JP2024004554A - Incombustible heat insulation panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an incombustible heat insulation panel which has high incombustibility evaluation, in a heat insulation panel using a laminate composed of a thermoplastic resin foam plate and a thermosetting resin foam plate as a core material.

SOLUTION: In a panel in which a laminate formed by bonding a thermoplastic resin foam plate 10 and a thermosetting resin foam plate 20 to each other through an adhesive layer 31 is used as a heat insulation layer, and metal surface materials 40, 40 are bonded to both surfaces of the laminate, unevenness 11 is formed on the surface on the adhesive surface side to the thermosetting resin foam plate 20, of the thermoplastic resin foam plate 10, and filler parts 51 in recesses 12 of the unevenness 11, and an adhesive layer 31 are formed of expanded graphite-containing adhesive.

SELECTED DRAWING: Figure 1

COPYRIGHT: (C)2024,JPO&INPIT

Description

The present invention relates to noncombustible heat insulating panels used as wall and roof materials of buildings.

Conventionally, materials that provide insulation and nonflammability to walls and roofs of buildings include inorganic insulation materials such as rock wool hardened with binder resin, and core materials made of foamed resins such as polyurethane foam and polystyrene foam. A panel is known in which two metal plates are attached to both sides of the board with an adhesive. Among these, panels using a thermosetting resin foam board such as polyurethane foam as a core material have high nonflammability (see Patent Document 1).

Patent No. 6117972

The heat generation test is a typical evaluation test for fire protection materials based on the Building Standards Act. The heat generation test is conducted using a cone calorimeter in accordance with ISO 5660, and is evaluated based on the total amount of heat generated, the maximum heat generation rate that is continuously shown, and the presence or absence of cracks or holes that penetrate to the back surface. be evaluated. Panels using thermosetting resin foam board as a core material have a high nonflammability rating in the heat generation test, but they have the problem of being expensive compared to thermoplastic resin foam boards such as polystyrene foam. . Therefore, a panel has been proposed in which a part of the core material made of a thermosetting resin foam board is replaced with a thermoplastic resin foam board in order to reduce the cost.

However, when performing the above exothermic test on a panel in which a laminate of a thermosetting resin foam board and a thermoplastic resin foam board is used as a core material and metal plates are laminated on both sides of the core material, the thermosetting resin foam board Even if the side of the panel was facing the cone heater, the thermoplastic resin foam board would melt and its volume would be significantly reduced, making it impossible to maintain the shape of the panel.

An object of the present invention is to provide a noncombustible heat insulating panel that uses a laminate made of a thermoplastic resin foam board and a thermosetting resin foam board as a core material and has a high noncombustibility evaluation.

The present invention provides a noncombustible heat insulating panel comprising a heat insulating layer made of synthetic resin foam and a metal surface material disposed on both surfaces of the heat insulating layer via an adhesive layer.
The heat insulating layer is composed of a thermoplastic resin foam board and a thermosetting resin foam board laminated on at least one surface of the thermoplastic resin foam board,
In at least one laminated surface of the thermoplastic resin foam board and the thermosetting resin foam board, at least one surface of the thermoplastic resin foam board and the thermosetting resin foam board has an uneven surface,
The minimum width of the recessed portion of the unevenness exceeds 1 mm,
It is characterized in that the concave portions of the unevenness are filled with at least expanded graphite.

The present invention includes the following configurations as preferred embodiments.
[1] The theoretical expansion volume of the expanded graphite is 2.0 times or more the volume of the thermoplastic resin foam board.
[2] In [1] above, an adhesive layer is interposed on the laminated surface of the thermoplastic resin foam board and the thermosetting resin foam board that are in contact with at least the recess, and the uppermost part of the protrusion adjacent to the recess is provided with an adhesive layer. The narrow width exceeds 1 mm.
[3] In [2] above, the recessed portion is filled with an expanded graphite-containing adhesive containing the expanded graphite.
[4] In the above [3], the adhesive layer with which the recess comes into contact is formed of the expanded graphite-containing adhesive.
[5] In [2] above, the recess is filled with only the expanded graphite.
[6] The thermoplastic resin foam board is made of extruded polystyrene foam, and the thermosetting resin foam board is made of polyisocyanurate foam.
[7] In the exothermic test using a cone calorimeter in accordance with ISO5660, the following (a) to (c) are satisfied.
(a) The total calorific value for 20 minutes after the start of heating is 8 MJ/m ² or less.
(b) There are no cracks or holes penetrating to the back surface that are harmful in terms of fire protection for 20 minutes after the start of heating.
(c) After the start of heating, the maximum heat generation rate does not exceed 200 kW/m ² for 10 seconds or more for 20 minutes.

