JP2006035675A - Embossed metal foil, phenol resin foam laminate, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a phenol resin foam laminate which adds design and beauty effect while realizing the effect covering surface defects of a phenol resin foam, and can maintain qualities such as corrosion-proof nature at the time of long-term use, flame retardancy, heat resistance, heat ray reflecting property, design nature and the like, and to provide a metal foil giving this laminate. <P>SOLUTION: An embossed metal foil 30 is made by giving an emboss to at least one surface of a metal foil 2 having malleability. In the phenol resin foam laminate, a sheet-like fabric material, an adhesive layer and the metal foil 2 are laminated in turn to at least one surface of a phenol resin foam, wherein the above embossed metal foil is used as the above metal foil, and the front surface side of the laminate is allotted to be an embossed section 31. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an embossed metal foil, a phenol resin foam laminate, and a method for producing the same. More specifically, the present invention has a malleable metal foil whose surface is embossed, in particular an aluminum foil, and the embossed metal foil, and exhibits the effect of covering the surface defects of the foam. Along with the design and aesthetic effects, the phenolic resin foam laminate that maintains the quality such as corrosion resistance, flame retardancy, heat resistance, heat ray reflectivity, and designability during long-term use, and the efficiency of this product It relates to a method of manufacturing well.

  Conventionally, as a flame-retardant thermal insulation panel and heat-resistant thermal insulation panel widely used in construction and other various industrial fields, a face material having flame retardancy and heat resistance is generally integrated on one or both sides of a phenolic resin foam. Attached one is used. As the face material having flame retardancy and heat resistance, for example, a metal foil such as an aluminum foil or a metal sheet is used. For example, a nonflammable heat insulating panel is known which is formed by laminating an aluminum foil coated with a resin coat via a nonwoven fabric or a woven sheet on one or both sides of a phenol resin foam (see, for example, Patent Document 1).

  Such a phenol resin foam laminate is prepared by, for example, bonding a metal foil such as an aluminum foil to a nonwoven fabric or woven fabric such as glass fiber to produce a face material, and supplying the face material to the phenol resin foam composition, Next, the phenol resin foam composition is cured to form a face material and a phenol resin foam integrally, or an adhesive layer is applied to a phenol resin foam having a face material such as a nonwoven fabric or a woven sheet laminated on the surface. It can be produced by a method of joining and integrating a metal foil such as an aluminum foil.

As the metal foil, aluminum foil is generally used because it is inexpensive. However, since the aluminum foil is thin, if a force is applied to the metal foil-covered phenolic resin foam using the aluminum foil from the outside during production or during storage or transportation after production, wrinkles may occur. In addition to being easily scratched, there is a drawback that the surface is easily scratched by its frictional force when it comes into contact with an object. Once the surface of the aluminum foil is wrinkled or scratched, it causes corrosion, flame retardancy, heat ray reflectivity and the like to be impaired starting from the surface, and design and commercial properties are reduced.
Accordingly, there has been a demand for the development of an aluminum foil-coated phenolic foam that is less likely to be scratched and less wrinkled, and has excellent aluminum foil coating workability.

  On the other hand, a composite heat insulating material is known in which a paper layer, an aluminum foil, and a synthetic resin layer are sequentially laminated on at least one surface of a heat insulating layer made of a phenol resin foam (see, for example, Patent Document 2).

  However, in this composite heat insulating material, since paper such as kraft paper is used as the paper layer, there is a problem that it is difficult to degas, and therefore gas peeling is likely to occur, and continuous molding cannot be performed with paper. Further, the aluminum foil has the above-mentioned drawbacks.

JP 2003-239417 A JP 2003-56090 A

  Under such circumstances, the present invention is coated with a metal foil such as an aluminum foil, and has the effect of covering the surface defects of the phenolic resin foam, and has a design and aesthetic effect. A phenolic resin foam laminate that is added and maintains quality such as anticorrosion, flame retardancy, heat resistance, heat ray reflectivity, and designability when used for a long period of time, a metal foil that provides this laminate, and the phenol resin An object of the present invention is to provide a method for producing a foam laminate.

