JP2010228960A - Slurry, prepreg, and nonflammable base material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a base material having flame retardancy by using an inorganic substance as a binder component. <P>SOLUTION: A slurry comprising components (a), (b) and (c) described below, and a suitable amount of water is impregnated in an inorganic fiber sheet, and dried. (a): An alkaline metal silicate salt; (b): a metal oxide and/or a metal hydroxide; and (c): an inorganic filler. The proportion of the (a) is 3 to 15 wt.% to the total weight of ((a)+(b)+(c)). As component (a), sodium silicate is used; as component (b), zinc oxide and aluminum hydroxide are used; and as component (c), calcium carbonate is used. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a slurry, a prepreg, and an incombustible substrate.

  Conventionally, a decorative board having a flame-retardant function is known, and the base material has been impregnated with a slurry containing an organic resin as a binder component and a flame retardant, and dried to use a prepreg. .

Japanese Patent Laid-Open No. 7-89753 JP 11-302064 A Japanese Patent Laid-Open No. 9-327808 JP-A-11-300877

  However, there is a limit to the amount of organic resin added as a binder component in order to impart flame retardancy. In other words, when the organic resin is increased, the flame retardancy tends to be lowered, and when it is decreased, the adhesion between the prepregs is deteriorated.

The present invention is characterized in that a slurry comprising the following components (a), (b) and (c) and an appropriate amount of water is impregnated into an inorganic fiber sheet and dried.
(A) alkali metal silicate (b) metal hydroxide and / or metal oxide (c) inorganic filler

  Alkali metal silicate as a binder component has low water resistance, but the product obtained by impregnating an inorganic fiber sheet with a slurry in which a metal hydroxide or metal oxide is dispersed in an appropriate amount of water and hot pressing is used. It has water resistance and nonflammability. Furthermore, since it is not necessary to use an organic flame retardant in the present application, there is no concern about toxicity.

The alkali metal silicate of component (a) according to the present invention represents an alkali metal silicate compound, is represented by the general formula M ₂ O · nSiO ₂ , and is cured to form a glassy silicate polymer. In this invention, it becomes a main material of an inorganic binder. M is an alkali metal, n is a molar ratio of M ₂ O and SiO _2, and generally 1.0 ≦ n ≦ 4.5. Specific examples include potassium silicate, sodium silicate, lithium silicate and the like, and two or more kinds may be used. The bond strength decreases in the order of Na>K> Li, and the water resistance decreases in the order of Li>K> Na.

The proportion of the component (a) in the total amount of ((a) + (b) + (c)) is preferably 3 to 15% by weight, more preferably 5 to 13.5% by weight. If it is less than 1, adhesion between prepregs cannot be obtained.
On the other hand, if the upper limit is exceeded, the glass component will ooze out during hot pressing.

The component (b) metal oxide and / or metal hydroxide according to the present invention functions as a curing agent for the (a) alkali metal silicate, and the component (a) is compatible with the component. Select and use. Examples of the metal oxide include zinc oxide, zinc borate (2ZnO.3B ₂ O ₃ .3.5H ₂ O), magnesium oxide, calcium oxide, aluminum oxide, and the like. Examples of the metal hydroxide include aluminum hydroxide, Examples thereof include metal hydroxides such as magnesium hydroxide and tricalcium aluminate hexahydrate. For water resistance, zinc oxide or aluminum hydroxide is largely involved.

  The average particle size of component (b) is preferably 0.3 to 50 μm, more preferably 0.5 to 10 μm. If the lower limit is not reached, secondary agglomeration is likely to occur, resulting in lumps and poor impregnation. On the other hand, if the upper limit is exceeded, unevenness on the surface of the non-combustible substrate tends to be noticeable. In addition, (b) component may use 2 or more types together, and may use together the same type and different average particle diameter.

  The blending ratio of the components (a) and (b) is preferably (a) :( b) = 100: 30 to 900 in weight ratio. More preferably, it is 100: 35-75. If the blending ratio of the component (b) is less than the lower limit, the water resistance of the incombustible substrate is lowered. On the other hand, if the upper limit is exceeded, the mixture thickens and it becomes difficult to control the impregnation rate.

  The metal hydroxide may be surface-treated with a coupling agent such as aminosilane, acrylic silane, or epoxysilane for the purpose of improving interfacial adhesion with alkali metal silicate (inorganic binder).