In the present invention, in the laminated surface of a thermoplastic resin foam board and a thermosetting resin foam board, at least one of the foam boards is formed with unevenness on its surface, and the concave portions of the unevenness are filled with expanded graphite. A large amount of expanded graphite can be placed between the plastic foam board and the thermosetting resin foam board. Therefore, in the exothermic test, the large volume change due to thermal melting of the thermoplastic resin foam board can be compensated for by the expansion of the expanded graphite, and a noncombustible heat insulating panel with a high noncombustibility evaluation can be provided.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view and a cross-sectional view in the thickness direction schematically showing the configuration of an embodiment of a noncombustible heat insulating panel of the present invention. FIG. 2 is a partially enlarged view of the cross-sectional view of FIG. 1; It is a sectional view in the thickness direction and a partially enlarged view schematically showing the configuration of another embodiment of the noncombustible heat insulating panel of the present invention. It is a top view which shows typically the structure of the unevenness|corrugation of other embodiment of the noncombustible heat insulation panel of this invention. It is a sectional view in the thickness direction schematically showing the configuration of another embodiment of the noncombustible heat insulating panel of the present invention.

The noncombustible heat insulating panel of the present invention has a heat insulating layer made of synthetic resin foam as a core material, and has metal surface materials on both surfaces of the heat insulating layer with adhesive layers interposed therebetween. In the present invention, the heat insulating layer is a laminate formed by laminating a thermosetting resin foam board and a thermoplastic resin foam board, and on at least one laminated surface, the thermosetting resin foam board and the thermoplastic resin foam board are stacked together. By providing irregularities on at least one surface of the foam board and filling the recesses of the irregularities with expanded graphite, a sufficient amount of expanded graphite can be filled in to fill the voids created by thermal melting of the thermoplastic resin foam board in the exothermic test. , is characterized in that it is placed between a thermosetting resin foam board and a thermoplastic resin foam board.

When a heat generation test is performed on a noncombustible insulation panel that uses a thermoplastic resin foam board as part of the core material, the thermoplastic resin foam board thermally melts and its volume decreases significantly. In order to compensate for such large volume fluctuations of the thermoplastic resin foam board, the present invention uses expanded graphite whose volume expands when heated. The laminated form of thermoplastic resin foam board and thermosetting resin foam board is generally to adhere with an adhesive layer interposed, but the laminated thermoplastic resin foam board and thermosetting resin foam board In some cases, the metal surface material is directly laminated, and the end of the metal surface material is folded back and fixed at the laminated end, or fixed with separately prepared hardware.

Here, in the laminated surfaces of the thermoplastic resin foam board and the thermosetting resin foam board, a case where there is no unevenness on the surface of either the thermoplastic resin foam board or the thermosetting resin foam board will be described. When the adhesive layer is not provided, the laminated surface with no unevenness is the interface between the flat surfaces of the foam boards, so it is easy to interpose powdered expanded graphite at a predetermined thickness on the laminated surface. isn't it. In addition, even if expanded graphite is mixed with a binder material such as an adhesive and made into a paste and interposed on the laminated surface, a large amount of expanded graphite will be generated in the process of laminating the thermoplastic resin foam board and the thermosetting resin foam board There is a risk that the mixture of the laminate and the binder material may flow out from the laminated ends, and it is not easy to interpose a large amount of expanded graphite without creating irregularities on the laminated surface.

Even when an adhesive layer is interposed between the laminated surfaces of a thermoplastic resin foam board and a thermosetting resin foam board, no unevenness can be created on the surface of either the thermoplastic resin foam board or the thermosetting resin foam board. If you try to include expanded graphite in the adhesive layer, you will need to include a large amount of expanded graphite in the adhesive, and if you try to maintain the adhesive concentration above a certain level from the viewpoint of adhesion, the adhesive itself will also be damaged. It is necessary to increase the amount, resulting in a thicker adhesive layer. When bonding a thermoplastic resin foam board and a thermosetting resin foam board with adhesive, apply the desired amount of adhesive to the surface of one foam board, place the other foam board, and apply press pressure. However, when press pressure is applied to a thick adhesive layer containing a large amount of expanded graphite and an increased amount of adhesive itself, the adhesive containing expanded graphite flows out from the laminated end of the two foam boards. Therefore, strong press pressure cannot be applied, resulting in poor adhesiveness between the thermoplastic resin foam board and the thermosetting resin foam board. Furthermore, since the adhesive is an organic substance, an increase in the amount of adhesive increases the total calorific value, resulting in a lower evaluation in the heat generation test.

