JP3062714B2 - Non-combustible laminates or laminates - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-combustible laminate or molded laminate, and more particularly, to a highly non-combustible laminate or a laminate.
The present invention also relates to a laminate or a laminate having excellent moldability.

[0002]

2. Description of the Related Art Conventionally, as a fire-retardant measure for buildings, a base material containing a large amount of aluminum hydroxide powder has been used as a non-combustible base material for imparting non-combustibility to various building materials. The base material containing a large amount of the aluminum hydroxide powder is made nonflammable by the dehydration endothermic reaction of aluminum hydroxide at 200 to 300 ° C.

[0003]

However, a substrate containing a large amount of a water-containing inorganic compound such as aluminum hydroxide has a drawback that the moldability is generally extremely poor. In order to impart moldability to the non-combustible substrate, a method of incorporating a synthetic polymer such as a thermosetting resin, a thermoplastic resin, or a synthetic rubber is considered, but the synthetic polymer is contained in the non-combustible substrate. , The noncombustibility deteriorates sharply with an increase in the content.

Therefore, in order to maintain a high degree of incombustibility, it is necessary to keep the content of the synthetic polymer which can be contained in the noncombustible substrate to a very small amount. The formability of the non-combustible substrate was extremely insufficient. In view of this, the present invention has been disclosed in Japanese Patent Application Laid-Open No. H5-112659, in which the amount of synthetic polymer that can be contained is increased due to the effect of reducing the amount of smoke generated by using a water-containing inorganic compound and a carbonate in a specific mixing ratio range. It has just been proposed that the formability of such a nonflammable substrate can be improved. However, there is a strong demand for improving the formability in such a field. In particular, building materials and the like may require a thickness of 9 mm to 15 mm or more. When the thickness is increased in this way, it becomes more difficult to form the workpiece. Therefore, development of a non-combustible molding material having both high non-combustibility and excellent moldability has been urgently required. The present invention has been made in order to solve the above problems, and has as its object to provide a laminate or a laminate having excellent non-combustibility and excellent moldability.

[0005]

According to the present invention, there is provided a non-combustible laminate or molded article comprising 65 to 95% by weight of a water-containing inorganic compound, and additionally a cellulose fiber and a synthetic polymer. Two or more materials are laminated and fixed with an adhesive layer interposed therebetween. Further, two or more non-combustible base materials having a total of 65 to 95% by weight of a water-containing inorganic compound and a carbonate and containing cellulose fiber and a synthetic polymer are laminated and fixed with an adhesive layer interposed therebetween. Things. Examples of the above-mentioned hydrated inorganic compound include aluminum hydroxide, magnesium hydroxide, calcium hydroxide, gypsum gypsum and calcium aluminate. Each of these compounds has water of crystallization in the molecule and has a chemically similar structure, and hydrous inorganic compounds decompose when heated at high temperatures, although there are some differences in decomposition temperature and endothermic amount depending on the type. They are completely common in that they exhibit a non-combustible effect by an endothermic effect. Therefore, basically any of the above-mentioned hydrated inorganic compounds may be used, but aluminum hydroxide is the most suitable in consideration of economical aspects such as acquisition price.

The synthetic polymer used in the present invention includes a thermosetting resin (including a fibrous resin) such as a phenol resin, a melamine resin, an epoxy resin, a urea resin, and an unsaturated polyester resin, or a polyolefin resin. Thermoplastic resins (including fibrous ones) such as polyester resin, acrylic resin, methacrylic resin, styrene resin, vinyl chloride resin and vinyl acetate resin, or SBR, NBR,
At least one selected from synthetic rubbers such as MBR is used.

