JP2011068117A - Surfacing sheet and foaming resin-made thermal insulation board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a surfacing sheet which neither causes resin leakage in a production process of an foaming resin-made thermal insulation board nor causes a failure even when used in a hot asphalt application method but which is suitable for obtaining the foaming resin-made thermal insulation board. <P>SOLUTION: The surfacing sheet of the foaming resin-made thermal insulation board is an inorganic fiber nonwoven fabric which is based on an inorganic fiber and a resin binder and has a surface layer portion on one surface thereof and a nonwoven fabric layer portion to be continued from the surface layer portion to the thickness direction thereof. The surface layer portion comprises such a nonwoven fabric-paint mixed layer that an inorganic pigment in the paint applied to the surface thereof and the resin binder are fixed in the nonwoven fabric in states penetrated into the surface layer portion. The nonwoven fabric layer portion comprises a sole layer of the nonwoven fabric having 30-500 μm average thickness. The surfacing sheet has 5-1,500 cc/min/cm<SP>2</SP>Coresta permeability (according to a measurement method based on the Coresta recommendation method No40 ISO2965) and 26-34 wetting index. The foaming resin-made thermal insulation board has the surfacing sheet as a surfacing. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

The present invention relates to an inorganic fiber sheet suitable for the surface material of a heat insulating board made of foam resin,
More specifically, the surface material sheet made of an inorganic fiber nonwoven fabric and the surface material sheet suitable for obtaining a heat-insulated board made of foamed resin that does not cause a problem even by a severe construction method such as a thermal asphalt method, and the surface material sheet The present invention relates to a foamed resin heat insulating board as a material.

For the purpose of heat insulation and waterproofing, a heat insulating structure in which a heat insulating board, a waterproof sheet, etc. are laminated on a concrete surface is adopted on the roof of a building. As a construction method for constituting this heat insulation structure, for example, a thermal asphalt construction method can be mentioned. In the thermal asphalt method, first, a molten asphalt of about 250 to 300 ° C. is applied to the concrete surface, and a heat insulation board is laid before the temperature is lowered. The area to apply hot asphalt at a time is usually one heat insulation board, and by repeating this, the heat insulation board is laid on the entire surface of the concrete. Next, a rolled-up waterproof sheet is rolled and pasted on the heat insulating board laid while applying hot asphalt.

As a heat insulating board used in the thermal asphalt method, a hard foamed urethane board having surface materials on both sides is generally used. An example of the manufacturing process of this rigid foam urethane board is shown in FIG. First, the polyol / polyisocyanate mixed solution 23 is applied to the surface material 21 (lower surface material), another surface material 22 (upper surface material) is adhered after the start of foaming, and cured while maintaining the thickness with the double conveyor 24. The rigid foamed urethane board 26 is obtained by cutting. The mixed solution 23 usually contains a foaming agent (for example, cyclopentane) and a foam stabilizer (for example, a silicone-based foam stabilizer) in addition to polyol and polyisocyanate. The polyol and polyisocyanate react at room temperature to form a urethane bond, thereby forming a urethane resin. Since this reaction is an exothermic reaction, foaming occurs when the foaming agent evaporates and expands. The foam stabilizer stabilizes the foam by increasing the surface tension of the foaming system, and increases the compatibility of each material during mixing.

The surface material holds the resin and plays a role of imparting mechanical strength and dimensional stability of the heat insulating material. Examples of the surface material include mixed paper of wood pulp and inorganic pigment, such as calcium carbonate mixed paper and aluminum hydroxide mixed paper. Wood pulp has a large dimensional change due to moisture absorption and desorption. Heating causes the wood pulp to dry and shrink, causing warpage and distortion of the board, which is not suitable because it tends to cause problems during construction. Moreover, since wood pulp corrodes, we are anxious also about durability.

Therefore, a nonwoven fabric mainly composed of inorganic fibers such as glass fibers has been used.
Nonwoven fabrics mainly composed of inorganic fibers generally have a large pore size, and the problem is that the resin solution gets through when the polyol / polyisocyanate mixed solution (hereinafter referred to as “resin solution”) is applied, thereby contaminating the process (hereinafter referred to as “resin”). Leakage ”). For this reason, the current situation is that wood pulp is mixed or impregnated with asphalt, but as mentioned above, the use of wood pulp is problematic, and asphalt is impregnated with asphalt. There is a problem in that the components contained therein are eluted, causing cell roughening and lowering the heat insulation performance.

