JP2013249619A - Composite sheet for building component and building component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite sheet for a building component composed of a core material of synthetic resin foam of which one face is provided with a front face material and another face is provided with a rear face material, which is suitable for the rear face material allowing the front face and the rear face to have a pattern and a shape freely selected, preventing defects such as warpage of the building component, and keeping the rear face material free from wrinkles in a manufacturing process, with thin thickness; and a building component having the composite sheet at least on one face of the synthetic resin foam.SOLUTION: A composite sheet for a building component as the rear face material is composed of a nonwoven cloth including glass fiber, to which at least two kinds of synthetic resin films having different breaking strength are laminated. The rear face material has a compression strength of 0.30 to 1.00 kN/m in the lateral direction, and a weight of 50 to 120 g/m.

Description

  The present invention relates to a composite sheet for building members and a building member suitable as a back material used for building members such as metal siding and building panels in which a core material made of a synthetic resin foam is sandwiched between a surface material and a back material. is there.

  Many building members such as metal siding and building panels in which a core material made of a synthetic resin foam is sandwiched between a front surface material and a back surface material are commercially available. However, the surface of the building member may be uneven or warped due to a change with time of the synthetic resin foam or a temperature difference or humidity difference between the inside and outside the room. In addition, when forming a core material made of synthetic resin foam in the manufacturing process of building members, the synthetic resin foam not only expands but also shrinks. There was something to do.

  In order to solve these problems, a concave groove is formed in the back surface material along the longitudinal direction thereof, and when the back material shrinks, the shrinkage is absorbed by the concave groove and warps the back surface. There has been proposed a method for mitigating the occurrence of this phenomenon (see, for example, Patent Document 1). However, this method has a problem that the warpage of the front surface cannot be reduced and the back surface does not become flat.

  In addition, a method for preventing a warp problem by improving the mechanical strength of the building member itself by making the surface material a concavo-convex pattern and making the size of the concave portion larger than the size of the convex portion has been proposed. (For example, refer to Patent Document 2). However, this method has a problem that the surface cannot be formed into an arbitrary shape.

  In addition, there is a building component in which a composite sheet in which a synthetic resin film or aluminum foil is bonded to a nonwoven fabric containing glass fibers that does not expand or contract due to changes in temperature or humidity is bonded to the front and back of a synthetic resin foam. It has been proposed and devised (see, for example, Patent Documents 3 to 4). Nonwoven fabrics containing glass fibers are excellent in dimensional stability because they are not easily affected by changes in temperature and humidity. However, if the strength of the composite sheet is weak, the core material made of synthetic resin foam expands due to changes in temperature and humidity. In some cases, the building material may warp due to shrinkage. In addition, when forming a core made of a synthetic resin foam in the manufacturing process of a building member, the synthetic resin foam not only expands but also contracts. Wrinkles may enter and promote the warping of building components. As a method for solving these problems, it is conceivable to increase the thickness of the composite sheet until it has sufficient strength. However, if the composite sheet is thick, there is a problem that it is difficult to handle in the manufacturing process of building members. In terms of cost, a thicker composite sheet is disadvantageous.

  In addition, it is possible to prevent defects such as warping and peeling, and skin irritation by a sheet in which a layer mainly composed of inorganic fibers such as glass fibers and a layer mainly composed of organic fibers such as wood pulp and polyester fibers are laminated. Has been proposed (see, for example, Patent Documents 5 to 8). However, these sheets have a problem that when the core material made of the synthetic resin foam is formed, the stock solution oozes out to the back surface side. Further, since the outermost surface of the seat is in contact with the outside air, it is easily affected by humidity that causes warping or the like.

Also, a synthetic resin film having a very low linear expansion coefficient of −2 × 10 ⁻⁵ to 1 × 10 ⁻⁵ / ° C. and a very high elastic modulus of ⁵ to 15 GPa is bonded to kraft paper, woven fabric, or nonwoven fabric. Therefore, there has been proposed a composite sheet that prevents problems due to warpage or the like (see, for example, Patent Document 9). However, in order to adjust the linear expansion coefficient and elastic modulus of the synthetic resin film to the above-mentioned range, it is necessary to carry out production with a draw ratio of 10 times to several tens of times, and after the synthetic resin film is produced, it is melted. Since it is necessary to bond together using resin and an adhesive agent, a back material cannot be made thin. In addition, since the molten resin or adhesive used causes expansion and contraction due to changes in temperature and humidity, it may not be possible to sufficiently prevent problems due to warpage.

  Thus, in a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the pattern and shape of the front surface and the back surface can be freely selected. There has not yet been obtained a back material that suppresses the problems of warping, suppresses wrinkles from entering the back material in the manufacturing process, and can reduce the thickness. Further, a building member in which such a back material is provided on at least one surface of the synthetic resin foam has not been obtained yet.

JP 2004-1116019 A JP 2003-147898 A Japanese Utility Model Publication No. 53-46372 JP 2002-4548 A JP-A-51-84161 JP-A-4-226747 JP 58-179641 A JP 2000-303389 A Japanese Patent Laid-Open No. 2006-212895

  An object of the present invention is to provide a building material in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, and the pattern and shape of the surface and the back surface can be freely selected. An object of the present invention is to provide a composite sheet for building members that is suitable as a back material that suppresses problems such as warping of members, prevents wrinkles from entering the back material in the manufacturing process, and can reduce the thickness. Moreover, it is providing the building member which provided such a composite sheet for building members on the at least single side | surface of the synthetic resin foam.

  Specific means for solving this problem is as follows.

(1) A composite sheet for building members used as a back member of a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the composite sheet for building members The sheet is formed by laminating at least two types of synthetic resin films having different breaking strengths to a nonwoven fabric containing glass fibers, and the composite sheet for building members has a lateral compression strength of 0.30 to 1.00 kN / m. The building material composite sheet is characterized in that the basis weight of the building material composite sheet is 50 to 120 g / m ² .