[0007] These synthetic polymers have some differences in curing temperature, melt softening temperature, etc. depending on the type, but various molding and shaping on a non-combustible base material by a fluid hardening action or a softening / melting re-solidifying action accompanying heat treatment. They are completely common in that they have an effect of hardening or exhibiting various strengths or an effect of preventing the hydrated inorganic compound or carbonate from falling off, that is, an effect of improving the surface strength. Therefore, basically any of the above-mentioned synthetic polymers may be used, but phenol resins, polyolefin resins, and the like are most suitable in consideration of the economics such as the acquisition price. As the carbonate used in the present invention, at least one selected from calcium carbonate, magnesium carbonate, barium carbonate, strontium carbonate, beryllium carbonate, zinc carbonate and the like is used. These carbonates have some difference in decomposition temperature and the like depending on the kind thereof, but they are completely common in that they decompose when heated at a high temperature and exhibit a non-combustible effect by an endothermic effect. Therefore, basically, any of the above-mentioned carbonates may be used, but calcium carbonate is most suitable in consideration of economical factors such as the price to obtain. As another important effect of the blending of carbonate, the present inventor disclosed in Japanese Unexamined Patent Publication No.
No. 59, etc., the effect of reducing the amount of smoke generated can be obtained.

[0008] The content range of the water-containing inorganic compound or the total amount of the water-containing inorganic compound and the carbonate in the non-combustible base material constituting the non-combustible laminate or molded laminate according to the present invention is 65 to 95% by weight in terms of solid content. It is. If the content is less than 65% by weight, sufficient incombustibility cannot be obtained. On the other hand, if the content exceeds 95% by weight, sufficient formability cannot be obtained due to an excessive amount of the hydrated inorganic compound or the total amount of the hydrated inorganic compound and the carbonate, and the mechanical strength is significantly reduced. It is unsuitable because salt is easily dropped off.

The desired purpose can be achieved without containing a carbonate only by a water-containing inorganic compound in the non-combustible base material according to the present invention. The better effect can be obtained. In this case, the weight ratio of the water-containing inorganic compound / carbonate in the non-combustible substrate is preferably in the range of 99.6 / 0.4 to 50/50 in solid content. This is because there is a possibility that the effect of the combined use of carbonates may not be sufficiently obtained on the side with excess of hydrous inorganic compound than 99.6 / 0.4, and on the side with excess of carbonate above 50/50, the net content of hydrous inorganic compound is too small. This is because the non-combustibility may deteriorate.

[0010] The thickness of the non-combustible substrate according to the present invention is 1 to 5 mm
And preferably 2 to 4 mm. If the thickness is less than 1 mm, the number of the adhesive layers of the laminate or the laminated molded article increases, and the adhesive layer with respect to the hydrous inorganic compound or the total of the hydrous inorganic compound and the carbonate contained in the laminate or the laminated molded article This is because there is a possibility that the ratio of the total amount of the organic matter becomes large and the non-combustibility is reduced. On the other hand, if it exceeds 5 mm, the gap between the adhesive layers of the laminated plate or the laminated molded article is too large, and the effect of improving the non-combustible performance by laminating two or more non-combustible substrates described later with the adhesive layer interposed therebetween. Is difficult to develop, and the moldability tends to deteriorate, which is not suitable.

The thickness of the non-combustible laminate or laminate of the present invention is at least 4 mm, preferably at least 6 mm. If the thickness is less than 4 mm, the ratio of the total amount of the organic matter in the adhesive layer to the total amount of the water-containing inorganic compound or the water-containing inorganic compound and the carbonate contained in the laminate or the laminate molded article may increase, and the nonflammability performance may be reduced. Because there is.

Use of the non-combustible laminate or molded laminate of the present invention for curved surfaces (application to corners)
As for (2), the above-mentioned non-combustible substrates are sandwiched by an adhesive layer.
The structure is such that more than one layer is laminated and fixed, and the required amount of cellulose fiber and synthetic polymer such as thermosetting resin or thermoplastic resin is contained in the non-combustible base material. In addition to ensuring good performance, the moldability is greatly improved compared to the case where a thick noncombustible base material is used alone, and is a non-combustible laminate formed in various shapes such as a curved shape, an L-shape, or a three-dimensional shape. The body can be obtained easily. In addition, each layer of the non-combustible base material is firmly fixed, and the strength of the obtained laminated plate or laminated molded article is improved, and the shape is maintained after molding, as compared with the case of hot-press lamination without using an adhesive. Accuracy also improves. In particular, in the case of responding to a demand for a thick material such as a thickness of 9 mm to 15 mm or more required for a building material or the like, by adopting the configuration of the present invention, the effect of improving non-combustibility and the effect of improving formability are more effectively exhibited, and A laminate or laminate having both noncombustibility and excellent moldability can be economically and easily obtained.

