工不織布である面材３を得る。 Then, the binder resin is dissolved in an aqueous emulsion or an organic solvent, and a mixture of CaCO 3 , white metal oxide and binder resin is applied to the nonwoven fabric surface by a coating machine such as a bar coater or a roll coater. To do. In this case, the mixture is applied to the non-woven fabric surface that faces the phenol resin foam 2, the back surface of the non-woven fabric surface, or both surfaces thereof. And the nonwoven fabric which coated this mixture is dried, and the face material 3 which is an inorganic substance coated nonwoven fabric is obtained.

次に、このようにして得られた面材３，３を用い、フェノール樹脂発泡体積層板１を製造する装置について、図２を参照しながら説明する。製造装置１０は、フェノール樹脂発泡体の厚み程度の間隔を開けて対向配置された上下一対のコンベア１１，１２を備えている。これらの上、下部コンベア１１，１２は、無端のスチールベルト１３が複数のローラ１４に巻架されて成る無端スチールベルトコンベアであり、搬送速度が同期されて駆動される。   Next, the apparatus which manufactures the phenol resin foam laminated board 1 using the face materials 3 and 3 obtained in this way is demonstrated, referring FIG. The manufacturing apparatus 10 includes a pair of upper and lower conveyors 11 and 12 that are arranged to face each other with an interval of about the thickness of the phenol resin foam. In addition to these, the lower conveyors 11 and 12 are endless steel belt conveyors in which an endless steel belt 13 is wound around a plurality of rollers 14, and are driven with the conveyance speed synchronized.

この製造装置１０は、上記得られた面材３をロール状に巻回すると共に回転可能に支持される支持部１５，１６を、上、下部コンベア１１，１２に対応して各々備え、上、下部コンベア１１，１２が駆動されることで、支持部１５，１６に巻回された面材３，３を各々繰り出し上、下部コンベア１１，１２の搬送面に沿って搬送すると共に、ミキサー１７で混合された発泡フェノール樹脂組成物１８を、一対の面材３，３間に供給すべく、ガイド管１９を介して、下部コンベア１２上の面材３上に供給する。また、製造装置１０は、一対の面材３，３間に供給され下流に搬送される発泡フェノール樹脂組成物１８を熱硬化させるための加熱装置２０を備えている。   The manufacturing apparatus 10 includes support portions 15 and 16 that are wound around the obtained face material 3 in a roll shape and are rotatably supported, corresponding to the upper and lower conveyors 11 and 12, respectively, By driving the lower conveyors 11 and 12, the face materials 3 and 3 wound around the support portions 15 and 16 are respectively fed out and conveyed along the conveying surfaces of the lower conveyors 11 and 12, and at the mixer 17. The mixed foamed phenol resin composition 18 is supplied onto the face material 3 on the lower conveyor 12 through a guide tube 19 so as to be supplied between the pair of face materials 3 and 3. Moreover, the manufacturing apparatus 10 is provided with the heating apparatus 20 for thermosetting the foaming phenol resin composition 18 supplied between a pair of face materials 3 and 3 and conveyed downstream.

さらに、製造装置１０は、上下一対のコンベア１１，１２により搬送される一対の面材３，３の搬送方向に沿った縁部３ａ，３ａを両側（図面手前側と向こう側；図では手前側のみ図示）において、搬送途中で繋ぎ合わせて閉じるための閉塞手段２１を備えている。この閉塞手段２１は、一対の面材３，３の縁部３ａ，３ａを縫合するためのミシンのような縫合装置であっても、接着部材により接着するための接着装置であっても、融着装置であっても良い。この閉塞手段２１に対しては、一対の面材３，３の縁部３ａ，３ａを、当該閉塞手段２１に向かって上流側から案内するためのガイド部材２２が付設されている。   Further, the manufacturing apparatus 10 has the edges 3a, 3a along the conveying direction of the pair of face materials 3, 3 conveyed by the pair of upper and lower conveyors 11, 12 on both sides (the front side and the other side in the drawing; the front side in the figure). (Only shown in the figure) is provided with closing means 21 for connecting and closing in the middle of conveyance. The closing means 21 may be a sewing device such as a sewing machine for sewing the edges 3a and 3a of the pair of face materials 3 and 3, or an adhesive device for bonding with an adhesive member. A landing gear may be used. A guide member 22 for guiding the edge portions 3 a and 3 a of the pair of face members 3 and 3 from the upstream side toward the closing means 21 is attached to the closing means 21.