Under such circumstances, an inorganic sheet has been proposed in which a coating layer made of an inorganic filler and an organic binder is provided on one or both sides of an inorganic sheet mixed with an inorganic filler (Patent Document 1).
). However, the inorganic sheet of this document has a low air permeability, and the inorganic sheet may be peeled off by the pressure of the secondary foaming gas due to heating during application of hot asphalt. If there is such peeling, for example, when a force for lifting the rooftop is generated in a strong wind such as a typhoon, the floor may be peeled off.
Therefore, the surface material is also required to have air permeability for allowing the secondary foaming gas to escape.

As a method for solving this, a sheet containing a fluorine-based water / oil repellent (Patent Document 2), a sheet substrate containing a polyfluoroalkyl group-containing compound (Patent Document 3), and the like have been proposed. Although these have sufficient breathability, they prevent penetration of the resin due to the water and oil repellency of the fluorine-based compound, but due to their strong water and oil repellency, they have excellent adhesion to asphalt and foamed resin. Inferior and easy to peel at the interface. Furthermore, the fluorine-based compounds are likely to generate decomposition products that are harmful to health and the environment when heated during application of hot asphalt, and cannot be easily adopted.

JP-A-1-198336 JP-A-9-310284 JP-A-57-107772

An object of the present invention is to provide a sheet for a surface material that is suitable for obtaining a foamed resin board that is free from resin leakage in the manufacturing process of the foamed resin board and that does not cause any problems even when used in a thermal asphalt method. is there.

As a result of various investigations to solve the above problems, the inventors of the present invention have made the air permeability and the wetting index within a specific range in a sheet for a surface material coated with a pigment on an inorganic fiber nonwoven fabric, and have a specific thickness. It has been found that providing a single layer of nonwoven fabric can prevent resin leakage and swelling during application of hot asphalt, and the present invention has been completed.
The present invention for solving the above problems includes the following inventions.

(1) A non-woven fabric in which a surface layer portion on one side of an inorganic fiber non-woven fabric mainly composed of an inorganic fiber and a resin binder is infiltrated into the surface layer portion on one side of the coating material coated on the one side. An inorganic fiber comprising a nonwoven fabric-coating composite layer fixed inside, and a nonwoven fabric layer portion having an average thickness of 30 μm or more and 500 μm or less, the nonwoven fabric layer portion continuing in the thickness direction from the surface layer portion comprising the nonwoven fabric-coating composite layer It is a non-woven fabric, characterized in that the Cholesta air permeability (according to a measurement method based on Cholesta recommended method No. 40 ISO 2965) is 5 to 1500 cc / min / cm ² and the wetness index of the coated surface is 26 to 34. , Sheet for surface material of insulation board made of foam resin.

(2) The sheet for a surface material of a heat insulating board made of foamed resin as described in (1) above, wherein the average thickness of the surface layer portion composed of the “nonwoven fabric-coating composite layer” is 20 μm or more.
(3) Item (1) or (2), wherein the inorganic fiber nonwoven fabric is a glass fiber nonwoven fabric.
The sheet for the surface material of the foamed resin heat insulating board as described in the item).
(4) The foamed resin according to any one of (1) to (3) above, wherein the resin binder in the paint is a polyolefin resin used in a resin emulsion state. Sheet for surface material of heat insulating board.
(5) The inorganic pigment in the paint is engineered kaolin, (1)
The sheet | seat for surface materials of the foaming resin heat insulation board in any one of claim | item (4).

(6) A foamed resin heat insulating board having the surface material sheet according to any one of the above items (1) to (5) as a surface material on at least one side of the foamed resin layer.
(7) The foamed resin thermal insulation board according to item (6), wherein the foamed resin layer is a hard foamed urethane resin layer.

By using the sheet for a surface material of the present invention, a foamed resin board can be produced without contaminating the process, and the obtained foamed resin board can be used without causing any trouble even in the thermal asphalt method.

Sheet cross-sectional schematic diagram for surface material Manufacturing process diagram of rigid foam urethane board Cross-sectional schematic diagram of rigid urethane foam board

The sheet | seat for surface materials of the heat insulation board made from foamed resin of this invention has a nonwoven fabric layer internal structure as it is shown by the cross-sectional schematic diagram illustrated by FIG.
The sheet for a surface material of the present invention is based on an inorganic fiber nonwoven fabric formed by bonding inorganic fibers 13 with a resin binder, and the back side that is pressed against the foamed resin layer in a molten state when the foamed resin board is formed is a paint. On the non-coating surface, the opposite surface side is the coating surface.