In the present invention, in the laminated surfaces of the thermoplastic resin foam board and the thermosetting resin foam board, at least one surface is formed with irregularities, and the recesses are filled with expanded graphite. An amount of expanded graphite sufficient to compensate for volume fluctuations can be placed between the thermoplastic foam board and the thermoset foam board.

Hereinafter, the present invention will be described in detail by citing embodiments, but the present invention is not limited to the following embodiments, and the present invention can be easily understood by those skilled in the art without departing from the spirit of the present invention. Based on the above, the scope of the present invention includes modifications, improvements, etc. made to the following embodiments as appropriate.

FIG. 1 is a diagram schematically showing the configuration of an embodiment of a noncombustible heat insulating panel of the present invention, in which (a) is a plan view, and (b) is a line AA' in (a). It is a sectional view of a part. Further, FIG. 2 is an enlarged view of region B surrounded by a broken line in FIG. 1(b).

The noncombustible heat insulating panel (hereinafter referred to as "panel") of the present invention uses a laminate in which a thermoplastic resin foam board 10 and a thermosetting resin foam board 20 are bonded together as a core material. In the present invention, such a laminate is used as a heat insulating layer, and metal surface materials 40, 40 are attached to both surfaces thereof via adhesive layers 32, 33. In this embodiment, a thermosetting resin foam board 20 is bonded and laminated on one surface of a thermoplastic resin foam board 10 via an adhesive layer 31. In this embodiment, irregularities 11 are formed on the surface of the thermoplastic resin foam board 10 facing the thermosetting resin foam board 20 via the adhesive layer 31, and in the recesses 12 of the irregularities 11, a filler is added. The portion 51 is filled with at least a filler made of expanded graphite.

The filler filled in the recesses 12 may be either only expanded graphite or a mixture of expanded graphite and a binder material that binds expanded graphites together. Expanded graphite is difficult to handle as a powder, but if it is mixed with a binder material to form a paste, it can be easily filled directly into the recess 12 as shown in FIG. 2(a). Alternatively, the recess 12 may be filled with a columnar molded product obtained by extruding a mixture of thermoplastic resin and expanded graphite. When only expanded graphite is to be filled into the recess 12, the recess 12 can be easily filled by filling the expanded graphite surrounded by the resin film 52 as shown in FIG. 2(b).

Further, the adhesive layer 31 may contain expanded graphite. In this case, the recesses 12 are filled with a filler made of expanded graphite and a binder material, and an adhesive containing expanded graphite is separately applied onto the unevenness 11 for bonding. Although the layer 31 may be formed and the thermosetting resin foam board 20 is attached, it is possible to fill the recess 12 with an expanded graphite-containing adhesive by using the adhesive used for forming the adhesive layer 31 as the binder material. The adhesive layer 31 can be formed at the same time.

In this embodiment, since at least the recess 12 is filled with expanded graphite, even if a large amount of expanded graphite is present between the thermosetting resin foam board 20 and the thermoplastic resin foam board 10, the adhesive layer 31 can be Can be made thinner. That is, since the adhesive layer 31 and the recess 12 serve as a region for disposing the expanded graphite and the adhesive, the thickness of the adhesive layer 31 can be reduced by sufficiently increasing the volume of the recess 12. Therefore, even if sufficient press pressure is applied when laminating the thermosetting resin foam board 20 and the thermoplastic resin foam board 10, the adhesive or the expanded graphite-containing adhesive will not protrude from the laminated ends, resulting in a good result. Provides good adhesion.

In this embodiment, from the viewpoint of adhesiveness between the thermosetting resin foam board 20 and the thermoplastic resin foam board 10, it is preferable that the adhesive layer 31 does not contain expanded graphite, or even if it contains it, the concentration is low. On the other hand, from the viewpoint of reducing the amount of expanded graphite contained in the adhesive layer 31, it is preferable to fill the recesses 12 with as much expanded graphite as possible. Furthermore, since increasing the amount of adhesive increases the total calorific value, it is preferable to use less adhesive. Therefore, it can be said that it is preferable to fill the recess 12 only with expanded graphite and to fill the adhesive layer 31 with only adhesive from the viewpoint of adhesiveness and total calorific value. Even if they are formed using a common expanded graphite-containing adhesive, sufficient press pressure can be applied, and the wall surface within the recess 12 becomes the adhesive area, so the concentration of expanded graphite in the expanded graphite-containing adhesive can be reduced. Good adhesion can be obtained even if the adhesive strength is increased. In addition, filling the recesses 12 and forming the adhesive layer 31 with the expanded graphite-containing adhesive can be performed in one step, thereby making it easier to manufacture the panel.