  In addition to the aggregates of the components (a) and (b), an inorganic filler is blended as the component (c). (C) Examples of the inorganic filler include calcium carbonate, magnesium carbonate, silica, talc, fly ash and the like. Among these, it is desirable to use calcium carbonate that is superior in terms of workability and machinability.

  There is no restriction | limiting in particular as calcium carbonate, Heavy calcium carbonate, light calcium carbonate (precipitation calcium carbonate), etc. can be used. Heavy calcium carbonate having an average particle diameter of 0.05 to 20 μm, more preferably 1 to 8 μm is preferable. If the lower limit is not reached, secondary agglomeration is likely to occur and agglomeration is likely to occur, and impregnation is likely to deteriorate. The surface of the material is not smooth, resulting in poor appearance. Light calcium carbonate refers to calcium carbonate that is chemically produced by firing limestone, and heavy calcium carbonate refers to finely powdered calcium carbonate prepared by dry or wet pulverization of white crystalline limestone. In addition, (c) component may use 2 or more types together, and may use together the same type and different average particle diameter.

  The blending ratio of the components (a) and (c) is preferably (a) :( c) = 100: 125 to 1800 in weight ratio. More preferably, it is 150: 720-900. If the blending ratio of the component (c) is less than the lower limit, the glass component oozes out during pressing. On the other hand, if the upper limit is exceeded, the mixture thickens and it becomes difficult to control the impregnation rate.

  In addition, a dispersant for improving the dispersibility of the components (a), (b) and (c), a penetrant, an antifoaming agent and a thickening agent for improving the permeability to the inorganic fiber sheet. An agent or the like may be added and mixed at a ratio of 1 to 10 parts by weight with respect to 100 parts by weight of component (a).

  Examples of the dispersant include anionic, cationic, nonionic and amphoteric dispersants. As the anionic dispersant, a carboxylic acid polymer or a salt thereof, naphthalene sulfonate formaldehyde condensate, melamine sulfonate formaldehyde condensate, lignin sulfonate, tripolyphosphate, hexametaphosphate and the like are preferable. As the cationic dispersant, alkyltrimethylammonium salt, dialkyldimethylammonium salt and the like are preferable. As the nonionic dispersant, polyoxyalkylene alkyl ether is preferable, and as the amphoteric dispersant, alkylbetaine is preferable.

  Examples of penetrants used in the present invention include anionic, cationic, nonionic, and amphoteric penetrants. As the anionic penetrant, alkylbenzene sulfonate, alkyl sulfate ester salt, polyoxyalkylene alkyl sulfate ester salt, and dialkyl sulfosuccinate are preferable. As the cationic penetrant, alkyltrimethylammonium salt, dialkyldimethylammonium salt and the like are preferable. As the nonionic penetrant, polyoxyalkylene alkyl ether is preferable. As the amphoteric penetrant, alkyl betaines are preferred.

  In particular, as the penetrant, it is preferable to use a nonionic surfactant that is not easily affected by acids, alkalis, and inorganic salts and has good compatibility with water and a solvent, particularly an ether type nonionic surfactant. it can.

  In the case where different ions coexist (cation type and anion type), a complex is formed. Therefore, the dispersing agent and the penetrating agent are selected to be the same ionic or nonionic type.

Components (a), (b), and (c) are dispersed in an appropriate amount of water to form a slurry, which is used for impregnation. Examples of the inorganic fiber sheet impregnated with this slurry include glass fiber, rock wool, carbon fiber, ceramic, non-woven fabric of inorganic fiber such as alumina, and woven fabric. The basis weight of the inorganic fiber sheet is 20 to 20%. A range of 200 g / m ² is preferred. In particular, it is preferable to use a glass fiber nonwoven fabric excellent in heat resistance and flame resistance.

  The prepreg is obtained by impregnating the slurry into an inorganic fiber sheet and drying, and the impregnation ratio (%) is operated to be 800 to 2000% by the calculation method shown in Equation 1.

Incombustible substrate 1 sheet of the prepreg of the present invention, or a plurality of stacked, temperature 120 to 150 ° C. in heat molding machine, pressure 30~70kg / cm ^2, is molded under conditions of time 60-120 minutes.