  As a result of intensive studies to achieve the above object, the present inventors have used a metal foil having an embossed surface, in particular an aluminum foil, to thereby obtain a phenol resin foam laminate having desired and desirable properties. A sheet is obtained, and this is a sheet-like cloth material, an adhesive layer, and a face material obtained by sequentially laminating an embossed metal foil having an embossed portion on the surface side. It discovered that it could manufacture efficiently by supplying so that the discharged phenolic resin foam composition might be in contact with a surface, and hardening this phenolic resin foam composition. The present invention has been completed based on such findings.

That is, the present invention
(1) An embossed metal foil characterized by being embossed on at least one surface of a malleable metal foil,
(2) On at least one surface, embossed portions and smooth portions having a predetermined width are alternately arranged in parallel at predetermined intervals to form a striped pattern, and at the substantially center of the smooth portion, The embossed metal foil according to (1), wherein the embossed metal foil has parallel fine groove portions parallel to the embossed portions,
(3) The embossed metal foil according to (1) or (2) above, wherein the malleable metal foil is an aluminum foil,
(4) A sheet-like cloth material, an adhesive layer, and a metal foil are sequentially laminated on at least one surface of the phenol resin foam, and the metal foil is described in (1), (2), or (3) above. A phenolic resin foam laminate, characterized in that the embossed metal foil is arranged so that the surface side becomes an embossed part,
(5) The phenolic resin foam laminate according to (4) above, wherein the sheet-like cloth material is a woven fabric, a knitted fabric or a non-woven fabric obtained using at least one selected from inorganic fibers and organic fibers. Board,
(6) The adhesive layer is composed of a single layer or a plurality of layers including at least one selected from polyolefin resins, acrylic resins, epoxy resins, urethane resins, silicone resins, synthetic rubbers, and natural rubbers. When the adhesive layer is a plurality of layers, the phenol resin foam laminate according to the above (4) or (5), wherein the type of adhesive constituting each layer is a different type,
(7) When the adhesive layer is composed of a single layer, the thickness is 5 to 100 μm. When the adhesive layer is composed of two layers, the thickness of each layer is 5 to 100 μm. The phenolic resin foam laminate according to
The phenol resin foam laminate according to the above item (6), wherein the adhesive layer consists of two layers, and each thickness is 5 to 100 μm,
(8) The phenol resin foam laminate according to any one of (4) to (7) above, which has a resin coat layer on the surface of an embossed metal foil, and (9) a sheet-like cloth material and an adhesive Supplying a face material formed by sequentially laminating a layer and an embossed metal foil having an embossed portion on the surface side so that the sheet-like cloth material of the face material is in contact with the phenol resin foam composition, The phenol resin foam laminate according to any one of (4) to (8) above, wherein the phenol resin foam composition is cured, and the phenol resin foam and the face material are integrated. Manufacturing method,
Is to provide.

  According to the present invention, the metal foil having a malleable surface embossed, in particular an aluminum foil, and the embossed metal foil have an effect of covering the surface defects of the foam, Phenol resin foam laminates that take into account design and aesthetic effects and maintain quality such as anti-corrosion properties, flame resistance, heat resistance, heat ray reflectivity, and design properties during long-term use, and efficiently produce them A method can be provided.

  The embossed metal foil of the present invention is obtained by embossing at least one surface of a malleable metal foil. For example, when this metal foil is used in the phenol resin foam laminate of the present invention described later, it is for imparting heat resistance, flame retardancy, heat ray reflectivity, design properties, and the like. There is no particular limitation on the material of the metal foil having malleability, and aluminum foil, stainless steel foil, and the like can be used. Among these, aluminum foil is preferable from the viewpoint of balance such as light weight and economy. is there. The thickness of the metal foil is usually about 7 to 100 μm, preferably 10 to 70 μm, and more preferably 15 to 50 μm.

