JP2014000718A - Composite sheet for building component and building component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite sheet for a building component in which a pattern and a shape of a front face and a rear face can be freely selected, defects such as curving and peeling of the building component are suppressed, a thickness can be thinned, and that is suitable as a rear face material in the building component in which a surface material is disposed on one surface of a core material comprising a synthetic resin foam and a rear face material is disposed on the other surface; and moreover to provide the building component in which the composite sheet for a building component is disposed on at least one surface of the synthetic resin foam.SOLUTION: Provided is a composite sheet for a building component in which a surface material is disposed on one surface of a core material comprising a synthetic resin foam and a rear face material is disposed on the other surface is used as a rear face material of the building component. The rear face material is a composite sheet in which a nonwoven cloth (A) containing a glass fiber and a binder fiber, and a synthetic resin film (B) are laminated, and the nonwoven cloth (A) is applied or impregnated with a water-soluble polymer (C) containing as one constitutional unit, a monomer having at least one selected from an aliphatic hydroxyl group or an aliphatic amino group.

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, due to the time-dependent change of the synthetic resin foam and the temperature difference and humidity difference between the inside and outside of the building, irregularities may occur on the surface of the building member, and problems such as warping and peeling may occur. 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 less susceptible to changes in temperature and humidity, so they have excellent dimensional stability. However, if the adhesive strength between the composite sheet and synthetic resin foam is weak, the core material is made of synthetic resin foam. Swells and shrinks due to changes in temperature and humidity, which may cause warping and delamination of building components.

  In addition, a sheet composed of 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 prevents problems due to warping and reduces skin irritation. Have been proposed (see, for example, Patent Documents 5 to 8). However, in these sheets, there is a problem that when the core material made of the synthetic resin foam is formed, the raw material component oozes out to the back 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 can suppress problems such as warping and peeling and can also 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 capable of suppressing problems such as warping or peeling of the member and reducing 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 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, A composite sheet obtained by laminating a nonwoven fabric (A) containing glass fibers and binder fibers and a synthetic resin film (B), and the nonwoven fabric (A) is at least selected from an aliphatic hydroxyl group or an aliphatic amino group A composite sheet for building members, which is coated or impregnated with a water-soluble polymer (C) having one kind of monomer as a constituent unit.

  (2) The composite sheet for building members according to (1), wherein the water-soluble polymer (C) is silanol-modified polyvinyl alcohol.

  (3) The nonwoven fabric (A) is a multilayer nonwoven fabric containing glass fibers, binder fibers, and wood pulp and having two or more layers, and is a layer to be bonded to the synthetic resin film (B) of the nonwoven fabric (A). Does not contain wood pulp 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 (A) does not contain glass fiber Or the composite sheet for building members as described in (1) or (2) which contains more wood pulp than glass fiber by mass ratio.

  (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. An object of the present invention is to provide a composite sheet for building members that is suitable as a back material capable of suppressing problems such as warping and peeling and reducing 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 obtained by bonding a nonwoven fabric (A) containing glass fibers and binder fibers and a synthetic resin film (B). And the non-woven fabric (A) is coated or impregnated with a water-soluble polymer (C) having a monomer having at least one selected from an aliphatic hydroxyl group or a monovalent or divalent amino group as one of the constituent units. It is the composite sheet for building members. Hereinafter, unless otherwise specified, “nonwoven fabric” in the present invention refers to “nonwoven fabric (A) containing glass fiber and binder fiber”, and “synthetic resin film” refers to “synthetic resin film (B)”. The “water-soluble polymer” refers to a “water-soluble polymer (C) having a monomer having at least one selected from an aliphatic hydroxyl group or an aliphatic amino group as one of the constituent units”.

  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.

  As long as the glass fiber according to the present invention is not easily broken and has a fiber sheet forming ability, any glass fiber of glass wool or glass fiber chopped strand (glass fiber cut product) can be used.

  2-20 micrometers is preferable, as for the fiber diameter of the glass fiber concerning this invention, 4-15 micrometers is more preferable, and 5-10 micrometers is 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, and the surface smoothness may be inferior. 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 are likely to occur, and the formed nonwoven fabric may be non-uniform.

  10-70 mass% is preferable with respect to the total fiber content of a nonwoven fabric, as for content of the glass fiber concerning this invention, 15-60 mass% is more preferable, and 20-55 mass% is further more preferable. If the glass fiber content is less than 10% by mass, the dimensional stability may deteriorate. On the other hand, if the glass fiber content exceeds 70% by mass, the dimensional stability is good, but the strength and surface smoothness may be inferior.