The surface layer portion of the non-woven fabric on the paint coating surface side is fixed in the non-woven fabric layer with the inorganic pigment and resin binder in the coated paint penetrating into the surface layer portion to form a “non-woven fabric-paint composite layer” 12 Yes. As shown in the drawing, in the “nonwoven fabric-paint composite layer” 12, voids formed between the inorganic fibers 13 in the nonwoven fabric layer are filled with a coating 14 made of an inorganic pigment and a resin binder, and the voids are formed. Although it is in a reduced state, the air permeability that allows the secondary foaming gas generated by the heat during the construction of the foamed resin board to escape to the outside through the “nonwoven fabric-paint composite layer” 12 is reduced as described above. It is ensured by the through hole formed by the gap.

The surface layer portion of the nonwoven fabric on the coating surface side is in a state where the coating material substantially penetrates into the nonwoven fabric to form a nonwoven fabric / paint composite layer. The state in which the coating material substantially penetrates into the nonwoven fabric refers to a state in which the inorganic fibers constituting the nonwoven fabric are exposed or the form can be observed when the coated surface of the surface material sheet is observed. If the coating layer is formed on the surface of the nonwoven fabric so that the coating does not sufficiently penetrate the nonwoven fabric and the form of the inorganic fibers that make up the nonwoven fabric is not observable, the interface failure of the nonwoven fabric / coating layer or the cohesive failure inside the coating layer Peeling easily occurs.

The layer on the non-coating surface side of the nonwoven fabric is the nonwoven fabric single layer 11 and is a layer rich in the voids unique to the nonwoven fabric. Therefore, in addition to being a layer having excellent heat insulation properties, A foamed resin board in which the molten resin layer is cured in a state where a part of the molten resin penetrates into the surface layer portion of the nonwoven fabric when pressed against the foamable resin layer, and the joined state between the foamed resin layer and the surface substrate is extremely good. Is a layer having a surface having an anchor function.

Next, the manufacturing process of the rigid foaming urethane board at the time of using the surface material sheet of this invention as a surface material of both surfaces is illustrated in FIG. In FIG. 2, the surface material 21 on the lower surface side and the surface material 22 on the upper surface side are fed so that the non-coated surface is in contact with the foamable resin layer 23. Surface material 21 on the lower surface side
The foamable resin liquid 23 is applied to the non-coated surface, and the top surface material 2 is applied to the foamed resin layer.
The hard foamed urethane board 26 in which the surface materials 21 and 22 are adhered to both surfaces of the foamed urethane resin layer 25 is produced by pressure-bonding the uncoated surface 2 and curing the molten urethane resin layer.
In addition, although the surface material 22 on the upper surface side may use a material other than the sheet for the surface material of the present invention, if different surface materials are used, the warpage of the board is likely to occur. It is preferable to use the surface material sheet of the present invention for any of these.

FIG. 3 illustrates a cross-sectional view of the obtained rigid foamed urethane board (reference numeral 26 in FIG. 2). The foamed urethane resin layer forms a “nonwoven fabric / foamed resin composite layer” 32 that is cured in a state in which the foamed urethane resin portion has penetrated into the nonwoven fabric single layer of the surface material on both sides of the foamed urethane resin single layer portion 31. Thus, a hard foamed urethane board is constructed in which the surface material and the hard foamed urethane layer 31 are firmly joined and integrated.

The average thickness of the nonwoven fabric / coating composite layer in the sheet for a surface material of the present invention is preferably 20 μm or more because the resin leakage decreases as the thickness increases. The upper limit of the thickness is not particularly set, but if it is too thick, the flexibility of the nonwoven fabric is impaired, the air permeability is insufficient, the weight is increased, and the cost is disadvantageous. Preferably has a thickness not exceeding 600 μm.