Further, as a specific and effective use of the non-combustible laminate or the laminated molded article of the present invention, a non-combustible corner portion or the like which is required to have non-combustibility as described in Example 9 described later. A curved construction part can be mentioned. That is, conventionally, as shown in FIG.
After fitting the mold table 12 to the required radius of curvature, the groove 1
A method is adopted in which a material 13 is filled with a filler 13 such as cement and then hardened, and then fixed to a predetermined place. However, the number of steps is increased, and the construction is complicated and troublesome. In addition, there is a method that does not rely on such groove processing on a part of a calcium silicate plate or the like. However, there is a limitation on an applicable radius of curvature (at most 1000 mm or more), and only a fairly gentle curved surface can be obtained. According to the present invention, as shown in FIG. 3, the plane portion uses a conventional nonflammable material 14 such as a gypsum board, and only the corner portion of the nonflammable laminated molded article 1 according to the present invention. The radius of curvature is minimized by forming
It is possible to construct a highly curved surface of about 30 to 50 mm extremely easily and with a beautiful appearance.

The non-combustible base material according to the present invention may have a composition of water-containing inorganic compound / cellulose fiber / synthetic polymer or water-containing inorganic compound / carbonate / cellulose fiber / synthetic polymer based on the above composition. Any method can be applied as the production method, such as a wet papermaking method and a dry molding method, and the method is not limited to a specific production method.
The present invention will be described in further detail with reference to a production method, taking as an example a case where a wet papermaking method in the field of the present invention is applied.

The non-combustible base material according to the present invention comprises various retention aids for improving the retention of the water-containing inorganic compound or carbonate, or, if necessary, glass fiber, rock wool fiber,
It may contain inorganic fibers such as carbon fibers or synthetic dyes for coloring. It goes without saying that, depending on the application, a dry or wet paper strength enhancer, a sizing agent, a water-proofing agent, etc. should be included in order to improve the mechanical strength or post-processing suitability. As a method for incorporating the synthetic polymer into the non-combustible base material according to the present invention, a liquid material, a fibrous material or a granular material of the synthetic polymer is internally added to the raw material slurry, or after the paper layer is formed or formed. It may be applied or impregnated later.

As a method of incorporating the hydrated inorganic compound or carbonate, a method of applying or impregnating a base material with a paint containing the hydrated inorganic compound or carbonate can be considered. In order to make the quality uniform in the thickness direction, it is most preferable to internally add the water-containing inorganic compound or carbonate in the raw slurry in the form of powder or slurry. In this case, the method and order of addition of the water-containing inorganic compound, carbonate, cellulose fiber and synthetic polymer are arbitrary, and may be beaten if necessary. The non-combustible base material according to the present invention can be produced by using the thus obtained raw material slurry by a usual papermaking method. That is, the slurry may be supplied in the form of a regular net, circular net, inclined net or the like, filtered, dewatered, squeezed and dried. If necessary, two or more paper layers may be laminated by various combination nets, multi-tank nets, various laminators, and the like.

In order to produce the non-combustible laminate or molded laminate of the present invention using the non-combustible substrate thus obtained, the non-combustible substrate is made of epoxy, phenol, urea or melamine. , Vinyl acetate, ethylene vinyl acetate, urethane, chloroprene, etc.
More than one layer is laminated and fixed, or molded by applying a conventional molding method to a non-combustible base material alone or in combination of two or more kinds. What is necessary is just to laminate and fix more than one layer. However, it is natural that the adhesive should be selected in consideration of the characteristics of the adherend and the amount of the adhesive used should be an appropriate amount.