  (2) The nonwoven fabric contains 20 to 80% by mass of a glass fiber having a fiber diameter of 5 to 10 μm and a fiber length of 6 to 20 mm based on the total fiber amount of the nonwoven fabric. Composite sheet for building materials.

  (3) The nonwoven fabric contains glass fibers and wood pulp, and is a multilayer nonwoven fabric of two or more layers, and the layer on the side to be bonded to the synthetic resin film of the nonwoven fabric does not contain wood pulp or is in a mass ratio It contains more glass fibers than wood pulp, and the layer on the side in contact with the core made of synthetic resin foam of non-woven fabric does not contain glass fibers or contains more wood pulp than glass fibers by mass ratio The composite sheet for building members according to (1) or (2).

  (4) A building member in which the composite sheet for building members according to any one of (1) to (3) is provided on one surface of a core made of a synthetic resin foam.

  According to the present invention, in a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the pattern and shape of the front surface and the back surface can be freely selected. It is possible to provide a composite sheet for a building member that is suitable as a back material that suppresses problems of warping, prevents wrinkles from entering the back material in the manufacturing process, and can reduce the thickness. Moreover, the building member which provided such a composite sheet for building members on the at least single side | surface of the synthetic resin foam can be provided.

The composite sheet for building members of the present invention (hereinafter sometimes abbreviated as “composite sheet”) is a building in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface. A composite sheet for building members used as a back material of a member, wherein the composite sheet for building members is a composite sheet in which at least two kinds of synthetic resin films having different breaking strengths are bonded to a nonwoven fabric containing glass fibers. And the lateral compression strength of the composite sheet for building members is 0.30 to 1.00 kN / m, and the basis weight of the composite sheet for building members is 50 to 120 g / m ^2. It is a composite sheet for building members.

  Since glass fibers are small in expansion and contraction due to changes in temperature and humidity, nonwoven fabrics containing glass fibers hardly undergo dimensional changes due to changes in temperature and humidity, and have good dimensional stability. Further, in order to prevent the stock solution from seeping out from the back surface in the process of forming the core material made of the synthetic resin foam in the manufacturing process of the building member (process of foaming the resin), the composite sheet of the present invention is used. Then, at least 2 types of synthetic resin films are bonded together to the nonwoven fabric containing glass fiber.

  However, when the resin is foamed in the manufacturing process of the building member, the foam is usually heated to 60 to 100 ° C. to complete the expansion reaction of the foam. However, in the process of cooling to near room temperature after the reaction, the foam may shrink. For this reason, when the compressive strength of the back surface material is weak, wrinkles may enter the back surface material, which may cause a problem of warping the building member.

  As a result of intensive studies by the present inventors, the composite sheet has a compression strength in the lateral direction (CD direction) of 0.30 to 1.00 kN / m, preferably 0.30 to 0.80 kN / m. It discovered that the wrinkle of the back surface material in the manufacturing process of a member could be suppressed. Even if the compressive strength in the transverse direction of the composite sheet exceeds 1.00 kN / m, wrinkles are suppressed, but if the compressive strength is too strong, the back surface material is difficult to deform, and conversely, molding becomes difficult. When the compressive strength in the lateral direction of the composite sheet is less than 0.30 kN / m, wrinkles are generated in the back material in the manufacturing process of the building member, and the building member is warped. The “compressive strength” referred to in the present invention is a compressive strength calculated from the maximum load when a test piece measured by the ring crush method defined in JIS P8126 is crushed.

  Note that the compressive strength of the composite sheet can be increased by increasing the basis weight. However, if the basis weight of the composite sheet is increased, for example, the surface material is usually folded back and fixed on the back side, but the surface material cannot be folded back and fixed because the back material is thick, and molding required for construction May not be applied to the back material. Moreover, the weight of winding of a back surface material may become heavy, or winding length may become short, and production efficiency may worsen.

As a result of intensive studies by the present inventors, the surface weight of the composite sheet is set to 50 to 120 g / m ² , preferably 60 to 100 g / m ² , so that the surface material can be easily folded when fixed on the back side. The material could be folded back and fixed. When the basis weight of the composite sheet is less than 50 g / m ² , the tensile strength of the back surface material is also reduced, so that the back material is easily broken when the resin is foamed in the manufacturing process of the building member. Moreover, when the fabric weight of a composite sheet exceeds 120 g / m < ² >, the above-mentioned surface material cannot be folded and fixed, and the problem which cannot perform shaping | molding required for construction to a back surface generate | occur | produces.

  Examples of the material for the synthetic resin film according to the present invention include polyolefins such as polyethylene and polypropylene, polyamide, acrylic, polyurethane, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinyl alcohol, styrene-butadiene copolymer, polyethylene terephthalate, Synthetic resins such as polyester such as polytrimethylene terephthalate, polyacrylonitrile, polystyrene, and modified resins thereof are used. Further, a synthetic resin film colored by kneading an inorganic or organic pigment may be used.

  The total thickness of the synthetic resin film is preferably 3 to 70 μm, more preferably 10 to 60 μm, and particularly preferably 20 to 50 μm. If it is thinner than 3 μm, the adhesion to the nonwoven fabric is weak and peels off, and pinholes are easily formed, and when trying to form a core made of a synthetic resin foam, the stock solution may ooze out. is there. On the other hand, if the synthetic resin film is thicker than 70 μm, the basis weight of the back surface material cannot be reduced, and warping may occur due to expansion and contraction of the synthetic resin film due to temperature.

  As a method of attaching a synthetic resin film to a non-woven fabric, (1) a synthetic resin composition is cast and melted between a traveling non-woven fabric and a sheet-like synthetic resin film in a heated and melted state, followed by pressure bonding. The so-called hot melt extrusion laminating method, (2) a method in which a thermoplastic synthetic resin film is laminated with a nonwoven fabric and integrated by hot pressing, and (3) a thermoplastic film is placed between the synthetic resin film and the nonwoven fabric. Examples include a method of sandwiching and laminating and integrating by hot rolling, and (4) a method of laminating a synthetic resin film with a nonwoven fabric using an adhesive, but the present invention is not limited thereto.