このような製造装置１０によれば、上、下部コンベア１１，１２の駆動が開始されると、支持部１５，１６が回転し、面材３，３が繰り出されて搬送されると共に、ミキサー１７からの発泡フェノール樹脂組成物１８が、下部の面材３を介して、搬送される一対の面材３、３間に供給される。この時、当該一対の面材３，３の搬送方向に沿った縁部３ａ，３ａは、ガイド部材２２により案内されて閉塞手段２１に送られ、この閉塞手段２１により縫合又は接着又は融着されて、一対の面材３，３間に閉空間が形成され、この閉空間内で発泡フェノール樹脂組成物１８が発泡し加熱装置２０により熱硬化されてフェノール樹脂発泡体２が形成されると同時に当該フェノール樹脂発泡体２の両面に面材３，３が積層されて搬送され、最後に、繋ぎ合わされて閉じている縁部３ａ，３ａが取り除かれることで、図１に示したフェノール樹脂発泡体積層板１が得られる。   According to such a manufacturing apparatus 10, when driving of the upper and lower conveyors 11, 12 is started, the support parts 15, 16 rotate, the face materials 3, 3 are fed out and conveyed, and the mixer 17 The foamed phenol resin composition 18 is supplied between the pair of face materials 3 and 3 to be conveyed via the lower face material 3. At this time, the edge portions 3a and 3a along the conveying direction of the pair of face materials 3 and 3 are guided by the guide member 22 and sent to the closing means 21, and are sewn, bonded or fused by the closing means 21. Thus, a closed space is formed between the pair of face members 3, 3, and the foamed phenol resin composition 18 is foamed in the closed space and is thermally cured by the heating device 20 to form the phenol resin foam 2. The phenolic resin foam 2 shown in FIG. 1 is obtained by laminating and transporting the face materials 3 and 3 on both sides of the phenol resin foam 2 and finally removing the edges 3a and 3a that are joined and closed. The laminated board 1 is obtained.

このようなフェノール樹脂発泡体積層板１の製造方法によれば、ＣａＣＯ３と白色の金属酸化物とバインダー樹脂の混合物を不織布面に塗工して無機物塗工不織布である面材３を製造し、この面材３，３を上下に並べて連続的に走行させると共に、この走行する面材３，３間に発泡フェノール樹脂組成物１８を供給して発泡硬化させることで、当該発泡硬化したフェノール樹脂発泡体２の両面に面材３，３を連続的に一体に積層するように製造しているため、フェノール樹脂発泡体積層板１が簡易に得られ、製造コストの低減が図られている。また、混合物を、フェノール樹脂発泡体２に積層した不織布面に後塗工するのでは無いため、製造が一層簡易とされている。 According to the method of manufacturing the phenolic foam laminate 1, a mixture of CaCO 3 and a white metal oxide and a binder resin is coated on the nonwoven surface to produce a surface material 3 which is an inorganic substance coating nonwoven These face materials 3 and 3 are continuously run side by side, and the foamed and cured phenol resin is supplied by foaming and curing the foamed phenol resin composition 18 between the running face materials 3 and 3. Since the face materials 3 and 3 are manufactured so as to be continuously and integrally laminated on both surfaces of the foam 2, the phenol resin foam laminate 1 can be easily obtained and the production cost can be reduced. Moreover, since the mixture is not post-coated on the non-woven fabric surface laminated on the phenol resin foam 2, the production is further simplified.

また、このようにして得られたフェノール樹脂発泡体積層板１にあっては、フェノール樹脂発泡体２の両面に面材３，３として、ＣａＣＯ３と白色の金属酸化物とバインダー樹脂の混合物を含む不織布が積層され、この不織布に含まれるＣａＣＯ３が金属の耐腐食性を向上する中和剤として機能している。このため、フェノール樹脂発泡体積層板１に接する金属の腐食を防止することが可能とされている。また、不織布に含まれる白色の金属酸化物がフェノール樹脂の原色を隠蔽しフェノール樹脂発泡体積層板１の外面が白色に見えると共に所望の着色が可能とされている。このため、フェノール樹脂発泡体積層板１の意匠性の向上が図られている。 In the phenol resin foam laminate 1 thus obtained, a mixture of CaCO 3 , white metal oxide, and binder resin is used as the face materials 3 and 3 on both sides of the phenol resin foam 2. nonwoven fabric comprising are stacked, the CaCO 3 contained in the non-woven fabric functions as a neutralizing agent for improving the corrosion resistance of metals. For this reason, it is possible to prevent the corrosion of the metal in contact with the phenol resin foam laminate 1. Further, the white metal oxide contained in the non-woven fabric conceals the primary color of the phenol resin so that the outer surface of the phenol resin foam laminate 1 appears white and desired coloring is possible. For this reason, the designability of the phenol resin foam laminate 1 is improved.