In some cases, lamination, fixing and molding of the non-combustible base material with the adhesive layer interposed therebetween can be performed simultaneously by integral hot-press molding or integral high-frequency heating molding. Furthermore, depending on the application, the obtained non-combustible laminate or laminated molded body is subjected to surface treatment such as spraying or application or printing of various paints, or decorative board,
It goes without saying that the added value of the non-combustible laminate or molded laminate can be further increased by bonding a laser synthetic resin film or the like. The laminated board or laminated molded article of the present invention has a high degree of noncombustibility by merely laminating and fixing two or more layers of a non-combustible base material containing a water-containing inorganic compound or a water-containing inorganic compound and a carbonate with an adhesive layer therebetween. It does, but does not prevent the use of conventional flame retardants. Examples of the flame retardant that can be used in combination include known flame retardants such as an organic phosphorus compound, a phosphorus-containing nitrogen-containing organic compound, a sulfamate, an inorganic phosphate, a halide, and an antimony compound. The method of using the flame retardant is to add it to a non-combustible substrate by, for example, internally adding it to a raw material slurry, or to apply or apply it during or after the step of laminating or molding the non-combustible substrate. A method such as impregnation may be used.

[0019]

The mechanism of the effect of improving the non-combustibility of the non-combustible laminate or molded article of the present invention has not yet been elucidated, but it may be related to the effect of promoting heat conduction due to the presence of the adhesive layer. I guess. Hereinafter, the contents of the invention based on the test results of the surface test of JIS A-1321 which will be described later in Examples will be described. First, a non-combustible base material containing a high content of a water-containing inorganic compound or a water-containing inorganic compound and a carbonate, a non-flammable base material having the same composition as the non-flammable base material, and simply increasing the weight per unit area and increasing the thickness, A surface test was conducted on three types of base materials obtained by hot-press lamination without using an adhesive. The non-combustibility deteriorated due to an increase in thickness or hot-press lamination (exhaust temperature rise area or maximum smoke generation coefficient or afterflame time). Increase).

Next, a surface test was performed on a laminate obtained by laminating and fixing the above-described non-combustible base material with an organic adhesive therebetween. It was also found that the exhaust temperature rise area, the maximum smoke generation coefficient, and the after-flame time were smaller than those of the noncombustible base material before the lamination, and the noncombustibility was improved. This is a very peculiar phenomenon. That is, the flammable component content in the laminate obtained by laminating and fixing the organic adhesive layer between them should be higher than that in the non-combustible base material before lamination and fixing. The reason for this is that, combined with the above-described increase in thickness under the same composition or the deterioration of the non-combustibility due to the hot-press lamination, it is generally considered that the non-combustibility of the laminated plate is considerably reduced.

The reason why the non-combustibility of the laminated plate is improved is presumed as follows. That is, the incombustibility of the laminate depends on the endothermic effect of the hydrolytic inorganic compound or the hydrous inorganic compound and the carbonate, which are the main components of the noncombustible base material as a component thereof. Therefore, if the hydrated compound or carbonate does not sufficiently absorb heat and thermally decompose, the incombustible effect is not exhibited. However, since the non-combustible base material according to the present invention has excellent heat insulating properties, heat conduction inside the non-combustible base material under high-temperature heating is considered to be extremely slow and a very uneven temperature distribution is likely to occur inside the non-combustible base material. It is difficult to say that the incombustible effect of the hydrolytic inorganic compound or carbonate contained in the incombustible base material by thermal decomposition is not always sufficiently exhibited.

On the other hand, in the case of a laminate having a predetermined thickness obtained by laminating and fixing non-combustible substrates having a predetermined thickness with an adhesive layer interposed therebetween, the adhesive layer is formed of a non-combustible substrate. Is also considered to have a high thermal conductivity, so when the laminate is heated to a high temperature,
The internal temperature distribution tends to be uniform due to the presence of the adhesive layer, and the heat from the heating surface is smoothly transmitted to the inside of the laminate and the hydrated inorganic compound or carbonate of the non-combustible base material constituting the laminate is formed. It is considered that the thermal decomposition is promoted, and the non-combustibility included in the laminate is very effectively and efficiently extracted.