  Further, the synthetic resin penetrates between the fibers of the nonwoven fabric in the above (1), in which the synthetic resin film is cast on the surface of the nonwoven fabric on the side to be bonded to the synthetic resin film while the synthetic resin is heated and melted. Therefore, it is particularly preferable not only because the strength is increased, but also because it is easy to be thinned, and it is more difficult to curl than a method using an adhesive or a method of integrating by hot pressing.

  In addition, the composite sheet for building members of the present invention is a composite sheet in which at least two types of synthetic resin films having different breaking strengths are bonded to a nonwoven fabric containing glass fibers.

  If the tensile strength of the back material is weak when the resin is foamed in the manufacturing process of the building member, the back material may be broken when the resin is foamed. On the other hand, as a method of bonding the synthetic resin to the nonwoven fabric, a method of casting and bonding the synthetic resin composition into a film in a state of being heated and melted as described above is preferable. However, synthetic resin films that can be easily bonded together by this method are relatively many resins such as polyolefins that have a low breaking strength.

  By laminating at least two types of synthetic resin films having different breaking strengths, it becomes easy to adjust not only the compressive strength in the lateral direction of the composite sheet but also the breaking strength, thereby facilitating the production of building members. In particular, when the breaking strength of the synthetic resin film directly bonded to the nonwoven fabric is weak, the back material is broken when the resin is foamed in the manufacturing process of the building member by laminating the strong breaking strength film. Can be prevented.

  The “breaking strength” referred to in the present invention is the maximum force (tensile strength) that can be withstood when the film is pulled in the tensile property test method defined in JIS K7127. In addition, although the breaking strength varies depending on the thickness, the “at least two kinds of synthetic resin films having different breaking strengths” referred to in the present invention refers to films having different breaking strengths when comparing the breaking strengths of films having the same thickness. Show. The reason is that when the same film having a different thickness is laminated, there is no significant difference in effect from the case where one film is thickened. Of at least two types of synthetic resin films having different breaking strengths, the breaking strength of at least one film is 100 MPa, which can reduce the trouble that the back material breaks when foaming the resin in the manufacturing process of building members. To preferred.

  The glass fiber according to the present invention can be used with any glass fiber of glass wool or glass fiber chopped strand (glass fiber cut product) as long as it is hard to break and has a fiber sheet forming ability. 2-20 micrometers is preferable, as for the fiber diameter of a fiber, 4-15 micrometers is more preferable, and 5-10 micrometers is still more preferable. When the fiber diameter of the glass fiber is less than 2 μm, the dimensional stability may be inferior. On the other hand, when the fiber diameter of the glass fiber exceeds 20 μm, the formation is deteriorated when the sheet is formed. As a result, the compressive strength becomes weak, and it becomes difficult to make the compressive strength 0.30 kN / m or more. There is. Moreover, 2-30 mm is preferable, as for the fiber length of glass fiber, 4-25 mm is more preferable, and 6-20 mm is further more preferable. If the fiber length of the glass fiber is less than 2 mm, the dimensional stability may be inferior. On the other hand, when the fiber length of the glass fiber exceeds 30 mm, kinks and clumps during papermaking tend to occur, and the formed nonwoven fabric becomes non-uniform. As a result, the compressive strength becomes weak and the compressive strength is reduced to 0. 0. It may be difficult to make it 30 kN / m or more.

  In addition, the glass fiber content is preferably 10 to 90% by mass, and preferably 20 to 80% by mass, based on the total fiber content of the nonwoven fabric of the present invention. This is preferable because it is easy to adjust the compressive strength of the composite sheet to 0.30 kN / m or more, and it is easy to suppress the occurrence of wrinkles on the back material in the manufacturing process of the building member. Moreover, when it contains 40-80 mass%, dimensional stability is especially good. If the glass fiber content is less than 10% by mass relative to the total fiber content of the nonwoven fabric, the dimensional stability may deteriorate. On the other hand, when the content of the glass fiber exceeds 90% by mass, the dimensional stability is good, but the nonwoven fabric becomes brittle, so that it may be difficult to make the compressive strength 0.30 kN / m or more.

  The nonwoven fabric according to the present invention is a nonwoven fabric containing glass fibers and wood pulp, and the nonwoven fabric is a multilayer sheet of two or more layers, and the layer on the side of the nonwoven fabric bonded to the synthetic resin film is wood pulp. Does not contain, or contains more glass fiber than wood pulp by mass ratio, and the layer on the side in contact with the core made of the synthetic resin foam of the nonwoven fabric does not contain glass fiber or by mass ratio. Most preferably, the nonwoven fabric contains more wood pulp than glass fibers.

  The synthetic resin film is bonded by using a hot melt extrusion laminating method, a hot press treatment, an adhesive, or the like, but the adhesive or the hot melt synthetic resin has a high viscosity. Glass fiber is coarser than wood pulp, so if there is a lot of glass fiber on the side to be bonded to the synthetic resin film of the nonwoven fabric, high-viscosity hot-melt synthetic resin or adhesive will penetrate between the nonwoven fabric fibers and adhere Strength increases. On the other hand, if the content of the wood pulp in the layer to be bonded to the synthetic resin film is large, not only the adhesive strength may be weakened, but the wood pulp is easy to absorb moisture, so moisture entering from the edge portion. May be susceptible to

  Furthermore, the layer in contact with the core material made of the synthetic resin foam does not contain glass fibers or contains more wood pulp than glass fibers in a mass ratio, thereby suppressing skin irritation caused by glass fibers. Therefore, it is possible to suppress adverse effects on workers when manufacturing building members. In addition, when forming a synthetic resin foam, the stock solution generally has a low viscosity, but the synthetic resin foam and the nonwoven fabric are integrated by the permeation of the low viscosity stock solution between the fibers of the nonwoven fabric due to the capillary action of wood pulp. The adhesion becomes stronger. Furthermore, when the undiluted | stock solution of a synthetic resin foam osmose | permeates a wood pulp, it becomes difficult to receive the influence of the moisture which penetrate | invades from an edge part. On the other hand, when there are more glass fibers than wood pulp, glass fibers are coarser than wood pulp, so the synthetic resin foam stock solution cannot be held between the fibers, and adhesion is not achieved. Insufficient glass fiber may be brittle because it is harder than wood pulp.