In the surface material sheet of the present invention, the average thickness of the single layer of the nonwoven fabric needs to be 30 μm or more. When the nonwoven fabric single layer is less than 30 μm, the bonding strength between the surface material and the hard foamed resin layer is insufficient, and the surface material is easily peeled off. The thickness of the nonwoven fabric single layer is preferably 500 μm or less. This is because if the thickness is greater than 500 μm, air in the single layer of the nonwoven fabric is mixed into the resin, and cells having a non-uniform size and shape are often formed in the hard resin. In addition, when used as a surface material on the upper surface side, the resin will penetrate into the nonwoven fabric single layer in a foamed state, but the foamed resin is less permeable to the nonwoven fabric single layer than the resin liquid. Since the thickness of the layer portion may be large and delamination may occur in the nonwoven fabric single layer portion, the preferred thickness of the nonwoven fabric single layer is 300 μm or less.

The sheet for a surface material of the present invention needs to have a cholester air permeability of 5 to 1500 cc / min / cm ² . If the Cholesta air permeability is too low, the air contained in the single layer of the nonwoven fabric is difficult to escape when the foamable resin solution is applied, and cell contamination is caused by mixing in the resin solution. Moreover, since the secondary foaming gas at the time of application of hot asphalt is difficult to escape, swelling occurs. On the other hand, if the cholesterol permeability is too high, even if the wetness index of the coated surface is small, resin leakage occurs and the process is fouled. For this reason, a Cholesta air permeability is 5 to 1500 cc / min / cm < ² >, Preferably it is 10 to 1500 cc / min / cm < ² >, More preferably, it is 15 to 1500 cc / min / cm < ² >.

Cholesta air permeability was measured as follows.
Permeability meter Filtrona Instrument & Out according to ISO 2965
Using the PPM-100 manufactured by operation limited, the coating surface is directed to the air inflow side, the air flow rate is measured when a pressure of 100 mmH ₂ O is applied to a ₂ cm ² area, and the flow rate is 1 minute per 1 cm ^2. The converted value was obtained.

As the inorganic fiber nonwoven fabric used for the sheet for the surface material of the present invention, either a wet nonwoven fabric or a dry nonwoven fabric can be used. However, the wet nonwoven fabric is preferable because the formation and void distribution are dense and uniform.
The inorganic fiber in the nonwoven fabric is not particularly limited, and glass fiber, rock wool, ceramic fiber, sepiolite and the like can be used, but it is preferable to use glass fiber which is inexpensive and easily available.

The kind of glass fiber is not particularly limited, and E glass, C glass, D glass, and the like can be used. Usually, E glass that is easily available in Japan is used. The fiber length of the glass fiber is not particularly limited, but is preferably 3 to 18 mm. If the fiber length is too short, the tear strength decreases, and if the fiber length is too long, it becomes difficult to uniformly disperse the glass fiber.
The fiber diameter of the glass fiber is not particularly limited, but a glass fiber having a diameter of about 9 to 13 μm is usually used. In general, when the fiber diameter is large, the paint is likely to penetrate, so the thickness of the coating layer to obtain the required air permeability is increased, which is disadvantageous in terms of cost and the flexibility of the nonwoven fabric. It is not preferable because it is damaged. On the other hand, glass fibers with a small fiber diameter are expensive, and glass fibers with a diameter of less than 3 μm are not appropriate because of the risk of carcinogenicity. In view of the above, the fiber diameter of the glass fiber is preferably about 6 μm to 10 μm.

The binder in the nonwoven fabric is not particularly limited, and resins such as acrylic resin, epoxy resin, vinyl acetate resin, polyester resin, urethane resin, polyvinyl alcohol (PVA), styrene-butadiene rubber (SBR), and nitrile-butadiene rubber (NBR) Inorganic binders such as system binder, silica sol, titania sol, and alumina sol can be used. The form of the resin binder is not particularly limited, and any of an emulsion, an aqueous solution, a powder form, a fiber form and the like may be used. In view of binder performance, weather resistance, cost, etc., an acrylic resin emulsion is preferred.
The binder content is not particularly limited, but if the binder is too small, the strength is insufficient. On the other hand, if the binder is too much, the nonwoven fabric is not flexible. Therefore, it is usually preferably about 5 to 30% by mass.

The inorganic pigment in the coating applied to the nonwoven fabric is not particularly limited, and known pigments such as calcium carbonate, talc, clay, kaolin, mica, aluminum hydroxide, magnesium hydroxide, and silica can be widely used. In particular, delamikaolin with a flat shape and high aspect ratio is used, and a paint containing a pigment called engineered kaolin with an adjusted particle size distribution by removing ultrafine particles and an aspect ratio of 36 or more is used. Then, since there exists a tendency for the nonwoven fabric / paint composite layer which has appropriate air permeability to be formed, it is preferable.