The effect of improving the incombustibility is sufficiently exhibited even when the incombustible base material contains only a high percentage of the water-containing inorganic compound. Therefore, it is considered that the difference in the thermal decomposition behavior of the water-containing inorganic compound and the carbonate, that is, the difference in the thermal decomposition temperature or the difference in the decomposition products is also related to the effect of improving the noncombustibility. Above all, the effect of the physical and chemical interaction between water vapor generated by the thermal decomposition of hydrous inorganic compounds and carbon dioxide generated by the thermal decomposition of carbonates on the combustion reaction due to the presence of the adhesive layer further improves the non-combustibility. It is presumed to act on further,
Even when an inorganic adhesive is selected as the adhesive,
As long as the heat conduction can be smoothed by the presence of the adhesive layer, it is expected that the adhesive itself is non-flammable and further excellent non-flammability improvement effect is exhibited.

[0024]

Next, the present invention will be described more specifically based on the following examples. The measurement of each item in this example was performed by the following method. Incombustibility: Based on JIS A-1321 surface test. Example 1 A predetermined amount of a cellulose fiber dispersion obtained by disintegrating a commercially available softwood-based unbleached sulfate pulp with a disintegrator was taken, and aluminum hydroxide powder (average particle diameter: 5.7 μm) was obtained. The same applies hereinafter) and a powdery phenol resin (average particle size 30 μm).
m. After that, the mixture was sufficiently dispersed and mixed by a stirrer, hand-dried by a square test paper machine, dried, and further heat-treated by a hot press (temperature: 175 ° C., pressure: 5 kg /
cm ² for 3 minutes) to obtain a non-combustible substrate a having a thickness of about 4 mm. Table 1 shows the content of each component for the noncombustible substrate a. Next, three non-combustible substrates a are sandwiched by urethane-based adhesive layers (the amount of the urethane-based adhesive used is 110 g / m ² in solid content for each adhesive layer; the same applies hereinafter). Then, a laminate A having a thickness of about 12 mm was obtained. The nonflammability of the laminate A was measured, and the results are shown in Table 1.

Example 2 In Example 1, calcium carbonate (average particle size 1.5
μm. A non-combustible substrate b having a thickness of about 4 mm was obtained in the same manner as in Example 1 except that the same was added. Table 1 shows the content of each component for the non-combustible substrate b. Next, two non-combustible substrates b were sandwiched between urethane-based adhesive layers and laminated and fixed in the same manner as in Example 1 to obtain a laminate B having a thickness of about 8 mm. The nonflammability of the laminate B was measured, and the results are shown in Table 1.

Example 3 The procedure of Example 1 was repeated except that glass fibers (fiber diameter: 3 μm; the same applies hereinafter) were added to the cellulose fiber dispersion and calcium carbonate was further added. A non-combustible substrate c having a thickness of about 3 mm was obtained (however, the hot pressing conditions were a temperature of 200 ° C., a pressure of 20 kg / cm ² , and a time of 20 minutes). Table 1 shows the content of each component in the non-combustible substrate c. Next, three non-combustible substrates c are laminated and fixed with an epoxy-based adhesive layer interposed therebetween (the amount of the epoxy-based adhesive used was 130 g / m ^{2 in} solid content for each adhesive layer; the same applies hereinafter). Thus, a laminate C having a thickness of about 9 mm was obtained. The noncombustibility of the laminate C was measured, and the results are shown in Table 1.

Example 4 A commercially available softwood-based unbleached sulfate pulp and glass fiber were disintegrated with a pulper, and aluminum hydroxide powder and a powdered phenol resin were added thereto. One layer of paper is wound on a paperboard machine with a mesh / wind-up roll configuration.
Five layers were laminated to form a paper, and dried to obtain a non-combustible substrate d 'having a thickness of about 3.5 mm. Table 1 shows the content of each component for the non-combustible substrate d '. Then across the incombustible base material d'together with urea-based adhesive layer (amount of urea-based adhesive was 110g / m ² on a solids per adhesive layer. Hereinafter the same) 3
The sheets were laminated and subjected to a heat treatment using a high-frequency heating type hot-press machine (pressure 15 kg / cm ² , time 20 minutes, temperature was 160 ° C. of the surface of the incombustible base material immediately after the completion of the heat treatment). Thus, three layers were fixed to obtain a laminate D having a thickness of about 9 mm. The nonflammability of the laminate D was measured.
It was shown to.