以上、本発明をその実施形態に基づき具体的に説明したが、本発明は上記実施形態に限定されるものではなく、例えば、上記実施形態においては、特に効果的であるとして、フェノール樹脂発泡体２の両面に面材３，３を積層するようにしているが、フェノール樹脂発泡体２の片面に面材３を積層するようにしても良い。   As described above, the present invention has been specifically described based on the embodiment. However, the present invention is not limited to the above embodiment. For example, in the above embodiment, the phenol resin foam is particularly effective. Although the face materials 3 and 3 are laminated on both surfaces of 2, the face material 3 may be laminated on one surface of the phenol resin foam 2.

以下、上記効果を確認すべく本発明者が実施した実施例１及び比較例１について述べる。結果は表１に示す。

Figure 2005131820
Hereinafter, Example 1 and Comparative Example 1 carried out by the present inventor to confirm the above effect will be described. The results are shown in Table 1.
Figure 2005131820

（実施例１）
アクリルエマルジョン液に対して、乾燥状態で、ＣａＣＯ３粉末：８２％、ＴｉＯ２粉末：５％、アクリル樹脂：１３％となるように調合し、この混合物を、スパンボンド不織布（ユニチカ製マリックス ７０５０５ＷＴＯ）の不織布面に対してバーコーターにより塗工し１５０°Ｃで乾燥して、混合物の乾燥質量を４０、６０、９０ｇ／ｍ２とする面材を各々作成した。ＣａＣＯ３粉末としては、粒径が４５〜８５０μｍのものを用い、ＴｉＯ２粉末としては、粒径が５０〜６０μｍのものを用いた。そして、図２に示した製造装置に、得られた面材を各々適用し、図１に示したのと同様な構成で面材の混合物の乾燥質量が相違するフェノール樹脂発泡体積層板１を各々得た。金属腐食試験として、図３に示すように、得られたフェノール樹脂発泡体積層板１により、脱脂した鉄板３０を挟んだサンプル４０を、面材の混合物の乾燥質量ごとに分けて各々用意し、４０°Ｃ、９０％の恒温恒湿機の中に入れ、経時的に鉄板３０に錆が生じるか否かを観察した。また、目視にて、フェノール樹脂発泡体積層板１の外面からフェノール樹脂の原色が見えるか否かを確認した。その結果を表１に示す。表１に示す隠蔽性の丸印は、フェノール樹脂の原色が見えないことを示し、×印は、フェノール樹脂の色が見えたことを示し、金属腐食試験の丸印は、鉄板に錆が生じなかったことを示し、×印は、鉄板に錆が生じたことを示している。表１より明らかなように、実施例１のフェノール樹脂発泡体積層板１は全て、隠蔽性及び金属の耐腐食性に優れているというのが分かる。 (Example 1)
The acrylic emulsion liquid was mixed in a dry state such that CaCO 3 powder: 82%, TiO 2 powder: 5%, acrylic resin: 13%, and this mixture was spunbonded non-woven fabric (Marix 70505 WTO manufactured by Unitika). The non-woven fabric surface was coated with a bar coater and dried at 150 ° C. to prepare face materials having a dry mass of 40, 60, and 90 g / m 2 , respectively. A CaCO 3 powder having a particle size of 45 to 850 μm was used, and a TiO 2 powder having a particle size of 50 to 60 μm was used. Then, each of the obtained face materials is applied to the manufacturing apparatus shown in FIG. 2, and the phenol resin foam laminate 1 having the same configuration as shown in FIG. Each got. As a metal corrosion test, as shown in FIG. 3, the obtained phenol resin foam laminate 1 is used to prepare samples 40 sandwiching the degreased iron plate 30 for each dry mass of the face material mixture, It was put in a constant temperature and humidity machine of 40 ° C. and 90%, and it was observed whether or not rust was generated on the iron plate 30 over time. Moreover, it was confirmed visually whether the primary color of the phenol resin could be seen from the outer surface of the phenol resin foam laminate 1. The results are shown in Table 1. The concealing circles shown in Table 1 indicate that the primary color of the phenolic resin is not visible, the Xs indicate that the color of the phenolic resin is visible, and the circles in the metal corrosion test indicate that the iron plate is rusted. The x mark indicates that rust has occurred on the iron plate. As is clear from Table 1, it can be seen that all the phenolic resin foam laminates 1 of Example 1 are excellent in concealment and metal corrosion resistance.

（比較例１）
混合物を塗工しないスパンボンド不織布を用いた点以外は、実施例１と同様である。その結果は、表１に示すように、隠蔽性及び金属の耐腐食性が共に不良であった。 (Comparative Example 1)
Example 1 is the same as Example 1 except that a spunbonded non-woven fabric not coated with the mixture is used. As a result, as shown in Table 1, both concealability and metal corrosion resistance were poor.