Therefore, regarding whether or not the adhesive layer 31 contains expanded graphite, and whether or not the filler portion 51 contains an adhesive, that is, the contents of expanded graphite and adhesive in the adhesive layer 31 and the filler portion 51, respectively. may be adjusted based on the amount of expanded graphite required and the amount of adhesive allowed from the viewpoint of total calorific value.

As the thermoplastic resin foam board 10 used in the present invention, a thermoplastic resin foam board whose volume decreases to 1/5 or less in a heat generation test is also preferably used, and for example, an extruded polystyrene foam is preferably used. , more preferably a density of 20 kg/m ³ to 50 kg/m ³ . It is an extruded polystyrene foam with a compressive strength of 10 N/cm ² to 50 N/cm ² and a thickness of 20 mm to 500 mm.
Further, as the thermosetting resin foam board 20 used in the present invention, polyurethane foam is preferably used, and polyisocyanurate foam is more preferably used.

As the adhesive used in the present invention, a two-component urethane resin adhesive, which is used in conventional heat insulation panels to bond metal surface materials and heat insulation plates, and between heat insulation plates, is preferably used. The two-component urethane resin adhesive can obtain an adhesive strength of 30 N/cm ² or more when used as is, and when the adhesive layer 31 and filler portion 51 contain expanded graphite uniformly, Adhesion can be obtained even when expanded graphite is contained up to 40% by mass in the expanded graphite-containing adhesive. In addition, since increasing the amount of the two-component urethane resin adhesive increases the total calorific value in the exothermic test, the expanded graphite contained in the expanded graphite-containing adhesive should be 20% by mass or more, and the amount of the adhesive must be increased. It is preferable to suppress it. That is, when forming the filler portion 51 and the adhesive layer 31 with an adhesive containing expanded graphite, the preferable content of expanded graphite is 20% by mass or more and 40% by mass or less.

Furthermore, when the adhesive layer 31 does not contain expanded graphite, or when the expanded graphite is in a higher concentration in the filler part 51 than in the adhesive layer 31, the binder material in the filler is different from the adhesive in the adhesive layer 31. However, adhesives other than adhesives, various emulsions, latex, etc., which can be mixed with powdered expanded graphite to prepare a paste filler, can be used as the binder material, and the present invention Various additives other than the binder material may be added as long as they do not impair the effect. Further, if sufficient adhesiveness can be obtained in the adhesive layer 31, the content of expanded graphite in the filler portion 51 can be more than 40% by mass.

In the present invention, expanded graphite is heated and foamed when the thermoplastic resin foam board 10 softens and melts to reduce its volume and a gap is created between it and the thermosetting resin foam board 20. increases, and the shape of the entire panel is maintained by filling the voids. Therefore, it is desirable to use expanded graphite so that its expansion volume upon heating and foaming is greater than or equal to the volume variation of the thermoplastic resin foam board 10 used. When the thermoplastic resin foam board 10 is a polystyrene foam, expanded graphite may be used so that the theoretical expansion volume of the expanded graphite is 2.0 times or more relative to the volume of the thermoplastic resin foam board 10. Desirably, if the theoretical expansion volume of the expanded graphite is 2.0 times or more relative to the volume of the thermoplastic resin foam board 10, expanded graphite can be used even for the thermoplastic resin foam board 10 made of a material other than polystyrene foam. Almost the same effect can be obtained. Here, the theoretical expansion volume is calculated by placing expanded graphite in a muffle furnace at 950°C for 1 minute and reading the expansion volume after taking it out. It is the value multiplied by the amount (mass).

Further, in the embodiment shown in FIG. 1, the unevenness 11 is formed on one surface of the thermoplastic resin foam board 10, but as will be described later, the unevenness is also formed on the surface of the thermosetting resin foam board 20. Furthermore, when a thermosetting resin foam board is bonded to both sides of the thermoplastic resin foam board 10, the number of surfaces of the foam board on which unevenness can be formed is a maximum of four, and at least one of these surfaces is provided with an unevenness. Just form it. In the present invention, the theoretical expansion volume is calculated based on the amount of all expanded graphite placed within the panel.

There are several types of expanded graphite with different expansion start temperatures and expansion volumes per unit mass (expansion magnification), and it is more economical to use expanded graphite with a high expansion volume per unit mass because the required amount of expanded graphite is smaller. Generally, expanded graphite having a high expansion volume per unit mass has a high expansion start temperature. The lowest expansion start temperature of expanded graphite is about 120°C, whereas thermoplastic resins such as polystyrene foams start softening at around 100°C, so it is preferable to use expanded graphite with a low thermal expansion start temperature. However, it is disadvantageous in terms of cost. Therefore, in the present invention, expanded graphite with a low expansion start temperature and expanded graphite with a high expansion temperature may be used in combination.