  When an aluminum foil is used as the metal foil, the type of aluminum foil is not particularly limited, but an aluminum foil defined in “Aluminum and aluminum alloy foil” of JIS H 4160 is preferable.

  Embossing can be performed on the entire surface or part of at least one surface of the malleable metal foil. In particular, embossed portions and smooth portions having a predetermined width are alternately arranged at predetermined intervals. It is preferable that a striped pattern is formed in parallel, and a linear narrow groove portion is provided substantially in the center of the smooth portion in parallel to the embossed portion.

  As a method for performing the embossing, for example, a method of mechanically pressing an embossing roller against at least one surface of a metal foil discharged from a metal foil roll or a surface of a metal foil having a nonwoven fabric or the like disposed on the back For example, a method of pressing an embossing roller on can be employed.

  Moreover, when using embossed metal foil as a coating material in a phenol resin foam laminate, a face material made of embossed metal foil / adhesive layer / sheet-like cloth material can be used in the present invention. This face material can be produced, for example, by inserting an adhesive between the sheet-like cloth material and the metal foil, pressing an embossing roller from the metal foil side, and embossing the metal foil.

  FIG. 1 is an explanatory view showing an example of a method for embossing a metal foil surface in the case of obtaining a face material composed of an embossed metal foil / adhesive layer / sheet-like cloth material, and FIG. It is the typical perspective view (a) and typical longitudinal section (b) of an example of a roller.

  As shown in FIG. 1, an adhesive 7 is inserted between the sheet-like cloth material 8 and the metal foil 2, the metal foil 2 is arranged on the embossing roller 4 side, and the metal is placed between the embossing roller 4 and the facing roller 5. The foil and the sheet-like cloth material are bonded and integrated to obtain the face material 3. At that time, the metal foil comes into contact with and is pressed against the sheet-like cloth material 8 from the convex portion and the opposite side of the embossing roller 4, and as a result, it is considered that an embossed pattern is generated on the surface of the metal foil.

  When the convex portion of the embossing roller is pressed against the metal foil, the metal foil in contact with the convex portion extends due to its malleability, and the metal foil between the convex portion and the adjacent convex portion is loosened. In the process in which the metal foil of the slack portion is then pulled in contact with the guide roller 6 and progresses, it is approximately the center portion of the slack portion of the metal foil, that is, the substantially center portion of the embossed striped smooth portion. In addition, it is presumed that a fine groove of a line is generated in parallel to the embossed portion (along the longitudinal direction of the metal foil).

  As shown in FIG. 2, the embossing roller 4 has uneven portions alternately on the roller, the surfaces of the concave portions and the convex portions are both smooth, and an embossed pattern is provided on the convex portions. Absent. In this case, as described above, the embossed pattern provided on the metal foil is formed in a striped pattern when the metal foil contacts and is pressed against the sheet-like cloth material from the convex portion and the opposite side of the embossing roller.

  FIG. 3 is a top view of an example of the embossed metal foil of the present invention. The embossed metal foil 30 has an embossed portion 31 and a smooth portion 32 having a predetermined width on the surface of the malleable metal foil 2 so as to form a striped pattern alternately in parallel at a predetermined interval. A linear narrow groove portion 33 is formed substantially in the center of the smooth portion 32 in parallel to the embossed portion 31.

  Such an embossed metal foil of the present invention generally exhibits the property that wrinkles do not easily appear on the surface, and even if they appear, they do not stand out. In addition, the presence of the embossed portion is thought to improve the strength of the metal foil, so the linearity of the roll of metal foil is enhanced and therefore less wrinkled.

  The embossed metal foil of the present invention can be used as, for example, a coating material that imparts heat resistance, flame retardancy, designability, etc. to a plastic molded body. Specifically, the following phenol resin foam of the present invention It is suitably used as a coating material in a laminate.