本発明の実施形態に係るフェノール樹脂発泡体積層板を模式的に示す断面図である。It is sectional drawing which shows typically the phenol resin foam laminated board which concerns on embodiment of this invention. 図１のフェノール樹脂発泡体積層板を製造する装置を示す概略構成図である。It is a schematic block diagram which shows the apparatus which manufactures the phenol resin foam laminated board of FIG. 実施例１で用いられるサンプルを示す斜視図である。1 is a perspective view showing a sample used in Example 1. FIG.

符号の説明Explanation of symbols

１…フェノール樹脂発泡体積層板、２…フェノール樹脂発泡体、３…混合物含有不織布（面材；無機物塗工不織布）、１０…製造装置、１１，１２…コンベア、１５，１６…面材支持部、１８…発泡フェノール樹脂組成物、２０…加熱装置。   DESCRIPTION OF SYMBOLS 1 ... Phenol resin foam laminated board, 2 ... Phenol resin foam, 3 ... Mixture containing nonwoven fabric (surface material; inorganic substance coated nonwoven fabric), 10 ... Manufacturing apparatus, 11, 12 ... Conveyor, 15, 16 ... Surface material support part 18, foamed phenol resin composition, 20 ... heating device.

Claims (4)

フェノール樹脂発泡体の両面又は片面に、ＣａＣＯ３と白色の金属酸化物と接着剤の混合物を含む不織布が積層されて成るフェノール樹脂発泡体積層板。 A phenol resin foam laminate in which a nonwoven fabric containing a mixture of CaCO 3 , a white metal oxide and an adhesive is laminated on both sides or one side of a phenol resin foam. 前記不織布は、スパンボンド不織布又はガラス繊維不織布であることを特徴とする請求項１記載のフェノール樹脂発泡体積層板。   The phenol resin foam laminate according to claim 1, wherein the nonwoven fabric is a spunbond nonwoven fabric or a glass fiber nonwoven fabric. 前記白色の金属酸化物は、ＴｉＯ２又はＺｎＯであることを特徴とする請求項１又は２記載のフェノール樹脂発泡体積層板。 The phenol resin foam laminate according to claim 1, wherein the white metal oxide is TiO 2 or ZnO. ＣａＣＯ３と白色の金属酸化物と接着剤の混合物を不織布面に塗工して無機物塗工不織布である面材を製造し、
この面材を連続的に走行させると共に、この走行する面材の上又は上下の間に発泡フェノール樹脂組成物を供給して発泡硬化させることで、当該発泡硬化したフェノール樹脂発泡体の両面又は片面に前記面材が連続的に一体に積層されたフェノール樹脂発泡体積層板を得ることを特徴とするフェノール樹脂発泡体積層板の製造方法。 A mixture of CaCO 3 , white metal oxide and adhesive is applied to the nonwoven fabric surface to produce a face material that is an inorganic coated nonwoven fabric,
The face material is continuously run, and the foamed phenol resin composition is foamed and cured by supplying a foamed phenol resin composition between the top and the bottom of the running face material. A method for producing a phenolic resin foam laminate comprising obtaining a phenolic resin foam laminate in which the face materials are continuously laminated integrally.
JP2003367748A 2003-10-28 2003-10-28 Phenol resin foam laminated panel and its manufacturing method Pending JP2005131820A (en)

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JP2010110978A (en) * 2008-11-06 2010-05-20 Sekisui Chem Co Ltd Foamed plastic-based heat insulation material
JP2010248412A (en) * 2009-04-17 2010-11-04 Sekisui Chem Co Ltd Method for manufacturing thermosetting resin foam
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JP2015533691A (en) * 2012-09-18 2015-11-26 キングスパン・ホールディングス・（アイアールエル）・リミテッド Thermal insulation phenolic foam

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WO1999034975A1 (en) * 1998-01-07 1999-07-15 Asahi Kasei Kogyo Kabushiki Kaisha Laminate of phenolic resin foam
JP2002292651A (en) * 2001-03-29 2002-10-09 Nitto Boseki Co Ltd Resin foam and method for manufacturing the same

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JP2010110978A (en) * 2008-11-06 2010-05-20 Sekisui Chem Co Ltd Foamed plastic-based heat insulation material
JP2010248412A (en) * 2009-04-17 2010-11-04 Sekisui Chem Co Ltd Method for manufacturing thermosetting resin foam
WO2010126024A1 (en) * 2009-04-28 2010-11-04 旭化成建材株式会社 Device for forming thermosetting resin foam plate and method of manufacturing thermosetting resin foam plate
JP5551155B2 (en) * 2009-04-28 2014-07-16 旭化成建材株式会社 Thermosetting resin foam board molding apparatus and method for producing thermosetting resin foam board
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JP2015533691A (en) * 2012-09-18 2015-11-26 キングスパン・ホールディングス・（アイアールエル）・リミテッド Thermal insulation phenolic foam

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