  Further, the nonwoven fabric according to the present invention contains at least one binder fiber in addition to the glass fiber in order to give the nonwoven fabric an appropriate strength.

  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 pressurized with equipment, it is particularly preferable because it expresses the binder ability to work across the glass fibers, re-solidifies by subsequent dehydration drying, and becomes a strong binder fiber that does not easily dissolve unless in high-temperature water. .

  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. When the fiber length of the binder fiber is less than 1 mm, the binder capacity may be reduced. On the other hand, when the fiber length of the binder fiber exceeds 20 mm, it may be easy to cause kinking or clumping 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.

  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 1 type of synthetic resin film is bonded together to the nonwoven fabric containing glass fiber.

  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 nonwoven fabric according to the present invention is coated or impregnated with a water-soluble polymer having one of the constituent units of a monomer having at least one selected from an aliphatic hydroxyl group or an aliphatic amino group.

  A core material made of a synthetic resin foam is obtained by reacting raw material components in the manufacturing process of building members and foaming using a foaming agent, but when the adhesive strength between the core material and the composite sheet is weak Inconveniences such as peeling of the composite sheet occur. A polyisocyanate or the like is used as a raw material component of the core material, and a water-soluble polymer having one of constituent units of a monomer having at least one selected from an aliphatic hydroxyl group or an aliphatic amino group is a raw material such as a polyisocyanate. Since it reacts with the component to form a chemical bond, the adhesion between the core material and the composite sheet becomes strong, and defects such as peeling can be suppressed.

In addition, some binder fibers contained in the nonwoven fabric have a functional group that reacts with a raw material component such as polyisocyanate such as an aliphatic hydroxyl group, but the binder fibers are localized between the glass fibers. Reactivity with raw material components such as polyisocyanate is weak.
By applying the water-soluble polymer to the nonwoven fabric, a large amount of the water-soluble polymer is present on the side to be bonded to the core material, or by impregnating the nonwoven fabric with the water-soluble polymer, so that it is uniformly present in the matrix of the nonwoven fabric, It can be made to react effectively with the raw material component of the core material, and the adhesion between the core material and the composite sheet can be strengthened.

  Examples of the water-soluble polymer according to the present invention include polyvinyl alcohol, silanol-modified polyvinyl alcohol, amino group-modified polyvinyl alcohol, modified polyvinyl alcohol such as epoxy-modified polyvinyl alcohol, water-soluble polybutyl alcohol, cellulose derivatives such as carboxymethyl cellulose, hydroxyethyl cellulose, Examples thereof include a copolymer of methylaminoethyl acrylate, polyallylamine, and a copolymer thereof, but the present invention is not limited thereto. Silanol-modified polyvinyl alcohol is particularly preferable because of good adhesion to glass fibers.

The coating or impregnation of the water-soluble polymer, the thickness and density of the nonwoven fabric, depending on the content of glass fibers and binder fibers, preferably 2g / m ² ~30g / m ² as dry weight of water-soluble polymers, in particular 5g ^{/ m 2} ~25g ^/ m 2 is preferred. If the amount of water-soluble polymer applied or impregnated is too small, the adhesive strength between the composite sheet and the core material may be the same as when no water-soluble polymer is used. In addition, if the amount of water-soluble polymer applied or impregnated is too large, the raw material component of the core material will not easily penetrate into the nonwoven fabric, and the adhesive strength may not be increased.

  Examples of methods for applying or impregnating a water-soluble polymer to a nonwoven fabric include various coating methods such as blades, rods, reverse rolls, lips, dies, curtains, and air knives, and various printing methods such as flexo, screen, offset, gravure, and inkjet. A system, a transfer system such as roll transfer and film transfer, a pulling system such as dipping, and a suction system such as a suction saturator can be selected and used as necessary.

  Further, the nonwoven fabric according to the present invention is a nonwoven fabric containing glass fibers, binder fibers and wood pulp, and the nonwoven fabric is a multilayer nonwoven fabric of two or more layers, and a layer on the side to be bonded to the synthetic resin film of the nonwoven fabric. Does not contain wood pulp, 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 It is preferable that it is a nonwoven fabric containing more wood pulp than a glass fiber by mass ratio.

  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 according to the present invention is a nonwoven fabric containing glass fiber, binder fiber and wood pulp, the content of wood pulp is preferably 5 to 70% by mass with respect to the total fiber content of the nonwoven fabric, and 10 to 60%. % By mass is more preferable, and 20 to 50% by mass is more preferable. When the content of the wood pulp is less than 5% by mass, the skin irritation due to the glass fiber may be the same as when the wood pulp is not contained. 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 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.