  The wood pulp according to the present invention may be NBKP, LBKP, NBSP, LBSP, GP, TMP, or any other type of pulp, and is not particularly limited, but NBKP is preferred from the viewpoint of strength. The beating degree (CSF) is preferably in the range of 300 to 600 ml. If the CSF is less than 300 ml, the dimensional stability of the nonwoven fabric may be reduced, and if the CSF exceeds 600 ml, the strength of the nonwoven fabric may be reduced.

  When the nonwoven fabric concerning this invention contains a wood pulp, 5-70 mass% is preferable with respect to the total fiber amount of a nonwoven fabric, 10-60 mass% is more preferable, and 20-50 mass is preferable. % Is more preferable. When the content of the wood pulp is less than 5% by mass, the water retention of the sheet before drying becomes poor when it is produced by the wet papermaking method, and it may be difficult to peel off from the felt. If the content of wood pulp exceeds 70% by mass, the dimensional stability of the nonwoven fabric may not be obtained.

  The nonwoven fabric according to the present invention preferably contains at least one binder fiber in order to increase the strength of the nonwoven fabric.

  Examples of the binder fiber used in the present invention include polyvinyl alcohol (PVA) fiber, viscose fiber, polyester fiber, and polyolefin fiber. The binder fiber may be a single fiber or a composite fiber such as a core-sheath fiber or a split fiber. Polyvinyl alcohol fiber is hardly dissolved in water at room temperature and keeps its fiber form, but when heated in a state containing moisture after paper making, it begins to dissolve easily. When pressed with equipment, it develops a binder ability that works between glass fiber and wood pulp, and then re-solidifies by dehydration and drying, resulting in a strong binder fiber that does not dissolve easily unless in high-temperature water. Are particularly preferred.

  The fiber diameter of the binder fiber according to the present invention is preferably 4 to 40 μm, more preferably 6 to 25 μm, and still more preferably 10 to 18 μm. When the fiber diameter of the binder fiber is less than 4 μm, it may fall off from the paper making wire during paper making, and the binder capacity may decrease. On the other hand, when the fiber diameter of the binder fiber exceeds 40 μm, the specific surface area of the fiber is It may be relatively lowered, the binder ability may be lowered, and the smoothness of the sheet surface may be inferior. The fiber length of the binder fiber is preferably 1 to 20 mm, more preferably 2 to 15 mm, and still more preferably 3 to 10 mm. If the fiber length of the binder fiber is less than 1 mm, the binder capacity may be reduced, while if the fiber length of the binder fiber exceeds 20 mm, it may be easy to generate kinks and clumps during papermaking, The formed nonwoven fabric may be non-uniform.

  The content of the binder fiber is preferably 5 to 40% by mass, more preferably 7 to 30% by mass, and still more preferably 10 to 25% by mass with respect to the total fiber content of the nonwoven fabric. When the content of the binder fiber is less than 5% by mass, the tensile strength is weak and the paper may be cut off during wet papermaking. When the content of the binder fiber exceeds 40% by mass, the air permeability is lowered, and when the core material made of the synthetic resin foam is formed, the synthetic resin hardly penetrates into the non-woven fabric. Adhesion may be weak.

  The nonwoven fabric according to the present invention may contain fibers other than glass fibers, wood pulp, and binder fibers as necessary, such as adjustment of voids and strength. Examples of such fibers include regenerated fibers such as rayon, cupra, and lyocell fibers, polyester-based, polyolefin-based, polyamide-based, polyacrylic-based, vinylon-based, vinylidene, polyvinyl chloride, polyester-based, benzoate, polyclar, phenol Examples thereof include synthetic fibers and the like, but the present invention is not limited to these.

  When the nonwoven fabric according to the present invention is a multilayer sheet having two or more layers, the nonwoven fabric is produced by a wet papermaking method. The paper machine that can be used in the present invention is a combination paper machine in which two or more of the same or different types of paper machines such as a long paper machine, a circular net paper machine, and an inclined wire type paper machine are installed on-line. is there. The wet paper web made by these paper machines is dried by heating. As the heating and drying means, methods such as a cylinder dryer, an air dryer, a suction drum dryer, and an infrared dryer can be used.

  Although an example of the manufacturing method in case the nonwoven fabric concerning this invention is a multilayer sheet | seat of 2 or more layers containing glass fiber and wood pulp below is given, this invention is not limited to this.

  For example, after adding a dispersant to water, glass fiber is added and stirred. The dispersant is not particularly limited, but it is preferable to use a nonionic dispersant. Thereafter, a viscous agent such as an aqueous polymer polyacrylamide solution or an aqueous polymer polyethylene oxide solution is added, and the mixture is stored as a glass fiber slurry while being stirred by a reciprocating stirrer. Moreover, after mixing and dispersing the wood pulp, the binder fiber, and the sizing agent after beating in water, it is sent to another storage tank as a wood pulp slurry. A glass fiber slurry and a wood pulp slurry are sent to a storage tank or a paper machine in a certain amount and mixed to form a wet paper web so as to obtain a target mixing ratio and basis weight. The obtained wet paper web is brought into contact with a cylinder dryer and dried by heating, whereby the binder fibers can be efficiently fused.

  The method of laminating two or more multilayer sheets is that the wet paper webs made by each paper machine are laminated while they are in a wet state, or after one wet paper web is formed, this wet paper web is formed. A method of forming a laminated nonwoven fabric by flowing a raw material slurry in which fibers are dispersed on a paper web may be used. Moreover, the method of flowing the raw material slurry which disperse | distributed fiber on the dried web, and forming the laminated nonwoven fabric may be used.