In the present invention, the cross-sectional shape of the recesses 12 of the irregularities 11 formed on the surface of the thermoplastic resin foam board 10 may be semicircular as shown in FIG. 3 in addition to the rectangular shape shown in FIG. 1. In FIG. 3, (a) is a cross-sectional view in the thickness direction schematically showing the configuration of another embodiment of the present invention, and (b) is a cross-sectional view of the area C surrounded by the broken line in (a). It is a partially enlarged view. The recesses 12 can be formed on the flat surface of the thermoplastic resin foam board 10 by cutting with a slot cutter or by pressing a face plate, a metal rod, or the like.

The dimensions of the unevenness 11 according to the present embodiment are such that the minimum width W1 of the recess 12 exceeds 1 mm, and the thermosetting resin The minimum width W2 of the convex portion 13 exceeds 1 mm in order to obtain good adhesion to the foam board 20. Note that the minimum width of the convex portion 13 and the minimum width of the concave portion 12 are the shortest distances between the surface of the convex portion 13 on the thermosetting resin foam board 20 side and the opening of the concave portion 12, respectively. Further, the depth D of the recess 12 (in the case of FIG. 3, the depth of the deepest part) is preferably 1 mm or more in order to fill a sufficient amount of the filler part 51. As shown in FIG. 1, the unevenness 11 preferably has a striped shape in which recesses 12 of the same width are arranged in parallel at regular intervals. In this case, the minimum width of the recess 12 is the width of the opening of the recess 12, The minimum width is the width of the surface of the convex portion 13. Note that the surface of the convex portion 13 is flat. Moreover, the unevenness 11 may have a form in which one side is in the shape of a grid and the other side is in the form of dots. The width is small. FIG. 4 is a schematic plan view of the thermoplastic resin foam board 10 in which the recesses 12 are shaped like a lattice. Further, from the viewpoint of adhesion, it is more preferable that the inner surface of the recess 12 exhibits, for example, a screw-like uneven shape because an embossing effect can be obtained.

As the metal surface material 40 used in the present invention, a metal plate used as a surface material in conventional heat insulation panels is preferably used, and a surface coated with resin is also preferably used. For example, a polyester resin coated galvalume steel plate (registered trademark) is preferably used, and the thickness is 0.1 mm to 3.0 mm.

In the present invention, the resin film 52 containing expanded graphite shown in FIG. A film made of resin is preferably used.

In the embodiment shown in FIG. 1, a structure in which unevenness 11 is provided on the surface of the thermoplastic resin foam board 10 is shown, but the present invention is not limited to such a structure, and the surface of the thermosetting resin foam board 20 is It is also possible to provide unevenness, and as shown in FIG. 5(a), unevenness 11 and 21 may be provided on both sides with the adhesive layer 31 in between. In FIG. 5(a), 22 is a concave portion and 23 is a convex portion. In addition, if it is a thermoplastic resin foam board, it is possible to easily form irregularities of desired dimensions by cutting, so it is preferable to provide the thermoplastic resin foam board 10 with irregularities.

In addition, in the embodiment of FIG. 1, a two-layer thermal insulation layer is shown in which the thermosetting resin foam board 20 is adhered to only one surface of the thermoplastic resin foam board 10, but in the present invention, FIG. As shown in (b), thermosetting resin foam boards 20 and 25 may be adhered to both sides of the thermoplastic resin foam board 10. When thermosetting resin foam boards 20 and 25 are bonded to both sides of the thermoplastic resin foam board 10, as shown in FIG. 5(c), unevenness 11 may be provided on both sides of the thermoplastic resin foam board 10, Further, it is possible to provide irregularities on the thermosetting resin foam boards 20 and 25 side, or to provide irregularities on both the foam boards 20 and 25.

Further, in the above embodiment, the thermoplastic resin foam board 10 and the thermosetting resin foam board 20 are laminated with the adhesive layer 31 interposed therebetween, but in the present invention, The thermoplastic resin foam board and the thermosetting resin foam board may be directly laminated, and the end of the metal surface material may be folded back at the end of the stack, or the laminate may be fixed with separately prepared hardware. In the case of such a form, it is sufficient that the recesses can be filled with at least a filler made of expanded graphite, and the minimum width of the projections is not limited as long as the minimum width of the recesses is more than 1 mm. Further, in the case of mixing expanded graphite with a binder material or thermoplastic resin, it is preferable to increase the content of expanded graphite as high as possible within a range that allows efficient filling of the recesses.
In the present invention, as illustrated in FIGS. 5(b) and 5(c), when the thermosetting resin foam boards 20 and 25 are laminated on both sides of the thermoplastic resin foam board 10, the two laminated surfaces One may have an adhesive layer interposed therebetween, while the other may not.