Example 5 In Example 1, magnesium hydroxide powder (having an average particle diameter of 10 μm; the same applies hereinafter) was used in place of the aluminum hydroxide powder, and fibrous polyolefin was used instead of the powdery phenol resin. A non-combustible substrate e having a thickness of about 4 mm was obtained in the same manner as in Example 1 except that a resin (a commercially available polyethylene synthetic pulp; the same applies hereinafter) was used. Table 1 shows the content of each component in the noncombustible substrate e. Next, the non-combustible substrate e
These were laminated and fixed to each other with the urethane-based adhesive layer interposed therebetween in the same manner as in Example 1 to obtain a laminate E having a thickness of about 12 mm. The nonflammability of the laminate E was measured, and the results were shown in Table 1.
It was shown to.

Example 6 Example 1 was repeated, except that a liquid acrylic resin (a commercially available thermoplastic acrylic ester / vinyl acetate copolymer; the same applies hereinafter) was used in place of the powdery phenol resin. In the same manner as in Example 1, a non-combustible substrate f having a thickness of about 4 mm was obtained.
Table 1 shows the content of each component for the non-combustible substrate f.
Next, three nonflammable substrates f were laminated and sandwiched with a urethane-based adhesive layer therebetween in the same manner as in Example 1 to obtain a laminated plate F having a thickness of about 12 mm. The nonflammability of the laminate F was measured, and the results are shown in Table 1.

Comparative Example 1 The noncombustibility of the noncombustible substrate a obtained in Example 1 was measured, and the results are shown in Table 1 together with the content of each component. Comparative Example 2 Three non-combustible substrates before hot pressing obtained in Example 1 were laminated without using an adhesive, and heat-treated with a hot press (temperature 175).
C., pressure 5 kg / cm ² , time 9 minutes), and the three layers were thermocompression-bonded to obtain a laminate G having a thickness of about 12 mm. The nonflammability of the laminate G was measured, and the results are shown in Table 1. Comparative Example 3 The noncombustibility of the noncombustible substrate b obtained in Example 2 was measured, and the results are shown in Table 1 together with the content of each component.

Comparative Example 4 An incombustible substrate b 'having a thickness of 8 mm was obtained in the same manner as in Example 2 except that the amount of each component was increased. 175 ° C, pressure 5kg / cm
² , time 6 minutes). The noncombustibility of the noncombustible substrate b 'was measured, and the results are shown in Table 1 together with the content of each component. Comparative Example 5 Two incombustible substrates before hot pressing obtained in Example 2 were laminated without using an adhesive, and heat-treated with a hot press (temperature 175).
C., pressure 5 kg / cm ² , time 6 minutes) to fix the two layers to obtain a laminated board H having a thickness of about 8 mm. The nonflammability of the laminate H was measured, and the results are shown in Table 1. Comparative Example 6 The noncombustibility of the noncombustible substrate c obtained in Example 3 was measured, and the results are shown in Table 1 together with the content of each component.

Comparative Example 7 Three non-combustible substrates before hot pressing obtained in Example 3 were laminated without using an adhesive, and heat-treated with a hot press (at a temperature of 200).
C., pressure 20 kg / cm ² , time 30 minutes) and thermocompression-bonded the three layers to obtain a laminate I having a thickness of about 9 mm. The nonflammability of the laminate I was measured, and the results are shown in Table 1. Comparative Example 8 The non-combustible base material d 'obtained in Example 4 was subjected to heat treatment (temperature: 175 ° C., pressure: 5 kg / cm ² , time: 3 minutes) by a hot press to obtain a non-combustible base material d having a thickness of about 3 mm. Obtained. The noncombustibility of the noncombustible substrate d was measured, and the results are shown in Table 1 together with the content of each component. Comparative Example 9 Three non-combustible substrates d 'obtained in Example 4 were laminated without using an adhesive, and heat-treated with a hot press (temperature: 175 ° C, pressure: 5).
kg / cm ² hours and 9 minutes), and the three layers were thermocompression-bonded to obtain a laminate J having a thickness of about 9 mm. The nonflammability of the laminate J was measured, and the results are shown in Table 1.