  Although the example of the manufacturing method of the nonwoven fabric concerning this invention is given to the following, this invention is not limited to this.

  As a method for producing a nonwoven fabric or the like, a method in which a fiber web is formed and the fibers in the fiber web are bonded, fused, or entangled can be used. The obtained nonwoven fabric may be used as it is or may be used as a laminate comprising a plurality of sheets. Examples of the method for producing a fiber web include a dry method such as a card method and an airlaid method, a wet method such as a papermaking method, a spunbond method, and a melt blow method, but the present invention contains glass fibers and binder fibers. In the case of the nonwoven fabric concerned, since a uniform fiber web is easy to obtain, a wet method can be used suitably.

  In the wet method, the fibers are uniformly dispersed in water to form a uniform papermaking slurry, and then passed through a process such as screen (removal of foreign matter, lump, etc.), and the final fiber concentration is 0.1 to 2.0% by mass. Adjusted to paper. Further, in order to obtain a more uniform nonwoven fabric or the like, chemicals such as a dispersion aid, an antifoaming agent, a hydrophilic agent, an antistatic agent, and a paper strength enhancing agent may be added in the process. In order to obtain a fiber web, a paper machine having at least one of a wire such as a circular net, a long net, and an inclined type can be used for the papermaking slurry.

  When the nonwoven fabric according to the present invention is a multilayer nonwoven fabric 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 or the like in which two or more types of paper meshes of the same type or different types selected from paper meshes such as long meshes, circular meshes, and inclined wires are installed on-line. 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 the case where the nonwoven fabric concerning this invention is a multilayer nonwoven fabric of 2 layers or more containing glass fiber, binder fiber, and wood pulp is given below, 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 nonwoven fabrics is the method of laminating wet paper webs made by each paper web while they are in a wet state, or after forming one wet paper web. 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 according to the present invention is preferably 15~200g / ^{m 2,} more preferably 20 to 120 g / ^{m 2,} more preferably 30 to 100 g / ^{m 2.} When the basis weight of the nonwoven fabric is less than 15 g / m ² , dimensional stability may not be ensured. Moreover, when the basic weight of a nonwoven fabric exceeds 200 g / m < ² >, the raw material component of a synthetic resin foam may not fully immerse in a nonwoven fabric, and strength may become insufficient. Moreover, 50-500 micrometers is preferable, as for the thickness of a nonwoven fabric, 70-350 micrometers is more preferable, and 100-300 micrometers is more preferable. When the thickness of the nonwoven fabric is less than 50 μm, rigidity may be insufficient. When the thickness exceeds 500 μm, the raw material component of the synthetic resin foam does not sufficiently penetrate into the nonwoven fabric, resulting in insufficient strength or thinning characteristics. May interfere. 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 inter-fiber adhesion may be poor and dimensional stability may not be ensured. 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.

  Further, the compressive strength in the transverse direction (CD direction) of the composite sheet of the present invention is preferably 0.30 to 1.50 kN / m, more preferably 0.30 to 1.00 kN / m, and 0.30 to 0.80 kN. / M is particularly preferred. When foaming a resin in the manufacturing process of a building member, it is usually heated to 60 to 100 ° C. to complete the expansion reaction of the foam, but the foam also shrinks in the process of cooling to near room temperature after the reaction. 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. Further, if the compressive strength in the lateral direction of the composite sheet is too strong, the back surface material becomes difficult to be deformed, so that molding may be difficult. 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.

  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. Moreover, unless otherwise indicated in a present Example, a part and a percentage are mass references | standards.

[Preparation of Glass Fiber Dispersion-A]
Commercially chopped strand glass fibers (fiber diameter 9 μm, fiber length 6 mm) and binder fibers (trade name: VPB107-1, manufactured by Kuraray Co., Ltd., 1.1 dt × 3 mm, PVA fibers) are added to the water in the pulper dispersion tank 85 respectively. A glass fiber dispersion-A was prepared by charging at a ratio of 15 and mixing and dispersing for 10 minutes.

[Preparation of Glass Fiber Dispersions-BD]
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 3 μm, fiber length 8 mm), and glass fiber dispersion liquid-A (commercially chopped strand glass fiber, fiber diameter 6 μm, fiber length 4 mm). In the same manner, glass fiber dispersions -BD were prepared.