The panel of the present invention achieves appropriate nonflammability and price by combining a thermosetting resin foam board with high heat insulation properties and a cheaper thermoplastic resin foam board. Therefore, it is preferable that 50% or more of the desired thickness of the heat insulating layer be made of thermoplastic resin foam board.

The panel of the present invention exhibits nonflammability that satisfies the following (a) to (c) in a heat generation test using a cone calorimeter in accordance with ISO5660.
(a) The total calorific value for 20 minutes after the start of heating is 8 MJ/m ² or less.
(b) There are no cracks or holes penetrating to the back surface that are harmful in terms of fire protection for 20 minutes after the start of heating.
(c) After the start of heating, the maximum heat generation rate does not exceed 200 kW/m ² for 10 seconds or more for 20 minutes.

In addition, in the panel of the present invention, the above evaluation (b) is also satisfied for the thermoplastic resin foam board portion. When a thermosetting resin foam board is bonded to both sides of a thermoplastic resin foam board, even if no cracks or holes penetrate to the back side of the thermosetting resin foam board in the heat generation test described above, the thermoplastic resin foam board If the panel melts and changes in volume, the panel itself will no longer be able to maintain its shape. In the present invention, since the expanded graphite expands and compensates for the volume fluctuation of the thermoplastic resin foam board, the volume of the thermoplastic resin foam board portion is substantially maintained, and the shape of the panel is maintained.

In the above exothermic test, the panel of the present invention was placed with the thermosetting resin foam board 20 side facing the cone heater. As shown in FIG. 5(b), when the thermosetting resin foam boards 20 and 25 are laminated on both sides of the thermoplastic resin foam board 10, the unevenness 11 is formed on the side where the expanded graphite is arranged. Place it facing the cone heater. Further, as shown in FIG. 5(c), when the expanded graphite is arranged with unevenness 11, 11 provided on both of the laminated surfaces, either of them may be arranged facing the cone heater. In the case of FIG. 5(c), the expanded graphite disposed on both sides of the thermoplastic resin foam board 10 compensates for volume fluctuations due to thermal melting of the thermoplastic resin foam board 10, and maintains the shape.

The members used in this example and comparative example are as follows.
[Insulation board]
XPS: extruded polystyrene foam insulation material specified in JIS A 9521, with thicknesses of 20 mm, 30 mm, 40 mm, 55 mm, 65 mm, 80 mm, and 90 mm (density: 35 kg/m ³ , compressive strength: 25 N/cm) ² )
PIR: Three types of polyisocyanurate foam with thicknesses of 10 mm, 20 mm, and 30 mm (density: 31 kg/m ³ )

[Metal surface material]
Polyester resin coated galvalume steel plate (registered trademark) (JIS G 3322) with a thickness of 0.5 mm

〔glue〕
Two-component urethane resin adhesive (“KU554/KU Hardener No. 2” manufactured by Konishi Co., Ltd.)

[Expanded graphite (EG)]
Expanded graphite A: "953240L" manufactured by Ito Graphite Industries Co., Ltd., expansion volume per unit mass 360 cc/g, expansion start temperature 160 ° C.
Expanded graphite B: "EXP50S120N" manufactured by Fuji Graphite Industries Co., Ltd., expansion volume per unit mass 240 cc/g, expansion start temperature 120 ° C.
The EG theoretical expansion volume V1 in Tables 1 to 3 below is calculated by multiplying the expansion volume per unit mass of the expanded graphite used in each example by the total amount (mass) of the expanded graphite used.

(Example 1)
A slot cutter was used to form irregularities with a rectangular cross section on one surface of the XPS with a thickness of 40 mm, and an adhesive containing expanded graphite, which is a mixture of expanded graphite and an adhesive, was applied to the surface of the XPS on the side where the irregularities were provided. It was applied to the entire surface, PIR was placed on it, and press pressure was applied to adhere it. The same adhesive was applied at 200 g/m ² to the PIR surface and the XPS surface on the side where the unevenness was not provided, and a metal surface material was placed thereon and adhered by applying press pressure to produce a panel. The unevenness was formed into a stripe shape in which concave portions of the same width were lined up in parallel at regular intervals.

(Examples 2 and 3)
As shown in Table 1, panels were produced in the same manner as in Example 1, except that the XPS thickness, PIR thickness, recess depth, and amount of expanded graphite-containing adhesive used were changed.

(Example 4)
As shown in Table 1, a panel was prepared by sandwiching the XPS between two PIRs, forming irregularities on one surface of the XPS, and applying an adhesive containing expanded graphite in the same manner as in Example 2. . The other surface of the XPS on which no unevenness was formed was bonded to the PIR by applying an adhesive at 300 g/m ² .