The organic binder in the paint is not particularly limited, and acrylic resin, epoxy resin, vinyl acetate resin, polyester resin, urethane resin, polyolefin resin, polyvinyl alcohol (P
VA), styrene-butadiene rubber (SBR), nitrile-butadiene rubber (NBR),
Starch, casein, and the like can be used, but for the reasons described later, it is preferable to use a polyolefin-based resin.

The organic binder ratio with respect to the inorganic pigment is not particularly limited, and can be adjusted in a wide range of 5 to 200 parts by mass with respect to 100 parts by mass of the inorganic pigment. It is also possible to add auxiliary agents such as dispersants, thickeners, preservatives, antifoaming agents, and coloring agents to the paint.
However, if too much of a so-called silicon-based antifoaming agent such as an emulsion of polyalkylsiloxane and silicon dioxide is added, uniform foaming of the foamed layer of polyol, polyisocyanate, etc. is inhibited, and locally large bubbles are generated. Careful attention is required because it causes problems such as

The method of applying the paint to the nonwoven fabric is not particularly limited, and known methods such as curtain coating, air knife coating, bar coating, blade coating, spray coating, gravure coating, kiss coating, etc. Although it can be widely used, a coating method in which the surface pressure is not applied as much as possible is preferable in consideration of preventing the coating material from unnecessarily penetrating into the nonwoven fabric at the time of coating or weighing. As a coating method, for example, the coating liquid is adhered to the surface of the nonwoven fabric by passing through the coating liquid while being in close contact with the backing roll, or by applying by a fountain method from below in the vertical direction while being in close contact with the backing roll. The method etc. can be mentioned as a preferable coating method. Moreover, as a method for measuring the adhering paint, a preferable method is a method in which a Mayer bar, a comma bar or the like is pressed lightly and scraped off.

The surface material sheet of the present invention preferably has a wet index of 36 or more on the non-coated surface. When the wetting index is less than 36, the penetration of the foamable resin liquid into the single nonwoven fabric layer is delayed. The upper limit of the wetting index is not particularly set, but is preferably 50 or less. As will be described later, the sheet for a surface material of the present invention needs to have a non-woven fabric single part. However, if the wetting index is too large, the paint penetrates to the back surface when the paint is applied to the non-woven fabric.

The wetting index in the present invention refers to a numerical value represented by the following method.
A liquid for wetting tension test specified in JIS K6768 is dropped on the sheet for surface material, and 5
Observe the state of the droplet after 2 seconds. If the wet tension test mixture does not penetrate into the sheet for more than 5 seconds and remains in the state of droplets, proceed to the wet tension test mixture with the next lowest surface tension,
On the other hand, if the liquid drops soak in less than 5 seconds, the process proceeds to a liquid mixture for wet tension test with the next highest surface tension.
This operation is repeated, and the surface tension of the lowest liquid mixture for wet tension test that keeps the droplet state for 5 seconds or more is set as the numerical value of the wet index of the sheet.

Since JIS K6768 is a measurement method defined for measuring a film that does not penetrate the liquid mixture for wet tension test, it is applied to the surface material sheet of the present invention in which a porous nonwoven fabric is coated. When applied, the wet tension test mixture tends to penetrate the sheet. Therefore, as defined in JIS K6768, the wettability test liquid mixture is spread on the substrate surface, and the wettability cannot be evaluated by the tearing of the film of the wet tension test liquid mixture. For the above reasons, in the present invention, the wetting index of the surface material sheet was measured according to the measurement method described above.

The surface material sheet of the present invention needs to have a coating surface wetting index of 26 to 34. If the wetting index exceeds 34, the resin leakage becomes remarkable, and the process becomes dirty. The smaller the wetting index, the less resin leakage, but if the wetting index is less than 26, the adhesiveness between the coated surface and the asphalt decreases. For this reason, the wetness index of a coating surface is 26-34, More preferably, it is 30-34.