The basis weight of the nonwoven fabric need not basis weight of the composite sheet is limited so placed in 50 to 120 / ^{m 2} after bonding the synthetic resin film is preferably 15~100g / ^{m 2,} 20~80g / ^{m 2} is more preferable, and 30 to 70 g / m ² is more preferable. When the basis weight of the nonwoven fabric is less than 15 g / m ² , it may be difficult to ensure dimensional stability or to make the compressive strength 0.30 kN / m or more. Moreover, since the synthetic resin film must be made thin when the basis weight of the nonwoven fabric exceeds 100 g / m ² , pinholes and the like are easily formed in the synthetic resin film. 50-250 micrometers is preferable, as for the thickness of a nonwoven fabric, 70-200 micrometers is more preferable, and 100-180 micrometers is more preferable. When the thickness of the nonwoven fabric is less than 50 μm, it may be difficult to make the compressive strength 0.30 kN / m or more. When the thickness exceeds 250 μm, the surface material is usually folded back and fixed, but the back material is thick. In some cases, the surface material cannot be folded back and fixed.

The density of the nonwoven fabric is preferably 0.10~0.90g / cm ^3, more preferably 0.15~0.80g / cm ^3, more preferably 0.20~0.60g / cm ^3. When the density of the nonwoven fabric is less than 0.10 g / cm ³ , the adhesion between fibers becomes poor, and dimensional stability cannot be ensured, and it may be difficult to make the compressive strength 0.30 kN / m or more. On the other hand, if the density of the nonwoven fabric exceeds 0.90 g / cm ³ , the glass fiber may be broken and sufficient dimensional stability may not be obtained.

  Moreover, the nonwoven fabric concerning this invention can be mix | blended with a sizing agent as needed, such as giving moisture resistance and water repellency. As the sizing agent, any reinforced rosin sizing agent, rosin emulsion sizing agent, petroleum resin sizing agent, synthetic sizing agent, neutral rosin sizing agent, alkyl ketene dimer (AKD) may be used as long as the desired effect of the present invention is not impaired. Any of known sizing agents such as) can be used.

  In addition to these, an anionic, nonionic, cationic or amphoteric retention improver, a filtering agent, a dispersant, a paper strength improver and a sticking agent are appropriately selected and used as necessary. Moreover, internal additives for papermaking, such as a pH adjuster, an antifoaming agent, a pitch control agent, and a slime control agent, can be appropriately added depending on the purpose.

  In addition, if necessary, it contains clay, kaolin, calcined kaolin, talc, calcium carbonate, titanium dioxide, and other self-extinguishing fillers such as aluminum hydroxide and magnesium hydroxide. Can be made.

  Moreover, this invention is also a building member by which the composite sheet for building members of this invention is provided in one surface of the core material which consists of a synthetic resin foam.

  The core material composed of the synthetic resin foam according to the present invention is composed of a synthetic resin foam such as polyurethane foam, polyisocyanurate foam, phenol foam, vinyl chloride foam, polyethylene foam, polystyrene foam, urea foam, and the like. Especially when fire resistance is required, it is formed by mixing a stock solution of resol type phenol, a curing agent and a foaming agent, and generally discharging it to the surface material and / or the backside material and heating it to react, foam and cure. It is a thing.

  In addition, lightweight aggregates (perlite grains, glass beads, gypsum slag, talc stone, shirasu balloon, aluminum hydroxide, etc.), fibrous materials (glass wool, rock wool, carbon fiber, graphite, etc.) ) Can be mixed to improve fire resistance and fire resistance.

  Examples of the surface material that can be used in the present invention include iron, aluminum, copper, stainless steel, titanium, aluminum / zinc alloy-plated steel plate, galvalume steel plate, enameled steel plate, clad steel plate, laminated steel plate (vinyl chloride steel plate, etc.), sandwich steel plate ( Damping steel plate, etc.), vinyl chloride resin, polycarbonate resin, etc. (including painted color plate) are molded into various shapes by roll molding, press molding, extrusion molding, etc., or inorganic material is extrusion molded, pressed Examples thereof include those formed into various arbitrary shapes by molding, autoclave ripening form, and the like.

  Further, on the synthetic resin film side of the composite sheet for building members of the present invention, aluminum vapor-deposited paper, kraft paper, asphalt felt, metal foil (Al, Fe, Pb, Cu), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper Alternatively, aluminum hydroxide paper or the like may be bonded as necessary.

  EXAMPLES Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited to the examples. Further, in the examples, unless otherwise indicated, parts and percentages are based on mass.

[Preparation of Glass Fiber Dispersion-A]
85:15 of commercially available chopped strand glass fiber (fiber diameter 9 μm, fiber length 6 mm) and binder fiber (trade name: VPB107, manufactured by Kuraray Co., Ltd., 1.1 dt × 3 mm, PVA fiber) in water in the pulper dispersion tank A glass fiber dispersion liquid-A was prepared by charging at a ratio and mixing and dispersing for 10 minutes.

[Preparation of Glass Fiber Dispersions-B to G]
Instead of commercially available chopped strand glass fibers in Glass Fiber Dispersion-A, Glass Fiber Dispersion-B (commercially chopped strand glass fibers, fiber diameter 6 μm, fiber length 9 mm), Glass Fiber Dispersion-C (commercially available) Chopped strand glass fiber, fiber diameter 9 μm, fiber length 18 mm), glass fiber dispersion-D (commercially chopped strand glass fiber, fiber diameter 3 μm, fiber length 8 mm), glass fiber dispersion-E (commercial chopped strand glass Fiber, fiber diameter 6 μm, fiber length 4 mm), glass fiber dispersion-F (commercially chopped strand glass fiber, fiber diameter 15 μm, fiber length 9 mm), glass fiber dispersion-G (commercially chopped strand glass fiber, fiber diameter) 9 μm, fiber length 22 mm) We were prepared glass fiber dispersion -B~G a manner.