[Preparation of wood pulp dispersion]
NBKP (wood pulp fiber) and binder fiber (trade name: VPB107-1, manufactured by Kuraray Co., Ltd., 1.1 dt × 3 mm, PVA fiber) beaten in 500 ml CSF are added to water in the pulper dispersion tank at a ratio of 85:15. For 10 minutes to prepare a wood pulp dispersion.

[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, A fine fiber of 1.1 dtex and a fiber length of 5 mm) was added at a ratio of 70:30, and mixed and dispersed for 10 minutes to prepare a synthetic fiber dispersion.

[Production of non-woven fabrics 1 to 12]
Nonwoven fabrics 1 to 12 were produced using a circular paper machine. The glass fiber dispersion, the pulp dispersion, and the synthetic fiber dispersion were sent to a storage tank and mixed so that the amount of fiber solids in each dispersion became the 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 the wet dispersion is applied to the Yankee dryer surface to obtain nonwoven fabrics 1 to 12 shown in Table 1. It was.

[Manufacture of composite sheets for building components]
<Examples 1 to 24>
Using a reverse roll type roll coater, the surface of the nonwoven fabric coated with a water-soluble polymer aqueous solution shown in Table 2 and applied to the Yankee dryer surface so as to have the coating amount shown in Table 2 (consisting of a synthetic resin foam) (The surface on the side in contact with the core material) and dried with a hot air dryer at 60 ° C.

The details of the abbreviations of the water-soluble polymer shown in Table 2 are as follows.
P-1: A water-soluble polymer having an aliphatic hydroxyl group. Commercial polyvinyl alcohol. Saponification degree 94 mol%. Viscosity of 15% mPa · s by B type viscometer of 4% aqueous solution at 20 ° C
P-2: A water-soluble polymer having an aliphatic hydroxyl group. Commercially available silanol-modified polyvinyl alcohol. Saponification degree 98 mol%. Viscosity 25 mPa · s by B-type viscometer of 4% aqueous solution at 20 ° C.
P-3: A water-soluble polymer having an aliphatic amino group. Commercially available polyallylamine hydrochloride. Weight average molecular weight 3000.
P-4: A water-soluble polymer having an aliphatic amino group. 10 parts of N, N-dimethylaminopropylacrylamide, 50 parts of N, N-dimethylacrylamide, and 40 parts of acrylamide are dissolved in ion-exchanged water to prepare a 20% by weight monomer aqueous solution. Of 2,2'-azobis (2-amidinopropane) dihydrochloride was dissolved in ion-exchanged water so that the polymer concentration after synthesis was 10% by mass and heated to 60 ° C. in a nitrogen atmosphere. The aqueous solution was added in small portions over 2 hours to synthesize a water-soluble polymer of P-4. Weight average molecular weight 6000.
P-5: A water-soluble polymer having neither an aliphatic hydroxyl group nor an aliphatic amino group. Polyacrylamide homopolymer. Weight average molecular weight 10,000.

  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 extruded between the nonwoven fabric and the cooling roll so as to have a film thickness of 50 μm. The composite sheet for building members of Examples 1 to 24 obtained by pressure bonding and cooling to the surface opposite to the surface coated with the water-soluble polymer of the nonwoven fabrics 1 to 11 coated with the water-soluble polymer shown in Table 2 Got.

<Examples 25 to 28>
Supply the aqueous solution of the water-soluble polymer shown in Table 2 to the surface opposite to the non-woven Yankee dryer surface (the surface on the side in contact with the core made of synthetic resin foam). Using a saturator, the nonwoven fabric is sucked from the surface in contact with the core made of synthetic resin foam, and the nonwoven fabric is impregnated with a water-soluble polymer so that the coating amount shown in Table 2 is obtained. Dried.

  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 nonwoven fabric and cooling surface are opposite to the surface in contact with the core made of a synthetic resin foam of nonwoven fabric. A synthetic resin film was obtained by extruding the film so as to have a thickness of 50 μm between the rolls, and crimped and cooled to obtain composite sheets for building members of Examples 25 to 28.

<Examples 29 to 31>
A stretched high-density polyethylene resin film (thickness 30 μm) was used as a synthetic resin film, and the nonwoven fabric 4 coated with the water-soluble polymers P-1, P-2 and P-3 shown in Table 2 was bonded together. The composite sheet for building members of Examples 29 to 31 was obtained. The low-density polyolefin resin is ejected into a film shape (thickness 20 μm) by extrusion molding, and the low-density polyethylene resin in a molten state is bonded to the stretched high-density polyethylene resin sheet and the water-soluble polymer of the nonwoven fabric 4. It was carried out by heat fusion while interposing between the coated surface and the opposite surface.