(Example 5)
As shown in Table 1, a panel was produced in the same manner as in Example 4, except that irregularities with different widths of recesses and projections and depths of recesses were formed on both sides of the XPS. The total amount of expanded graphite-containing adhesive used is the same as in Example 4.

(Examples 6 to 10)
As shown in Tables 1 and 2, panels were produced in the same manner as in Example 1, except that the thickness of the XPS, the thickness of the PIR, the depth of the recess, and the amount of expanded graphite-containing adhesive used were changed. did.

(Example 11)
As shown in Table 2, a panel was produced in the same manner as in Example 1, except that the recesses were filled with an adhesive containing expanded graphite and the adhesive layer was formed only with the adhesive.

(Example 12)
As shown in Table 2, a panel was produced in the same manner as in Example 1, except that the recesses were filled only with expanded graphite and the adhesive layer was formed only with an adhesive.

(Comparative Examples 1 to 6)
As shown in Table 3, the same as Examples 1, 2, 4, 6, 8, and 9 except that 300 g/m ² of adhesive was applied as an adhesive layer for bonding XPS and PIR without forming any unevenness. A panel was prepared. In Comparative Example 3 using two PIR sheets, 300 g/m ² of adhesive was applied to each adhesive layer on both sides of the XPS.

(Comparative example 7)
As shown in Table 3, a panel was produced in the same manner as in Example 1, except that no unevenness was formed and an adhesive layer was formed with an adhesive containing expanded graphite.

(Comparative example 8)
As shown in Table 3, a panel was produced in the same manner as in Example 1, except that the concavities and convexities were formed with different widths of concave portions and convex portions.

(Reference example 1)
As shown in Table 3, panels were produced in the same manner as in Example 1, except that the XPS thickness, PIR thickness, recess depth, and amount of expanded graphite-containing adhesive used were changed.

(Test method)
[Pyrogenicity test]
For each of the panels of Examples 1 to 12, Comparative Examples 1 to 8, and Reference Example 1, a heat generation test was conducted using a cone calorimeter in accordance with ISO5660. In addition, during the test, the panels were arranged so that the PIR side was on the cone heater side, and in the case of two PIRs, the panel was arranged so that the side on which the unevenness was provided on the XPS was on the cone heater side. Regarding Example 5 and Comparative Example 3, all aspects are the same. In addition, for panels in which the adhesive or expanded graphite-containing adhesive protrudes by applying normal press pressure when attaching the metal surface material, the test is performed using a panel that is re-fabricated so that there is no protrusion. went. The evaluation criteria are as follows. The results are shown in Tables 1 to 3.

Total calorific value (THR): If the total calorific value for 20 minutes after the start of heating is 8 MJ/m ² or less, it is passed; if it exceeds 8 MJ/m ₂ , it is rejected.
Shape retention: The falling distance of the metal surface material for 20 minutes after the start of heating is 10 mm or less, which satisfies the requirement that "there are no cracks or holes that penetrate to the back surface that are harmful from a fire safety standpoint for 20 minutes after the start of heating." Pass the case. If at least one of the following is observed: the falling distance of the metal surface material for 20 minutes is 10 mm, or 20 minutes after the start of heating, there are cracks or holes penetrating to the back surface that are harmful in terms of fire protection.
Maximum heat generation rate: 20 minutes after the start of heating, if the maximum heat generation rate is 200kW/ ^m2 or less for 10 seconds or more, it is passed; if it exceeds 200kW/ ^m2 , it is rejected.

[Protrusion from the edge]
When manufacturing the panels of Examples 1 to 12, Comparative Examples 1 to 8, and Reference Example 1, normal press pressure was applied when attaching the metal surface material, causing the adhesive or expanded graphite-containing adhesive to protrude. The presence or absence of was confirmed. The evaluation criteria are as follows. The results are shown in Tables 1 and 2.
○: There was no protrusion.
×: There was protrusion.

[Adhesive strength]
For each of the panels of Examples 1 to 12, Comparative Examples 1 to 8, and Reference Example 1, the adhesive strength between XPS and PIR was measured according to ASTM D 1623. In addition, when bonding XPS and PIR, for panels in which the adhesive or expanded graphite-containing adhesive protrudes by applying normal press pressure, bond it using a panel that has been re-fabricated so that there is no protrusion. The strength was measured. The evaluation criteria are as follows. The results are shown in Tables 1 to 3.
〇: Adhesive strength is 30 N/cm ² or more ×: Adhesive strength is less than 30 N/cm ²

In Tables 1 to 3, the numbers following PIR and XPS are thickness (mm). For example, "PIR10/XPS40" means a laminate of 10 mm thick PIR and 40 mm thick XPS. If the filler part of the recess and the adhesive layer are made of the same expanded graphite-containing adhesive, the columns for adhesive, EG, and adhesive + EG do not distinguish between the recess and the adhesive layer; The numerical value is the sum of the values for the adhesive layer and the EG concentration column shows the concentration of expanded graphite in the expanded graphite-containing adhesive.