[0033]

[Table 1]

Example 7 Two non-combustible substrates 2 obtained in Example 1 before hot pressing were laminated with an epoxy-based adhesive layer 3 interposed therebetween, and were bent by a mold before the adhesive 3 was cured. (Mold temperature: 175 ° C., pressure: 2 kg / cm ² , time: 6 minutes) to obtain a good laminated molded product 1. FIG. 1 shows the shape of the obtained laminated molded body 1 (the thickness is about 8 mm). Example 8 Example 7 was the same as Example 7 except that the non-combustible substrate 2 before hot pressing obtained in Example 3 was used instead of the non-combustible substrate 2 before hot pressing obtained in Example 1. In the same manner as described above, bending was performed using a mold (mold temperature: 200 ° C., pressure: 20 kg / cm ² , time: 30 minutes), and a good laminated molded body 1 having the same shape as that of FIG. About 6 mm). Example 9 Three nonflammable base materials 2 obtained in Example 4 were laminated with a urea-based adhesive layer 3 interposed therebetween, and were subjected to high-frequency heating molding using a wooden mold (pressure 15 kg).
/ Cm ² , time 20 minutes, the temperature was 160 ° C. on the surface of the noncombustible base material immediately after completion of the molding. ) To obtain a good laminated molded product 1. The obtained laminated molded body 1 (however,
FIG. 2 shows a shape having a thickness of about 9 mm. Next, the laminated molded body 1 is bisected in the longitudinal direction and combined with a gypsum board 4 having a thickness of 9 mm to form a curved surface cord as shown in FIG.
The knurled part could be manufactured easily and easily.

Comparative Example 10 The procedure of Example 1 was repeated, except that the powdery phenol resin was not used, and the non-combustible base material before hot pressing obtained in the same manner as in Example 1 was used. Bending was performed using a mold, but cracks occurred, and the peel strength inside the non-combustible substrate was extremely weak, and a good laminated molded body could not be obtained. Comparative Example 11 Using the non-combustible base material before hot pressing obtained in the same manner as in Example 3 except that the powdery phenol resin was not added in Example 3, bending was performed using a mold in the same manner as in Example 8. However, cracking occurred and the peel strength inside the non-combustible substrate was extremely weak, and a good laminated molded product could not be obtained. Comparative Example 12 Example 7 was repeated except that the non-combustible substrate before hot pressing obtained in Comparative Example 4 was used, and only one sheet was used without laminating two sheets without using an adhesive.
Bending was performed using a mold in the same manner as described above, but a good laminated molded body could not be obtained because the non-combustible substrate was too thick or a slight crack occurred.

Examples 1-9, Comparative Examples 1-12, Table 1
As can be seen from FIGS. 1 to 3, the water-containing inorganic compound or the total amount of the water-containing inorganic compound and the carbonate is 65 to 95% by weight.
In addition, two or more non-combustible base materials containing cellulose fiber and synthetic polymer are laminated and fixed with an adhesive layer interposed between them, so that they have high non-combustibility and have excellent moldability. It was found that a laminated plate or a laminated molded article was obtained. In particular, regarding noncombustibility, when comparing the composition of the noncombustible base material to be equal, simply increasing the basis weight to increase the thickness, or when the noncombustible base material is hot-press laminated without using an adhesive However, while the non-combustible performance is deteriorated, such as an increase in the exhaust temperature rise area or an increase in the maximum smoke generation coefficient or the after-flame time, the non-combustible base material may be fixed by laminating two or more layers with an adhesive layer interposed therebetween. Even when the organic adhesive layer is sandwiched, the area where the exhaust temperature rises or the maximum smoke generation coefficient or the after-flame time is reduced as compared with the case of the non-combustible substrate alone before lamination and fixing, and the non-combustible performance is improved. It was found that a very unique effect was obtained.

[0037]

As can be seen from the above description, the incombustible laminate or laminate of the present invention has a water-containing inorganic compound or a total of 65 to 95% by weight of a water-containing inorganic compound and a carbonate.
In addition, a non-combustible base material having a thickness of 1 to 5 mm containing cellulose fibers and a synthetic polymer is sandwiched between adhesive layers.
Since the thickness is made 4 mm or more by laminating and fixing more than one layer, it occurs when simply increasing the basis weight of the non-combustible base material or hot-pressing the non-combustible base materials without using an adhesive. Deterioration of non-combustibility such as an increase in the exhaust temperature rise area or the maximum smoke generation coefficient or the after-flame time is eliminated. The laminated plate or laminated molded article of the present invention has an extremely high non-combustible performance because the exhaust temperature rise area, the maximum smoke generation coefficient or the after-flame time is reduced as compared with the non-combustible base material before lamination and fixing.