<Examples 32-34>
A stretched high-density polyethylene resin film (thickness 30 μm) was used as a synthetic resin film, and the nonwoven fabric 4 coated with the water-soluble polymers P-1, P-2 and P-3 shown in Table 2 was bonded together. The composite sheet for building members of Examples 32-34 was obtained. The method of laminating is to apply 20 g / m ^{2 of} a solventless acrylic resin adhesive to one side of a stretched high-density polyethylene resin film, and then apply the water-soluble polymer of the nonwoven fabric 4 to the side on which the adhesive is applied. This was carried out by pasting the finished surface and the opposite surface.

<Comparative Example 1>
A composite sheet for building members of Comparative Example 1 was obtained in the same manner as in Examples 1 to 24 without applying a water-soluble polymer to the nonwoven fabric 4.

<Comparative example 2>
A composite sheet for a building member of Comparative Example 2 was obtained in the same manner as in Examples 1 to 24 except that the non-woven fabric 4 was coated with a water-soluble polymer P-5 having neither an aliphatic hydroxyl group nor an aliphatic amino group shown in Table 2. It was.

<Comparative Examples 3-6>
Using the nonwoven fabric 12 containing no glass fiber, composite sheets for building members of Comparative Examples 3 to 6 were obtained in the same manner as in Examples 1 to 24.

[Manufacture of building components]
<Examples 35-68>
An iron plate (0.27 mm) is used as a surface material, the composite sheet for building members obtained in Examples 1 to 34 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 35 to 68 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 7-12>
In the same manner as in Examples 35 to 68 except that the composite sheet for building members obtained in Comparative Examples 1 to 6 was used instead of the composite sheet for building members obtained in Examples 1 to 34 in Examples 35 to 68. The building members of Comparative Examples 7 to 12 were manufactured.

[Evaluation]
The adhesive strength of the building members obtained in Examples 35 to 68 and Comparative Examples 7 to 12 and the warpage (dimensional stability) of the building members were evaluated by the following methods. The results are shown in Table 3.

[Adhesive strength with core material]
A notch with a width of 5 cm was made on the composite sheet side of the building members of Examples 35 to 68 and Comparative Examples 7 to 12, and the adhesive strength between the composite sheet and the core material was determined in the same manner as the 90 ° peel test described in JIS K 6854. It was measured. The results are shown in Table 3.

[Warping of building components]
About the construction member of Examples 35-68 and Comparative Examples 7-12, 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 The difference in warpage before and after the test after the cycle 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.

  Comparison between Examples 35-68 and Comparative Examples 7-8, especially Examples 38, 49, 58-68 using the same nonwoven fabric, and comparison with Comparative Examples 7-8, aliphatic hydroxyl group or aliphatic amino When a water-soluble polymer having a monomer having at least one selected from a group as one of the constituent units is applied or impregnated, the adhesive strength is increased. In addition, comparison between Examples 35 to 45 and Examples 46 to 56, comparison between Example 59 and Example 60, comparison between Example 63 and Example 64, and comparison between Example 66 and Example 67. Further, when silanol-modified polyvinyl alcohol is used as the water-soluble polymer, the adhesive strength is further increased. Moreover, as compared with Examples 35-68 and Comparative Examples 9-12, when the nonwoven fabric contains glass fibers, the warpage of the building member is small (that is, the dimensional stability is good).

[Production of non-woven fabrics 13 to 15]
Nonwoven fabrics 13 to 15 were manufactured using a combination paper machine in which inclined wires and circular nets were installed online. The glass fiber dispersion and the wood pulp dispersion are used for the first layer (for inclined wires) and for the second layer (for circular nets) so as to have the glass fiber / wood pulp (G / P) mass ratio shown in Table 4. ) To storage tank and mixed. The mixed dispersions are sent to the first papermaking head (for inclined wire) and the second papermaking head (for circular mesh), respectively, so that the basis weight shown in Table 4 is reached. And dried so that the surface of the second layer was in contact with the Yankee dryer surface, and nonwoven fabrics 13 to 15 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 69 to 78>
Instead of the nonwoven fabrics 1 to 11 in Examples 1 to 24, the nonwoven fabrics 13 to 15 are used, and the aqueous solution of the water-soluble polymer shown in Table 5 is made of a synthetic resin foam of nonwoven fabric so as to have the coating amount shown in Table 5. Examples 69 to 69 are applied in the same manner as in Examples 1 to 24 except that the surface is in contact with the core (second layer side) and a synthetic resin film is bonded to the first layer side of the nonwoven fabrics 13 to 15. 78 composite sheets for building members were obtained.