  In the phenolic resin foam laminate of the present invention, a sheet-like cloth material, an adhesive layer and a metal foil are sequentially laminated on at least one surface of the phenolic resin foam, and the embossed metal foil described above is used as the metal foil. Used, and has a structure arranged so that the surface side becomes an embossed part.

  Although there is no restriction | limiting in particular in the manufacturing method of the phenol resin foam laminated board of this invention which has such a structure, According to the method of this invention shown below, desired phenol resin foam laminated board can be manufactured efficiently. Can do.

  According to the method of the present invention, a sheet-like cloth material of the face material is discharged onto a face material obtained by sequentially laminating a sheet-like cloth material, an adhesive layer, and an embossed metal foil having an embossed portion on the surface side. The phenol resin foam laminate of the present invention is supplied by bringing the phenol resin foam composition into a face-to-face contact, curing the phenol resin foam composition, and integrating the phenol resin foam and the face material. Can be manufactured.

  The phenolic resin foam laminate of the present invention uses a phenolic resin foam as a base material.

  As the phenol resin foam of the base material, as described in JP-A-6-93128, a phenol resin foam composition obtained by adding, for example, an acid curing agent, a foam stabilizer, a foaming agent, or the like to the phenol resin is cured. Can be obtained.

  Phenol resins used include phenols such as phenol, cresol, xylenol, paraalkylphenol, paraphenylphenol, resorcin, and modified products thereof, and aldehydes such as formaldehyde, paraformaldehyde, furfural, acetaldehyde, sodium hydroxide, potassium hydroxide. A resol type phenol resin obtained by reacting in the presence of an alkaline catalyst such as calcium hydroxide, hexamethylenetetramine, trimethylamine or triethylamine is preferred, but is not limited thereto.

  Examples of the acidic curing agent used include inorganic acids such as sulfuric acid and phosphoric acid, and organic acids such as benzenesulfonic acid, paratoluenesulfonic acid, naphtholsulfonic acid, and phenolsulfonic acid, but are not limited thereto. .

  Examples of the foam stabilizer used include, but are not limited to, silicone-based nonionic surfactants and modified castor oil.

  Examples of the blowing agent used include low boiling point aliphatic hydrocarbons such as pentane, hexane, and heptane, ethers such as isopropyl ether, chlorinated aliphatic hydrocarbons such as methylene chloride, trichloromonofluoromethane, and trichlorotrifluoroethane. Examples include, but are not limited to, fluorine compounds or a mixture of these compounds.

  The above phenol resin foam composition contains metal oxides such as aluminum oxide and zinc oxide, metal powders such as zinc, magnesium and aluminum, and powdery basic substances such as calcium carbonate, magnesium carbonate, barium carbonate and zinc carbonate. You may let them.

  The phenol resin foam can have any shape, but in the case of a rectangular parallelepiped, the thickness between its two main surfaces is preferably 0.5 to 20 cm, particularly 2 to 10 cm.

  As the sheet-like cloth material in the phenol resin foam laminate, a woven fabric, a knitted fabric or a non-woven fabric obtained using at least one selected from inorganic fibers and organic fibers can be used. Of these, non-woven fabric is preferred. The nonwoven fabric may be any nonwoven fabric as long as it is fibrous, has voids, and is hydrophobic, and particularly includes at least one selected from inorganic fiber paper, inorganic fiber nonwoven fabric, and organic fiber nonwoven fabric. Those are preferably used.

  Examples of the inorganic fibers constituting the sheet-like cloth material include glass fibers, carbon fibers, and silicon carbide fibers. Examples of the organic fibers include polyester fibers, vinylon fibers, polyolefin fibers, and polyamide fibers.

Although there is no restriction | limiting in particular in the thickness of the said sheet-like cloth material in this invention, Usually, about 0.1-1 mm, Preferably it is 0.2-0.6 mm, and a fabric weight is about about 10-200 g / m < ² > normally. , Preferably 30 to 150 g / m ² .