Such a coating layer having a wetness index range is realized by using a polyolefin-based resin as the organic binder in the paint. The form of the resin is not particularly limited, but those obtained by emulsifying these resins are preferably used. The polyolefin-based resin is not particularly limited, and ethylene vinyl acetate (EVA), polyethylene, polypropylene, and modified products thereof are preferably used. In particular, ethylene vinyl acetate and modified products thereof, polyethylene,
Polypropylene or the like is preferable because it has low wettability. A resin obtained by adding polyethylene wax or the like to ethylene / vinyl acetate to improve water repellency is more preferable. By using these resins as an organic binder in the paint, penetration of the resin can be prevented while maintaining sufficient air permeability without using a fluorine-based water and oil repellent agent as in the past.

The foamed resin layer of the foamed resin heat insulating board of the present invention is a heat-resistant material formed from a foamable raw material liquid that can be foamed and cured in a state where it is appropriately permeated into the nonwoven fabric single layer of the sheet for surface material of the present invention. Any foamable resin layer can be used, and a polypropylene resin or the like can be used. At present, a hard urethane resin layer is suitable as the foamed resin layer that satisfies the above conditions.

Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples. In Examples,% means mass% unless otherwise specified.

Examples 1-7 and Examples 9-11
<Production of non-woven fabric>
E glass fiber having a fiber length of 13 mm and a fiber diameter of 10 μm is dispersed in water and made into a sheet by a wet method.
The acrylic resin emulsion was added to this sheet by a spray method so that the content in the nonwoven fabric after drying was 10%, followed by heating and drying to obtain a nonwoven fabric of US basis weight shown in Table 1.

<Preparation of paint>
As an inorganic pigment, engineered kaolin with a particle diameter of 2 μm or less of 97% and an aspect ratio of about 36 (Imeris Minerals Japan Co., Ltd., “Contour Extreme”),
An emulsion of polyalkylsiloxane and silicon dioxide as an antifoaming agent is added in water so that the solid content concentration is 60% by mass, and the dispersant (polysodium acrylate) is 0.2 parts by mass with respect to 100 parts by mass of kaolin. (Toshiba Silicone Co., Ltd., “TSA-730”) was added to 100 parts by mass of kaolin to 0.8 parts by mass, and the mixture was vigorously stirred with a disperser to obtain a pigment slurry.
A modified ethylene resin emulsion (manufactured by Sumika Chemtex Co., Ltd., “N-3000”) as a binder was added to the obtained pigment slurry so that the solid content ratio with respect to the pigment was as shown in Table 1, and the mixture was stirred and mixed.
A thickener (sodium polycarboxylate) was appropriately added to the obtained slurry, and water was further added to obtain a concentration as shown in Table 1. The viscosity of the obtained paint was measured using a B-type viscometer.
The viscosity of the paint was as shown in Table 1.

<Creation of sheet for surface material>
The non-woven fabric prepared as described above is passed through the paint prepared as described above in close contact with the backing roll, scraped off excess paint with a Mayer bar, and then dried with hot air to obtain a sheet for surface material It was. Table 1 shows the weight of the surface sheet before coating, the coating amount, the wetness index of the coated surface, the air permeability, and the thickness of the nonwoven fabric / paint mixture layer. The coating amount was adjusted by appropriately changing the count of the Mayer bar.

<Creation of urethane foam board>
The obtained surface material sheet was heated to 50 ° C. while moving on the lower conveyor on the double conveyor with the coating surface down, and cyclopentane was added as a blowing agent to the polyol / polyisocyanate mixture. In addition, a mixed liquid further added with a silicone-based foam stabilizer was applied on the surface material sheet and foamed. Before completion of foaming, the surface material sheet was adhered to urethane foam with the coated surface facing up, and foaming was completed while being pressed by the upper conveyor, to obtain a urethane foam board having a thickness of 30 mm.

Example 8
The binder used in the paint is changed to an acrylic resin (Showa Polymer Co., Ltd., “AG-100”), and the amount of silicone water repellent (Shin-Etsu Silicone Co., Ltd., “POLON-MWS”) added is 100 mass of kaolin. A coating material was prepared in the same manner as in Examples 1 to 7 except that 1.0 part by mass was added to the part, and a sheet for surface material and a urethane foam board were prepared in the same manner as in Examples 1 to 7 and Examples 9 to 11. Created.

Comparative Examples 1, 4, 5, 6
<Creation of non-woven fabric>
A wet nonwoven fabric was prepared in the same manner as in Examples 1-5. Table 2 shows the weight of the nonwoven fabric.
<Preparation of paint>
Example 1 except that the concentration and the mass ratio of the binder to the paint were as shown in Table 2.
A paint was prepared in the same manner as above. The viscosity of the obtained paint is shown in Table 2.