The non-combustible base materials are sandwiched by an adhesive layer.
The effect of improving the noncombustibility by laminating and fixing the layers is sufficiently exhibited even when the noncombustible base material is composed of a water-containing inorganic compound / cellulose fiber / synthetic polymer. Carbonate / cellulose fiber /
By selecting a non-combustible substrate having a structure of a synthetic polymer, the effect can be obtained more remarkably. In addition, two or more non-combustible base materials having a thickness of 1 to 5 mm, each containing a water-containing inorganic compound or a water-containing inorganic compound and a carbonate as main components, are laminated and fixed to each other with an adhesive layer interposed therebetween to form a layer having a thickness of 4 mm or more. And a non-combustible base material containing a required amount of cellulose fiber and a synthetic polymer such as a thermosetting resin or a thermoplastic resin. The moldability is greatly improved as compared with the case where the non-combustible base material is used alone, and a non-combustible laminated molded body having various shapes such as a curved shape, an L-shape, or a three-dimensional shape can be easily obtained. . In addition, each layer of the non-combustible base material is firmly fixed compared to the case of hot-press lamination without using an adhesive, and the strength of the obtained laminated plate or laminated molded body is improved, and the shape retention accuracy after molding is also improved. improves.

In particular, in the case of responding to the demand for a thick material having a thickness of 9 mm to 15 mm or more required for building materials and the like, the configuration of the present invention makes it possible to more effectively exhibit the effect of improving the incombustibility and formability. Thus, it is possible to economically and easily obtain a laminate or a laminate having both high noncombustibility and excellent moldability.

[Brief description of the drawings]

FIG. 1 is a perspective view of an L-shaped laminated body obtained by the present invention.

FIG. 2 is a perspective view of a laminated molded product having a curved shape obtained by the present invention.

FIG. 3 is a perspective view of a laminated molded article having a curved shape obtained by the present invention used as a corner portion of a non-combustible building material.

FIGS. 4 (a) and 4 (b) are views showing a manufacturing process of a corner portion using a conventional grooved gypsum board, and FIG.
It is a perspective view which shows the use state of a part.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Laminated molded object 2 Noncombustible base material 3 Adhesive layer

Claims (7)

(57) [Claims] 1. An aqueous inorganic compound comprising 65 to 95% by weight,
In addition, two or more non-combustible base materials containing cellulose fiber and synthetic polymer and having a thickness of 1 to 5 mm are laminated and fixed to each other with an adhesive layer therebetween to form a thickness of 4 mm or more. Characteristic non-combustible laminates or laminates. 2. The total of the hydrated inorganic compound and the carbonate is 65 to 65.
95% by weight, two or more non-combustible substrates each containing cellulose fiber and synthetic polymer and having a thickness of 1 to 5 mm are laminated and fixed to each other with an adhesive layer therebetween to make the thickness 4 mm or more. A non-combustible laminate or molded laminate characterized by being formed. 3. The water-containing inorganic compound is aluminum hydroxide,
3. The non-combustible laminate or molded laminate according to claim 1, comprising at least one selected from magnesium hydroxide, calcium hydroxide, dihydrate gypsum and calcium aluminate. 4. A non-combustible laminate or laminate according to claim 1, wherein the synthetic polymer comprises at least one selected from a thermosetting resin, a thermoplastic resin and a synthetic rubber. 5. The non-combustible laminate or laminate according to claim 1, wherein the carbonate is calcium carbonate. 6. The non-combustible laminate or laminate according to claim 1, wherein the non-combustible substrate comprises a laminate of two or more sheet layers. 7. A non-combustible laminated molded article characterized in that the non-combustible laminated molded article according to claim 1 or 2 is used as a corner material between non-combustible plate materials such as gypsum board.