  In the phenolic resin foam laminate, there is no particular limitation on the adhesive constituting the adhesive layer interposed between the sheet-like cloth material and the embossed metal foil, and conventionally known resins such as polyolefin resins and acrylic resins A resin containing at least one selected from resins, epoxy resins, urethane resins, silicone resins, synthetic rubbers, and natural rubbers can be used. Examples of the polyolefin resin include a polyethylene resin such as a low density polyethylene resin.

The adhesive layer may have either a single layer structure or a multiple layer structure.
The adhesive layer having a single layer structure is composed of the above-mentioned various adhesives, and the thickness thereof is preferably 5 to 100 μm.

  In the case of a multi-structure layer, it is preferable that the type of adhesive constituting each layer is different, for example, a two-layer structure composed of a first adhesive layer and a second adhesive layer. It is done. In this case, the first adhesive layer is provided in contact with the sheet-like cloth material, and the adhesive constituting the first adhesive layer has an original function as an adhesive (adhesion between the phenol resin foam and the face material). In order to exhibit the property, those containing at least one selected from the aforementioned resins are used.

  On the other hand, the second adhesive layer is provided in contact with the embossed metal foil layer in the face material, and the second adhesive layer adhesive is generated by a curing reaction of the phenol resin foam composition. Then, in order to dissipate the thermal water vapor that has risen through the sheet-like cloth material and the first adhesive layer from the end portion to the outside, a resin having a relatively low affinity with water vapor or water is preferably used. Examples of such resins include polyolefin resins such as polyethylene resins, ethylene-vinyl acetate resins, ethylene-vinyl acetate resin portions or complete hydrolysates, ethylene-acrylic acid ester-anhydride group-containing monomers ternary copolymer Examples thereof include modified polyolefin resins such as coalescence.

  In addition, when the adhesive agent of a 1st adhesive bond layer is polyolefin resin, and the adhesive agent of a 2nd adhesive bond layer is modified polyolefin resin, both shall use another kind of polyolefin resin. For example, when the adhesive of the first adhesive layer is a polyethylene resin, a modified polyolefin resin is used as the adhesive of the second adhesive layer.

The thickness of the first adhesive layer is preferably 5 to 100 μm, particularly preferably 15 to 45 μm, in order to achieve the purpose of strong bonding between the phenol resin foam and the face material. Further, the thickness of the second adhesive layer is preferably 5 to 100 μm, particularly preferably 15 to 45 μm, in order to achieve the purpose of escape of water vapor from the end portion to the outside.
In the phenolic resin foam laminate of the present invention, a resin coat layer can be provided on the surface of the embossed metal foil provided on the outer surface as desired.

The resin coat layer preferably has heat resistance and transparency. A resin that can be baked at 100 ° C. or higher and forms a transparent coating layer that does not hinder the radiant heat reflection function of the metal foil can be used. For example, an epoxy resin baking coat and a silicone resin baking coat are preferably used. In addition, a polyethylene coat or film, a polypropylene coat or film, a vinyl chloride sheet, an acrylic coat, and the like are possible, but it is generally difficult to coat thinly. Moreover, the coating amount of a resin coat is about 0.3-5 g / m < ² > normally, Preferably it is 0.4-3 g / m < ² >. If the coating amount is less than 0.3 g / m ² , uniform surface coating becomes difficult and sufficient anticorrosion properties cannot be obtained. On the contrary, if the coating amount exceeds 5 g / m ² , the corrosion resistance is not a problem, but the heat resistance and the combustion resistance are insufficient, and the flame retardancy of the laminate is lowered, which is not suitable.