<Creation of sheet for surface material>
Except having set it as the coating amount shown in Table 2, it carried out similarly to Examples 1-7, and obtained the sheet | seat for surface materials.
<Creation of urethane foam board>
A foamed urethane board was prepared in the same manner as in Examples 1-6.

Comparative Example 2
A surface material sheet and a urethane foam board were prepared in the same manner as in Comparative Examples 1, 4, 5, and 6 except that the binder in the paint was an acrylic emulsion ("AG-100" manufactured by Showa Polymer Co., Ltd.). .

Comparative Example 3
The binder in the paint is an acrylic emulsion (“AG-100” manufactured by Showa Polymer Co., Ltd.), and a fluorine-based water repellent (Maruishi Oil Co., Ltd.) is added to 1.0 part by mass with respect to 100 parts by mass of the solid content of the acrylic emulsion. Comparative Examples 1, 4, 5, 6 except that “Opel FS”) was added.
In the same manner as above, a surface material sheet and a foamed urethane board were prepared.

<Measurement of air permeability>
The air permeability was measured as follows.
Using an air permeability meter Filtrona Instrument & Automation Limited manufactured by PPM-100 in accordance with ISO 2965, measure the air flow rate when applying a pressure of 100 mmH ₂ O to an area of 2 cm ² with the coated surface facing the air inflow side, A numerical value converted into a flow rate of 1 minute per 1 cm ² was obtained. The measurement was performed at 10 locations, and the average value was adopted.

<Measurement of composite layer thickness and single layer thickness of nonwoven fabric>
The cross section of the obtained sheet for surface material was cut out with a single-tooth razor, the cut surface was magnified 500 times using a microscope (manufactured by Keyence Corporation), and the thicknesses of the composite layer and the nonwoven fabric single layer were measured. In the measurement, the surface material sheets were sampled evenly at 10 locations from the width direction, each was cut into 1 cm square, 10 locations were measured per piece, and the total average was adopted.

<Measurement of wetting index>
A wetting reagent (“mixed liquid for wetting tension test” manufactured by Wako Pure Chemical Industries, Ltd.) was dropped onto the surface material sheet, and the surface tension of the wetting reagent that had started to penetrate within 5 seconds was defined as the wetting index. The measurement was performed at 10 locations, and the average value was adopted.

(Evaluation methods)
<Uniform foam layer>
Observe the cross section of the obtained foamed urethane board visually, the one with good cell uniformity ○,
A cell having a slightly non-uniform size was observed, but a cell having no problem in practical use was evaluated as Δ, and a cell having poor cell uniformity and causing a practical problem was evaluated as ×.

<Peeling of surface material after asphalt construction>
On the concrete, asphalt heated to 250 ° C. to 300 ° C. was applied, and the urethane foam board was laid before the temperature dropped. And the hot asphalt heated at 250 to 300 degreeC was apply | coated on the laid urethane board, and the foaming urethane board was constructed on concrete.
Normally, a waterproof sheet is affixed to the laid urethane foam board while applying hot asphalt, but this time, the waterproof sheet was not affixed to facilitate observation of the surface state.
And after asphalt construction, observe the presence or absence of the part where the swelling occurred on the surface, if there is a part where the swelling occurred, cut there and observe the cross section, the swollen part is in the surface material layer, or the surface material When the section was urethane, it was evaluated that peeling of the surface material after asphalt construction occurred.
The case where the peeling of the surface material did not occur was evaluated as “◯”, the case where the surface material was slightly generated but did not cause a problem in practice was evaluated as “Δ”, and the case where a large peeling occurred and a problem occurred in practice was evaluated as “X”.

<Asphalt floating after asphalt construction>
On the concrete, asphalt heated to 250 ° C. to 300 ° C. was applied, and the urethane foam board was laid before the temperature dropped. And on the laid urethane board, 2
Hot asphalt heated to 50 ° C. to 300 ° C. was applied, and a urethane foam board was constructed on the concrete.
And, after asphalt construction, observe the presence or absence of the part where the swelling occurred on the surface, if there is a part where the swelling occurred, cut it out and observe the cross section, if the swelling part was the interface between the asphalt and the surface material It was evaluated that asphalt float occurred.
The case where asphalt float did not occur was evaluated as ◯, the case where slight assemblage did not occur but the problem occurred practically, and the case where large peeling occurred and the problem occurred practically was evaluated as x.
Tables 1 and 2 show measurement results of physical properties and evaluation results of Examples and Comparative Examples.