  The abbreviations for water-soluble polymers shown in Table 5 are the same as those in Table 2.

<Examples 79 to 82>
Instead of the nonwoven fabric 4 in Examples 25 to 28, the nonwoven fabrics 13 to 15 are used, and the surface on the side opposite to the surface in contact with the core made of the synthetic resin foam of the nonwoven fabric (the first layer side) is shown in Table 5. An aqueous solution of the water-soluble polymer shown is supplied, and using a suction saturator, the nonwoven fabric is impregnated with the water-soluble polymer so as to have the coating amount shown in Table 5, and a synthetic resin film is placed on the first layer side of the nonwoven fabric 13-15. Except having pasted together, it carried out similarly to Examples 25-28, and obtained the composite sheet for building members of Examples 69-78.

<Comparative Examples 13-15>
The composite sheet for building members of Comparative Examples 13 to 15 was obtained in the same manner as in Examples 69 to 78 without applying the water-soluble polymer to the nonwoven fabrics 13 to 15.

<Comparative Examples 16-18>
For building members of Comparative Examples 16 to 18 as in Examples 69 to 78 except that the water-soluble polymer P-5 having neither aliphatic hydroxyl group nor aliphatic amino group shown in Table 5 was applied to the nonwoven fabrics 13 to 15. A composite sheet was obtained.

[Evaluation]

[Skin irritation]
The nonwoven fabric side surface of the composite sheet for building members of Example 4 and Examples 69 to 82 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 the comparison of Examples 4 and 76 to 78 and Examples 69 to 75, the layer on the side in contact with the core material made of the synthetic resin foam of the nonwoven fabric does not contain glass fibers or is in a mass ratio from glass fibers. In addition, when a large amount of wood pulp was contained, no 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 83 to 96>
In the same manner as in Examples 35 to 68, except that the composite sheet for building members obtained in Examples 69 to 82 was used instead of the composite sheet for building members obtained in Examples 1 to 34 in Examples 35 to 68. The building members of Examples 54 to 58 were manufactured.

<Comparative Examples 19-24>
Instead of the composite sheet for building members obtained in Examples 69 to 82 in Examples 83 to 96, the same as in Examples 83 to 96, except that the composite sheet for building members obtained in Comparative Examples 13 to 18 was used. The building members of Comparative Examples 19 to 24 were manufactured.

[Evaluation]
The building members obtained in Examples 83 to 96 and Comparative Examples 19 to 24 were bonded in the same manner as the building members of Examples 35 to 68 and Comparative Examples 7 to 12, and the warping of the building members (dimensional stability). Sex). The results are shown in Table 6.

  From comparison between Examples 83 to 96 and Comparative Examples 19 to 24, when a water-soluble polymer having one of constituent units of a monomer having at least one selected from an aliphatic hydroxyl group or an aliphatic amino group is applied or impregnated, adhesion is achieved. Strength increases.

  Also, the comparison between Example 84 and Examples 83 and 85 to 86, the comparison between Example 88 and Examples 87 and 89, the comparison between Example 91 and Examples 90 and 92, and the example 94 and Example. From the comparison with 93 and 95 to 96, when silanol-modified polyvinyl alcohol is used as the water-soluble polymer, the adhesive strength is further increased.

  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 a building member 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 back material comprising glass fibers A composite sheet obtained by laminating a nonwoven fabric (A) containing a binder fiber and a synthetic resin film (B), and the nonwoven fabric (A) contains at least one selected from an aliphatic hydroxyl group or an aliphatic amino group. A composite sheet for building members, which is coated or impregnated with a water-soluble polymer (C) having a monomer as a constituent unit.   The composite sheet for building members according to claim 1, wherein the water-soluble polymer (C) is silanol-modified polyvinyl alcohol.   The nonwoven fabric (A) contains glass fibers, binder fibers, and wood pulp, and is a multilayer nonwoven fabric of two or more layers. The layer on the side to be bonded to the synthetic resin film (B) of the nonwoven fabric (A) is wood pulp. Or the layer on the side in contact with the core made of the synthetic resin foam of the nonwoven fabric (A) does not contain glass fibers, or The composite sheet for building members according to claim 1 or 2, which contains more wood pulp than glass fiber in a mass ratio.   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.