  FIG. 4 is a schematic cross-sectional view of an example of the phenolic resin foam laminate of the present invention. The phenolic resin foam laminate 40 is embossed on one side of the phenolic resin foam 41 on the sheet-like cloth material 8, the first adhesive layer 42, the second adhesive layer 43, and the resin coat layer 44 side. The embossed metal foil 30 having a portion and the resin coat layer 44 are sequentially laminated.

Next, the suitable embodiment for manufacturing the phenol resin foam laminated board of this invention is demonstrated.
First, a face material is prepared by sequentially laminating a sheet-like cloth material, a first adhesive layer, a second adhesive layer, and an embossed metal foil having an embossed portion on the surface side.

  The face material having the above-described structure is extruded into two layers so as not to mix the adhesive to be the first adhesive layer and the adhesive to be the second adhesive layer through the die, thereby forming the first adhesive layer. The sheet-like cloth material is supplied to the adhesive side, and the embossed metal foil is supplied to the adhesive side serving as the second adhesive layer, while being inserted between the pair of rolls to be integrated.

  According to the method of the present invention, the face material obtained in this way is supplied so as to come into contact with the phenol resin foam composition from which the sheet-like cloth material of the face material is discharged, and the phenol resin foam composition is supplied. It hardens | cures and a desired phenol resin foam laminated board is obtained by integrating a phenol resin foam and a face material.

  In such a manufacturing method, the used face material has a first adhesive layer having high adhesiveness between the sheet-like cloth material and the embossed metal foil layer, and a second adhesive layer having water vapor escape properties. Therefore, the phenol resin foam and the face material are firmly bonded to each other, and there is no problem of peeling of the metal foil layer in the face material due to the stay of hot water vapor generated when the phenol resin foam composition is cured. Therefore, the phenol resin foam laminated board which has desired heat resistance, a flame retardance, heat ray reflectivity, and designability can be obtained.

Below, the manufacture example of the phenol resin foam laminated board by which the face material was provided in the two surfaces of the phenol resin foam is demonstrated concretely based on FIG.
In FIG. 5, the phenol resin foam laminate manufacturing apparatus 10 includes a pair of upper and lower conveyors 11 and 12 that are opposed to 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.

  The manufacturing apparatus 10 includes support portions 15 and 16 that are wound around the face materials 3 and 3 in a roll shape and are rotatably supported, corresponding to the upper and lower conveyors 11 and 12, respectively. , 12 are driven so that 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 upper and lower conveyors 11 and 12 and mixed by the mixer 17. The phenol resin foam 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 includes a heating device 20 for thermosetting the phenol resin foam composition 18 that is supplied between the pair of face materials 3 and 3 and conveyed downstream.

  Further, the manufacturing apparatus 10 has the edges 3a and 3a along the conveying direction of the pair of face materials 3 and 3 conveyed by the pair of upper and lower conveyors 11 and 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 edges 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.

  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 phenol resin foam 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 and 3, and the phenol resin foam composition 18 is foamed in the closed space and is thermally cured by the heating device 20 to form the phenol resin foam 2. Face materials 3 and 3 are laminated and conveyed on both sides of the phenol resin foam 2, and finally, the edge portions 3 a and 3 a that are joined and closed are removed, thereby obtaining the phenol resin foam laminate 1. It is done.

  According to such a method for producing the phenol resin foam laminate 1, the face materials 3 and 3 are continuously run side by side, and the phenol resin foam composition 18 is placed between the running face materials 3 and 3. By supplying and foam-curing, since the face materials 3, 3 are continuously laminated integrally on both surfaces of the foam-cured phenol resin foam 2, the phenol resin foam laminate 1 is It can be obtained easily and the manufacturing cost can be reduced.