As shown in Table 1, in each example, it was possible to produce a urethane board without any problem.
In addition, the obtained urethane board has good adhesion between the urethane and the coating material of the surface material and the adhesion of the asphalt to the surface material. No floating occurred, and the cell uniformity of the foam layer was good.

In Comparative Example 1 shown in Table 2, since the air permeability of the surface material was too high, the urethane liquid passed through the surface material and got through, and the conveyor was soiled, making it impossible to manufacture.
In Comparative Example 2, since the wettability of the surface material was too high, the urethane liquid leaked in the same manner, and the production was impossible.
In Comparative Example 3, since the wettability of the coated surface was too low, the adhesiveness between the asphalt and the surface material was poor, and the asphalt floated due to the gas generated during the thermal asphalt construction.

Further, in Comparative Example 4, the air permeability was too low so that the air in the foam layer could not escape, the uniformity of the cells was poor, and further, the gas generated during hot asphalt construction could not escape, so the surface material was peeled off after asphalt construction There has occurred.
In Comparative Example 5, since the thickness of the single layer of the nonwoven fabric was insufficient, the adhesive force between urethane and the surface material was insufficient, and the surface material peeled after asphalt construction.
In Comparative Example 6, since the thickness of the nonwoven fabric single layer was too thick, the uniformity of the foam layer was inferior.

The sheet for a surface material of the present invention is a sheet for a surface material that is suitable for obtaining a heat-insulated board made of a foamed resin that does not cause a resin leak in the manufacturing process of the foamed resin board and does not cause a problem even when used in a thermal asphalt method. The foamed resin heat insulation board created using the surface material sheet is a heat insulation structure in which a heat insulation board, a waterproof sheet, etc. are laminated on a concrete surface for heat insulation and waterproofing of a building. Therefore, it is possible to expand new application fields such as a thermal asphalt method using these heat insulating boards.

11: Non-woven fabric single layer 12: Non-woven fabric / paint composite layer 13: Inorganic fiber 14: Paint 21: Surface material (lower surface side)
22: Surface material (upper surface side)
23: Resin liquid 24: Double conveyor 25: Hard foamed urethane resin 26: Hard foamed urethane board 31: Hard urethane resin 32: Nonwoven fabric / foamed resin composite layer 33: Nonwoven fabric / paint composite layer

Claims (7)

The surface layer part on one side of the inorganic fiber nonwoven fabric mainly composed of inorganic fiber and resin binder is fixed in the nonwoven fabric in a state where the inorganic pigment and resin binder in the coating applied on the one side penetrated the surface layer part on one side. The nonwoven fabric layer is composed of a nonwoven fabric-paint composite layer, and the nonwoven fabric layer portion continuous in the thickness direction from the surface layer portion comprising the nonwoven fabric-paint composite layer is an inorganic fiber nonwoven fabric composed of a single nonwoven fabric layer having an average thickness of 30 μm to 500 μm. Cholesta air permeability (measured in accordance with ISO 2965) is 5 to 1500 cc / min / cm ² and the coating surface has a wetting index of 26 to
A sheet for a surface material of a heat insulating board made of foamed resin, characterized by being 34. The sheet for a surface material of a heat insulating board made of foamed resin according to claim 1, wherein an average thickness of a surface layer portion made of the "nonwoven fabric-paint composite layer" is 20 µm or more. The sheet for a surface material of a heat insulating board made of foamed resin according to claim 1 or 2, wherein the inorganic fiber nonwoven fabric is a glass fiber nonwoven fabric. The sheet for a surface material of a foamed resin heat insulation board according to any one of claims 1 to 3, wherein the resin binder in the paint is a polyolefin resin used in a state of a resin emulsion. . The inorganic pigment in the paint is engineered kaolin, characterized in that
The sheet | seat for surface materials of the foaming resin heat insulation board in any one of 4. A foamed resin heat insulating board having the sheet for a surface material according to any one of claims 1 to 5 as a surface material on at least one side of the foamed resin layer. The foamed resin heat insulating board according to claim 6, wherein the foamed resin layer is a hard foamed urethane resin layer.

Images