In Example 5, unevenness is formed on both sides of the XPS, and the same configuration is taken on both sides of the XPS. The values in the adhesive, EG, and adhesive+EG columns in Table 1 are the combined values for both surfaces, and the EG concentration is a value common to both surfaces.

Furthermore, since the volume of the recesses is very small relative to the volume of the XPS and can be virtually ignored, the volume of the XPS is determined by the thickness regardless of the presence or absence of irregularities.

As is clear from Tables 1 to 3, all of the panels of the examples exhibited good non-combustibility as the voids created by thermal melting of XPS were filled with expanded graphite, and the adhesive properties were also good. However, in all of the panels of Comparative Examples 1 to 6 in which expanded graphite was not arranged, the shapes could not be maintained due to voids created by thermal melting of the XPS. In addition, in the panel of Comparative Example 7 in which no unevenness was formed, and in the panel of Comparative Example 8 in which the width of the convex portion and the width of the concave portion were narrow even though the unevenness was formed, sufficient pressure was not applied during bonding. When the expanded graphite-containing adhesive protruded and was adhered without protruding, good results were obtained in the exothermic test, but the adhesive strength was poor.

10: Thermoplastic resin foam board, 11, 21: Irregularities, 12, 22: Recesses, 13, 23: Convex parts, 20, 25: Thermosetting resin foam board, 31 to 34: Adhesive layer, 40: Metal surface material , 51, 61: filler part, 52: resin film

Claims (9)

A noncombustible heat insulating panel comprising a heat insulating layer made of synthetic resin foam and a metal surface material disposed on both surfaces of the heat insulating layer via an adhesive layer,
The heat insulating layer is composed of a thermoplastic resin foam board and a thermosetting resin foam board laminated on at least one surface of the thermoplastic resin foam board,
In at least one laminated surface of the thermoplastic resin foam board and the thermosetting resin foam board, at least one surface of the thermoplastic resin foam board and the thermosetting resin foam board has an uneven surface,
The minimum width of the recessed portion of the unevenness exceeds 1 mm,
A noncombustible heat insulating panel characterized in that the concave portions of the unevenness are filled with at least expanded graphite. The noncombustible heat insulating panel according to claim 1, wherein the theoretical expansion volume of the expanded graphite is 2.0 times or more the volume of the thermoplastic resin foam board. An adhesive layer is interposed at least on the laminated surfaces of the thermoplastic resin foam board and the thermosetting resin foam board that are in contact with the recess, and the minimum width of the protrusion adjacent to the recess exceeds 1 mm. The noncombustible insulation panel according to claim 2. 4. The noncombustible heat insulating panel according to claim 3, wherein the recess is filled with an expanded graphite-containing adhesive containing the expanded graphite. 5. The noncombustible heat insulating panel according to claim 4, wherein the adhesive layer in contact with the recess is formed of the expanded graphite-containing adhesive. The noncombustible heat insulating panel according to claim 3, wherein the recess is filled only with the expanded graphite. The non-combustible material according to any one of claims 1 to 6, wherein the thermosetting resin foam board is made of polyisocyanurate foam, and the thermoplastic resin foam board is an extruded polystyrene foam. insulation panel. The noncombustible heat insulating panel according to any one of claims 1 to 6, which satisfies the following (a) to (c) in a heat generation test using a cone calorimeter in accordance with ISO5660.
(a) The total calorific value for 20 minutes after the start of heating is 8 MJ/m ² or less.
(b) There are no cracks or holes penetrating to the back surface that are harmful in terms of fire protection for 20 minutes after the start of heating.
(c) After the start of heating, the maximum heat generation rate does not exceed 200 kW/m ² for 10 seconds or more for 20 minutes. The noncombustible heat insulating panel according to claim 7, which satisfies the following (a) to (c) in a heat generation test using a cone calorimeter in accordance with ISO5660.
(a) The total calorific value for 20 minutes after the start of heating is 8 MJ/m ² or less.
(b) There are no cracks or holes penetrating to the back surface that are harmful in terms of fire protection for 20 minutes after the start of heating.
(c) After the start of heating, the maximum heat generation rate does not exceed 200 kW/m ² for 10 seconds or more for 20 minutes.

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