The phenol resin foam laminate of the present invention has the following effects.
When a metal foil such as an aluminum foil is pasted on a phenolic resin foam, the surface of the metal foil after coating is a metal foil due to irregularities in the smoothness of the surface of the phenolic resin foam or defects in processing when the metal foil is coated. The surface may be uneven, distorted or scratched. On the other hand, in the phenolic resin foam laminate of the present invention, the occurrence of wrinkles and unevenness of metal foil or wrinkles due to defects in the smoothness of the surface of such a foam becomes inconspicuous, and scratches are not noticeable. Hard to occur. As a result, quality such as anti-corrosion property during long-term use, flame retardancy during high-temperature heating, heat resistance, heat ray reflectivity, and designability (high quality) is maintained. The effect of obscuring the surface defects of the phenol resin foam is much greater than when using an unembossed metal foil.

  In particular, when an aluminum foil is used as the embossed metal foil, in addition to the above effects, it becomes inexpensive and is economically advantageous.

EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited at all by these examples.
Example 1
(1) Production of face material As a nonwoven fabric, Cumulus VH-4260 (Nippon Vilene Co., Ltd. glass fiber nonwoven fabric basis weight 60 g / m ² ) is used as an adhesive layer, and low density polyethylene resin 1384R (Tosoh Corp. Density polyethylene resin), using an aluminum foil (as defined in JIS H 4160) as a metal foil, and by embossing the surface of the metal foil according to a method of embossing, a nonwoven fabric / A face material having a configuration of adhesive layer / embossed aluminum foil was produced.
(2) Manufacture of phenolic resin foam laminates 84 parts by weight of phenol, 558 parts by weight of formalin 558 parts by weight, and 11.1 parts by weight of sodium hydroxide were placed in a flask and reacted at 90 ° C. for 60 minutes, followed by reaction. The reaction solution was neutralized by adding oxalic acid so that the pH of the solution became 7.0 to 7.3, and dehydrated at 80 ° C. under reduced pressure to obtain a resol type phenol resin. This resol type phenol resin was 3.0% by weight of free phenol and 1.9% by weight of free formalin.

  20 parts by weight of phenolsulfonic acid as an acidic curing agent and 7 parts by weight of methylene chloride as a foaming agent were added to the resol type phenolic resin obtained above and stirred to obtain a resol type phenolic resin foamed composition.

  The obtained resol type phenolic resin foam composition was supplied to the production apparatus shown in FIG. 5 together with the face material obtained in (1) above to produce a phenolic resin foam laminate. The body laminate had no peeling of the metal foil layer in the face material, and had excellent heat resistance, flame retardancy, heat ray reflectivity, and design.

  Table 1 shows the evaluation results of the noticeability of wrinkles and scratches of the aluminum foil in the face material and the aluminum foil in the laminate.

Comparative Example 1
A phenolic resin foam laminate was produced in the same manner as in Example 1 except that an unembossed aluminum foil face material was used. The obtained phenol resin foam laminate had no exfoliation of the metal foil layer in the face material as in Example 1, and had excellent heat resistance, flame retardancy, heat ray reflectivity, and design.
Table 1 shows the evaluation results of the noticeability of wrinkles and scratches of the aluminum foil in the face material and the aluminum foil in the laminate.

Example 2
A phenol resin foam laminate was produced in the same manner as in Example 1 except that the second adhesive layer was not provided in the production of the face material in Example 1.
Table 1 shows the evaluation results of the noticeability of wrinkles and scratches of the aluminum foil in the face material and the aluminum foil in the laminate.

Example 3
A phenolic resin was prepared in the same manner as in Example 2 except that a polyester fiber nonwoven fabric [manufactured by Unitika Ltd., “Matrix 70505FLV”, spunbond] was used instead of the glass fiber nonwoven fabric for the production of the face material in Example 2. A foam laminate was produced.
Table 1 shows the evaluation results of the noticeability of wrinkles and scratches of the aluminum foil in the face material and the aluminum foil in the laminate.

(Note) Evaluation of wrinkle / scratch conspicuousness of aluminum foil 100 face plates and 90 phenolic foam laminates each having a width of 90 cm and a length of 180 cm were evaluated visually according to the following criteria.
○: Wrinkles and scratches are hardly noticeable.
Δ: Wrinkles and scratches are slightly noticeable.
X: Wrinkles and scratches are conspicuous and cannot be shipped as a product.