[Preparation of wood pulp dispersion]
NBKP (wood pulp fiber) beaten in 500 ml CSF and binder fiber (trade name: VPB107, manufactured by Kuraray Co., Ltd., 1.1 dt × 3 mm, PVA fiber) are added at a ratio of 85:15 to the water in the pulper dispersion tank. A wood pulp dispersion was prepared by mixing and dispersing for a minute.

[Preparation of synthetic fiber dispersion]
Commercially available polyester short fibers (fineness 0.6 dtex, fiber length 5 mm) and heat-sealable core / sheath binder fibers (core polyester, low melting point copolymer polyester having a sheath flow start temperature of 110 ° C., in water in a pulper dispersion tank, (Fineness 1.1 dtex, fiber length 5 mm) was added and mixed and dispersed for 10 minutes to prepare a synthetic fiber dispersion.

[Production of non-woven fabrics 1 to 21]
Nonwoven fabrics 1-21 were produced using a circular net paper machine. The glass fiber dispersion, the pulp dispersion, and the synthetic fiber dispersion were sent to a storage tank and mixed so as to have a mixing ratio shown in Table 1. The mixed dispersion is fed to the paper making head so as to have the basis weight shown in Table 1. After the wet paper web is made, pressing is performed, and it is applied to the Yankee dryer surface and dried to obtain nonwoven fabrics 1 to 21 shown in Table 1. It was.

[Manufacture of composite sheets for building components]
<Examples 1 to 21>
A polyolefin resin (mixed resin of 60 parts of high-density polyethylene and 40 parts of low-density polyethylene) was melted by heating with an extruder and extruded to the thickness shown in Table 2 to obtain a synthetic resin film (A). In addition, the breaking strength in 25 micrometers of this synthetic resin film (A) was 21 MPa. Transparent polyester was used as the synthetic resin film (B) having different breaking strengths. The breaking strength at 25 μm of the synthetic resin film (B) was 230 MPa.

  The synthetic resin film (A) is ejected into a film by extrusion, and the synthetic resin film (A) in a molten state is bonded to the synthetic resin film (B) and the Yankee dryers 1 to 5 and 7 to 20 The composite sheet for building members of Examples 1 to 21 shown in Table 2 was obtained by heat-sealing while interposing between the surface and the surface of the building member.

<Example 22>
Example 3 is the same as Example 3 except that 12 μm thick aluminum vapor-deposited PET is used instead of transparent PET as the synthetic resin film (B) in Example 3, and the aluminum vapor-deposited surface is bonded to the nonwoven fabric side. 22 composite sheets for building members were obtained. In addition, the breaking strength in 25 micrometers of this aluminum vapor deposition PET was 228 MPa.

<Example 23>
As a synthetic resin film (B) in Example 3, a composite sheet for building members of Example 23 was obtained in the same manner as in Example 3 except that a stretched polypropylene film having a thickness of 30 μm was used instead of transparent PET. In addition, the breaking strength in 25 micrometers of this stretched polypropylene film was 181 MPa.

<Example 24>
A 12 μm transparent polyester was used as the synthetic resin film (A). The laminating method was carried out by applying 10 g / m ^{2 of} a solventless acrylic resin adhesive on one side of the synthetic resin film (A), and laminating the nonwoven fabric 3 on the surface on which the adhesive was applied. Further, a polyolefin resin (mixed resin of 60 parts of high density polyethylene and 40 parts of low density polyethylene) is heated and melted by an extruder, and the synthetic resin film (A) side of the nonwoven fabric 3 bonded with the synthetic resin film (A). A synthetic resin film (B) was obtained by extruding the film between the surface and the cooling roll so as to have a thickness of 20 μm, followed by pressure bonding and cooling to obtain a composite sheet for building members of Example 24.

<Comparative Examples 1-5>
A polyolefin resin (mixed resin of 60 parts of high-density polyethylene and 40 parts of low-density polyethylene) was melted by heating with an extruder and extruded to the thickness shown in Table 2 to obtain a synthetic resin film (A). In addition, the breaking strength in 25 micrometers of this synthetic resin film (A) was 21 MPa. Transparent polyester was used as the synthetic resin film (B) having different breaking strengths. The breaking strength at 25 μm of the synthetic resin film (B) was 230 MPa.

  The method of laminating is that the synthetic resin film (A) is ejected into a film by extrusion, and the molten synthetic resin film (A) is applied to the non-woven Yankee dryer shown in Table 2 and the synthetic resin. It carried out by heat-seal | fusing while interposing between films (B), and obtained the composite sheet for building members of Comparative Examples 1-5 shown in Table 2.

<Comparative Example 6>
Polyolefin resin (mixed resin of 60 parts of high density polyethylene and 40 parts of low density polyethylene) is heated and melted with an extruder, and the thickness of the nonwoven fabric 3 is 20 μm between the surface of the non-woven fabric 3 applied to the Yankee dryer and the cooling roll. To obtain a synthetic resin film (A), which was pressure-bonded and cooled to obtain a nonwoven fabric bonded with the synthetic resin film (A).

  Further, the same polyolefin resin (mixed resin of 60 parts of high-density polyethylene and 40 parts of low-density polyethylene) is heated and melted by an extruder, and the synthetic resin film side surface of the nonwoven fabric bonded with the above synthetic resin film and a cooling roll In between, it extrude | pushed out so that thickness might be set to 30 micrometers, and obtained the synthetic resin film (B), crimped | bonded and cooled, and the composite sheet for building members of the comparative example 6 was obtained.

<Comparative Example 7>
A polyolefin resin (mixed resin of 60 parts of high density polyethylene and 40 parts of low density polyethylene) is heated and melted with an extruder, and the thickness of the nonwoven fabric 3 is 50 μm in thickness between the surface of the nonwoven fabric 3 applied to the Yankee dryer and the cooling roll. To obtain a synthetic resin film (A), which was pressure-bonded and cooled to obtain a nonwoven fabric bonded with the synthetic resin film (A). The synthetic resin film (B) having different breaking strengths was not bonded thereto, and used as a composite sheet for building members of Comparative Example 7.