A slurry (A) containing the following components was impregnated into a glass fiber nonwoven fabric of 78 g / m ² so that the impregnation amount shown in Equation 1 was 1130% and dried to obtain a prepreg.
Inorganic binder component (a) 80 parts by weight of sodium silicate (No. 1 sodium silicate, manufactured by Toso Sangyo Co., Ltd.)
Curing agent (b) 50 parts by weight of zinc oxide (average particle size 0.6 μm)
Inorganic filler (c) 720 parts by weight of calcium carbonate (average particle size 1-8 μm, manufactured by Maruo Calcium Co., Ltd.)
(D) Water 300 parts by weight Dispersant 3 parts by weight (Polycarboxylic acid type polymer surfactant, trade name Demol EP, manufactured by Kao Corporation)
3 parts by weight of penetrant (polyoxyethylene alkyl ether, trade name Emulgen 707, manufactured by Kao Corporation)
Next, five of the obtained prepregs were hot-press molded at a temperature of 140 ° C., a pressure of 70 kg / cm ² and a time of 105 minutes to obtain a non-combustible substrate.

  In Example 1, it implemented similarly except having made the (a) component into 40 weight part.

  In Example 1, it implemented similarly except having made the (a) component into 120 weight part.

  In Example 1, it implemented similarly except having made (b) component 30 weight part.

  In Example 1, it implemented similarly except having made the (b) component into 80 weight part.

  In Example 1, (b) component was changed similarly to aluminum hydroxide with an average particle diameter of 8 micrometers, and it implemented similarly except having been 50 weight part.

  In Example 6, it implemented similarly except having made aluminum hydroxide into 30 weight part.

  In Example 6, it implemented similarly except having made aluminum hydroxide into 100 weight part.

  In Example 1, it implemented similarly except having used 20 weight part of zinc oxides and 100 weight part of aluminum hydroxide as (b) component.

  In Example 1, it implemented similarly except having used 100 weight part of zinc oxides and 20 weight part of aluminum hydroxide as (b) component.

  In Example 1, it implemented similarly except having made the (c) component into 400 weight part.

  In Example 1, it implemented similarly except having made (c) component 900 weight part.

  In Example 5, it implemented similarly except having made (b) component 600 weight part and (c) component 120 weight part.

Experimental example 1
In Example 1, it implemented similarly except having made the (a) component into 50 weight part.

Experimental example 2
In Example 1, it implemented similarly except having made the (a) component into 350 weight part.

Experimental example 3
In Example 1, it implemented similarly except having made the (b) component into 10 weight part.

Experimental Example 4
In Example 1, it implemented similarly except having made (b) component into 150 weight part.

Experimental Example 5
In Example 4, it implemented similarly except having made the (b) component into 10 weight part.

Experimental Example 6
In Example 4, it implemented similarly except having made (b) component 150 weight part.

Experimental Example 7
In Example 4, it implemented similarly except having made 100 weight part of (c) component.

Experimental Example 8
In Example 4, it implemented similarly except having made the (c) component into 1000 weight part.

  The evaluation results are shown in Table 1, Table 2, and Table 3.

The test method is shown below.
Nonflammability: The total calorific value is 8 MJ / m ² or less and the maximum heat generation rate exceeds 200 kW / m ² for 10 seconds or more in the exothermic test / evaluation method of a 20 minute test using a corn calorimeter according to ISO 5660. The case where there is not is set as ◯.
Formulation and impregnation property: A slurry was prepared, and the viscosity was ◯ that could be impregnated.
Formability: When the component (a) did not exude at the time of press molding, it was indicated as ◯, and when it was present, it was indicated as ×.
Adhesiveness: Cracks between layers of the incombustible base material were visually confirmed. No cracks were marked with ◯, and cracks with x.
Boiling resistance: JIS K 6902; 1998 (Thermosetting resin high-pressure decorative board test method) boiling resistance test was carried out.

Claims (6)

A slurry comprising the following components (a), (b), (c) and an appropriate amount of water.
(A) alkali metal silicate (b) metal hydroxide and / or metal oxide (c) inorganic filler The slurry according to claim 1, wherein the ratio of the component (a) to the total weight of ((a) + (b) + (c)) is 3 to 15% by weight. The slurry according to claim 1 or 2, wherein a blending ratio of the components (a) and (b) is (a) :( b) = 100: 30 to 900 in a weight ratio. 4. The slurry according to claim 1, wherein the blending ratio of the components (a) and (c) is (a) :( c) = 100: 125 to 1800 in a weight ratio. A prepreg obtained by impregnating and drying an inorganic fiber sheet with the slurry according to claim 1, 2, 3 or 4. A non-combustible base material obtained by hot-pressing the prepreg according to claim 5.