  The phenolic resin foam laminate of the present invention is coated with an embossed metal foil, exhibits the effect of covering the surface defects of the foam, and takes into account the design and aesthetic effects, and is used for a long time Corrosion resistance, flame retardancy, heat resistance, heat ray reflectivity, design characteristics, etc. are maintained, and it is suitably used as a flame retardant thermal insulation panel, a heat resistant thermal insulation panel, and the like.

It is explanatory drawing which shows an example of the method of embossing on the metal foil surface, when obtaining the face material which consists of embossing metal foil / adhesive layer / sheet-like cloth material. It is a typical perspective view (a) and a typical longitudinal section (b) of an example of an embossing roller. It is a top view of one example of the embossing metal foil of this invention. It is typical sectional drawing of one example of the phenol resin foam laminated board of this invention. It is the schematic of one example of the manufacturing apparatus of a phenol resin foam laminated board.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1,40 Phenolic resin foam laminated board 2 Metal foil 3 Face material 3a Edge of face material 4 Embossing roller 5 Face-to-face roller 6 Guide roller 7 Adhesive 8 Sheet-like cloth material 10 Manufacturing apparatus 11 Upper conveyor 12 Lower conveyor 13 Endless steel Belt 14 A plurality of rollers 15 and 16 Face material support portion 17 Mixer 18 Phenolic resin foam composition 19 Guide tube 20 Heating device 21 Closing means 22 Guide member 30 Embossed metal foil 31 Embossed portion 32 Smooth portion 33 Linear strip groove portion 41 Phenol resin foam 42 First adhesive layer 43 Second adhesive layer 44 Resin coat layer

Claims (9)

  An embossed metal foil obtained by embossing at least one surface of a malleable metal foil.   On at least one surface, embossed portions and smooth portions having a predetermined width are alternately arranged in parallel at a predetermined interval to form a striped pattern, and the embossed portion is provided at substantially the center of the smooth portion. The embossed metal foil according to claim 1, wherein the embossed metal foil has a linear narrow groove portion parallel to the surface.   The embossed metal foil according to claim 1 or 2, wherein the malleable metal foil is an aluminum foil.   A sheet-like cloth material, an adhesive layer and a metal foil are sequentially laminated on at least one surface of the phenol resin foam, and the metal foil is used as an embossed metal foil according to claim 1, 2 or 3, A phenolic resin foam laminate, characterized in that the side is an embossed part.   The phenolic resin foam laminate according to claim 4, wherein the sheet-like cloth material is a woven cloth, a knitted cloth or a non-woven cloth obtained by using at least one selected from inorganic fibers and organic fibers.   The adhesive layer is composed of a single layer or a plurality of layers including at least one selected from polyolefin resins, acrylic resins, epoxy resins, urethane resins, silicone resins, synthetic rubbers, and natural rubbers, and is bonded. The phenol resin foam laminate according to claim 4 or 5, wherein when the agent layer is a plurality of layers, the type of adhesive constituting each layer is different.   The phenol resin according to claim 6, wherein when the adhesive layer is a single layer, the thickness is 5 to 100 μm, and when the adhesive layer is composed of two layers, the thickness of each layer is 5 to 100 μm. Foam laminate.   The phenolic resin foam laminate according to any one of claims 4 to 7, which has a resin coat layer on the surface of the embossed metal foil.   A face material formed by sequentially laminating a sheet-like cloth material, an adhesive layer, and an embossed metal foil having an embossed portion on the surface side, and the phenol resin foam composition on which the sheet-like cloth material of the face material is discharged The phenol resin foam according to any one of claims 4 to 8, wherein the phenol resin foam composition and the face material are integrated by supplying them so as to contact each other and curing the phenol resin foam composition. A method for manufacturing a body laminate.

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