[Manufacture of building components]
<Examples 25 to 48>
An iron plate (0.27 mm) is used as a surface material, the composite sheet for building members obtained in Examples 1 to 24 is used as a back material, a hard polyurethane foam is used as a core material (10 mm), and 2 between the surface material and the back material. A stock solution of liquid rigid polyurethane foam was poured and allowed to stand for 24 hours to sufficiently complete foaming and curing, and building members of Examples 25 to 48 were obtained. In addition, the composite sheet for building members was such that the surface on the nonwoven fabric side was in contact with the core material.

<Comparative Examples 8-14>
In the same manner as in Examples 25 to 48 except that the composite sheet for building members obtained in Comparative Examples 1 to 7 was used instead of the composite sheet for building members obtained in Examples 1 to 24 in Examples 25 to 48. The building members of Comparative Examples 8 to 14 were manufactured.

[Evaluation]
[Compressive strength of composite sheet]
The composite sheet was cut into a size of 12.7 mm in width and 152.4 mm in length and measured using a ring crush tester (model number: TMC-R-5000, manufactured by Nippon TM Co., Ltd.). The results are shown in Table 2.

  From the comparison with Example 8 and Example 12, the fiber diameter of the glass fiber is 10 μm or less, and the compressive strength is stronger. From the comparison between Example 14, Example 3 and Examples 15 to 17, the compression strength is stronger when the glass fiber content in the total fiber is 80% by mass or less.

[Back surface wrinkles]
About the building member manufactured in Examples 25-48 and Comparative Examples 8-14, the wrinkles of the back surface material (composite sheet) which generate | occur | produce at the time of manufacture were confirmed. The wrinkle was evaluated by using a building member having a length of 1 m and a width of 37 cm, marking the length of a wrinkle with a length of 30 mm or more, and calculating the total length of all wrinkles with a length of 30 mm or more. . The total wrinkle length is preferably less than 100 mm, and more preferably less than 80 mm. The results are shown in Table 3. Note that the more wrinkles there are, the easier it is to warp during production and over time.

[Break of back material]
At the time of manufacturing the building members manufactured in Examples 25 to 48 and Comparative Examples 8 to 14, the amount of the hard polyurethane foam stock solution was intentionally increased by 1.05 times and immediately put into a chamber at 80 ° C. for 30 minutes for foaming. Curing was accelerated and the presence or absence of breakage of the back material (composite sheet) accompanying expansion of the rigid polyurethane foam was confirmed. In addition, evaluation of the fracture | rupture used the construction member of the magnitude | size of 1 m in length, and the width of 37 cm, and measured the length of the part to which the length broke 5 mm or more. The results are shown in Table 3. In addition, it is good not to fracture.

[Formability of backside material]
About the building member manufactured in Examples 25-48 and Comparative Examples 8-14, the moldability of the back material (composite sheet) was confirmed. Evaluation of formability was carried out through a roll at a pressure of 20 kgf / cm ^{2 in} order to provide a mold having a depth of 3 mm and a width of 1 cm between 2 and 3 cm from one end in the width direction at the time of manufacturing a building member. If the mold is not well formed, it can be a problem when constructing building components. The depth on both sides of the formed mold having a width of 1 cm (that is, the depth at 3 cm (inner side) and 2 cm (outer side) from one end in the width direction) was measured. The evaluation of formability was made using a building member with a length of 1 m and a width of 37 cm, measured at 5 locations of 30, 40, 50, 60, and 70 cm from one end in the length direction, and indicated by the average value It was. The results are shown in Table 3. The difference in depth between the inside and outside of the mold having a width of 1 cm is less than 0.5 mm, and the depths on both sides are preferably 2.0 to 3.0 mm, and 2.5 to 3.0 mm. Even better.

[Warping of building components]
About the building member of Examples 25-48 and Comparative Examples 8-14, the thermal cycle test which makes 12 cycles at -20 degreeC for 12 hours, 70 degreeC 60% RH, and a total of 24 hours is implemented, 48 cycles The difference in warpage before and after the subsequent test was measured. In addition, the evaluation of the warp uses a building member having a length of 1 m and a width of 37 cm, and is 20 cm, 50 cm, and 80 cm from one end in the length direction at the center in the width direction (ie, 18.5 cm from one end). The warpage was measured at three locations, and the maximum value and the minimum value of the warpage were described in width. The results are shown in Table 3. The maximum value of the warp is preferably less than 1.5 mm, and more preferably less than 1.0 mm.

  From the comparison between Example 25 and Comparative Example 9, even when the same nonwoven fabric was used and the basis weight was substantially the same, if the compressive strength of the back material was less than 0.3 kN / m, the back material was often wrinkled. . Further, from the comparison between Example 27 and Comparative Examples 13 and 14, even when the same nonwoven fabric was used, when the synthetic resin films having different breaking strengths were not bonded together, the back material was often wrinkled.

From the comparison between Examples 28 and 29 and Comparative Example 10, when the compressive strength of the back material exceeds 1.00 kN / m, the back material is too hard and the formability of the back material is deteriorated. Moreover, even if the synthetic resin film bonded together is the same from the comparison with Examples 26-28 and 30 and the comparative example 11, when the fabric weight of a back surface material exceeds 120 g / m < ² >, since a back surface material becomes too thick. In addition, the formability of the back surface material becomes worse. Moreover, since the tensile strength of a back material also falls that the basis weight of a back material is less than 50 g / m < ² > from the comparison with the comparative example 8 and Example 25, a back material is easy to fracture | rupture.

  Further, for example, from the comparison between Examples 27 and 38 to 44 and Comparative Example 12, when glass fiber is not contained, the maximum value of the warpage of the building member is large (that is, the dimensional stability is poor). Further, from comparison between Examples 27 and 38 to 41 and Example 44, the dimensional stability is further improved when the content of the glass fiber in the total fibers is 20% by mass or more. Further, from comparison between Examples 27 and 38 to 40 and Example 41, the dimensional stability is further improved when the glass fiber content in the total fibers is 40% by mass or more. Moreover, the comparison with Example 27, 39-41,44 and Example 38 WHEREIN: If the content of the glass fiber in all the fibers is 80 mass% or less, the wrinkles of a back surface material will decrease.

  From comparison between Examples 32 and 35, when the fiber length of the glass fiber is 6 mm or more, the dimensional stability is good and the warpage of the building member is small. From the comparison with Examples 9 and 13 and the comparison with Examples 33 and 37, when the fiber length of the glass fiber exceeds 20 mm, the compressive strength of the back material is lowered, and the wrinkles of the back material at the time of manufacturing the building member are reduced. There was a tendency to increase.

  In addition, the comparison between Example 12 and Examples 3 and 8 and the comparison between Example 36 and Examples 27 and 32 indicate that the compression strength of the back material is increased when the fiber diameter of the glass fiber is 10 μm or less. There are also few wrinkles of the back material at the time of manufacture of a building member. From comparison between Example 34 and Examples 27 and 32, when the fiber diameter of the glass fiber is 5 μm or more, the dimensional stability is good and the warpage of the building member is small.

[Production of non-woven fabrics 22 to 26]
The nonwoven fabrics 22 to 26 were manufactured using a combination paper machine in which an inclined wire type paper machine and a circular net paper machine were installed online. The glass fiber dispersion and the wood pulp dispersion are used for the first layer (for the inclined wire type paper machine) and for the second layer so that the glass fiber / wood pulp (G / P) mass ratio shown in Table 4 is obtained. Sent to a storage tank (for a circular net paper machine) and mixed. The mixed dispersions are sent to the first papermaking head (tilted wire type papermaking machine) and the second papermaking head (circular papermaking machine), respectively, so that the basis weight shown in Table 4 is reached. After that, it was pressed and dried so that the surface of the second layer was in contact with the Yankee dryer surface, and nonwoven fabrics 22 to 26 having two layers shown in Table 4 were obtained.

The details of the abbreviations shown in Table 4 are as follows.
G: Glass fiber P: Wood pulp

[Manufacture of composite sheets for building components]
<Examples 49 to 53>
Instead of the nonwoven fabric 3 in Example 3, the nonwoven fabrics 22 to 26 were used, and the same procedure as in Example 3 was performed except that two types of synthetic resin films having different breaking strengths were bonded to the first layer side of the nonwoven fabrics 22 to 26. Thus, composite sheets for building members of Examples 49 to 53 were obtained.

[Evaluation]
[Compressive strength of composite sheet]
It measured similarly to the composite sheet for building members of Examples 1-24. The results are shown in Table 5.

[Skin irritation]
The surface on the nonwoven fabric side of the composite sheet for Example 27 and Examples 49 to 53 was touched, and skin irritation was confirmed according to the following criteria. The results are shown in Table 5.
A: No skin irritation is felt.
B: Almost no skin irritation is felt.
C: Slightly irritating to skin
A or B is particularly good.

  From a comparison between Examples 49 to 51 and Examples 27, 52, and 53, the layer on the side in contact with the core made of the synthetic resin foam of the non-woven fabric does not contain glass fibers, or from glass fibers in a mass ratio. In the case of containing a large amount of wood pulp, no or little skin irritation was felt. Therefore, the adverse effect on the operator when manufacturing the building member can be suppressed, which is particularly good.

[Manufacture of building components]
<Examples 54 to 58>
In the same manner as in Examples 25 to 48 except that the composite sheet for building members obtained in Examples 49 to 53 was used instead of the composite sheet for building members obtained in Examples 1 to 24 in Examples 25 to 48. The building members of Examples 54 to 58 were manufactured.

[Evaluation]
In the same manner as the building members of Examples 25 to 48 and Comparative Examples 8 to 14, the building members obtained in Examples 54 to 58 were creased on the back material, the back material was broken, and the back material was formable. The warpage of building members was evaluated. The results are shown in Table 6.

  Comparison between Examples 54 to 56 and Examples 57 to 58, in particular, the glass fiber content is substantially the same. Comparison between Examples 55 to 56 and Example 58 shows that the nonwoven fabric synthetic resin film is bonded to the side. If this layer does not contain wood pulp or contains more glass fibers than wood pulp by mass ratio, the dimensional stability is good and the warpage of the building member is small.

  The composite sheet for building material of the present invention can be suitably used as a back material used for building members such as metal siding and building panels.

Claims (4)

A composite sheet for building members used as a back material of a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the building material composite sheet being glass A composite member comprising at least two kinds of synthetic resin films having different breaking strengths bonded to a nonwoven fabric containing fibers, and the composite sheet for building members has a lateral compressive strength of 0.30 to 1.00 kN / m, and a building member A composite sheet for building members, wherein the basis weight of the composite sheet is 50 to 120 g / m ² .   2. The building member according to claim 1, wherein the nonwoven fabric contains 20 to 80 mass% of glass fibers having a fiber diameter of 5 to 10 μm and a fiber length of 6 to 20 mm based on the total fiber amount of the nonwoven fabric. Composite sheet.   The nonwoven fabric contains glass fibers and wood pulp, and is a multilayer nonwoven fabric of two or more layers, and the layer on the side to be bonded to the synthetic resin film of the nonwoven fabric does not contain wood pulp or is made of wood pulp by mass ratio. The glass fiber is contained in a large amount, and the layer on the side in contact with the core made of the synthetic resin foam of the non-woven fabric does not contain glass fiber or contains more wood pulp than glass fiber by mass ratio. The composite sheet for building members according to 1 or 2.   The building member by which the composite sheet for building members in any one of Claims 1-3 is provided in one surface of the core material which consists of a synthetic resin foam.