JP3076644B2 - Flame retardant insulation board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat insulating board excellent in flame retardancy.

[0002]

2. Description of the Related Art A rigid synthetic resin foam has excellent heat insulating performance and material properties, and one of its typical uses is a heat insulating board for construction. Among them, phenol foam, which can be certified as semi-flammable while utilizing the excellent properties of organic materials, has been commercialized as a building board. However, since phenol foam is an organic material, the material itself burns due to the presence of oxygen, and thus non-combustible or quasi-noncombustible materials are generally used as the surface material.

That is, a phenol foam board that has been certified as semi-flammable is made of an inorganic material such as gypsum board or calcium silicate plate or a metal material such as iron or aluminum on the surface of phenol foam, or asbestos paper as a soft surface material. Is a composite.

[0004]

However, when an inorganic material such as a gypsum board or a calcium silicate board is compounded on the surface of the above-mentioned phenol foam, the weight of the board increases, which has recently been required in the field of building construction. It is not preferable in terms of reducing the weight of building materials. In addition, when a metal material such as iron or aluminum is combined, it is necessary to treat the metal surface combined with the phenol foam with a corrosion-resistant treatment in order to deal with the metal corrosiveness peculiar to phenol foam. It will be expensive.

On the other hand, when asbestos paper is used as the soft surface material, a lightweight and inexpensive heat insulating board excellent in fire protection can be obtained, but there is a concern that asbestos may adversely affect the human body. It is difficult to use asbestos paper because the use of asbestos has been promoted. Therefore, the development of soft surface materials to replace asbestos paper has been carried out, for example,
Although there are calcium carbonate paper and aluminum hydroxide paper, when phenol foam and those noncombustible papers are combined as face materials, the pulp contained in the noncombustible paper is flammable. Acceptance is difficult due to the heat generated by the combustion.

Although a glass fiber nonwoven fabric is used as a soft surface material containing no pulp, when a phenol foam is foam-molded using the glass fiber nonwoven fabric as a surface material, the phenol resin is immersed in the surface of the surface material due to a large gap between the glass fibers. Will protrude. In such a case, if the basis weight of the glass fiber nonwoven fabric is increased, leaching of the phenolic resin can be prevented, but the folding property of the face material is deteriorated, so that the phenol foam board cannot be integrally molded by the continuous laminator. When phenol foam is combined with non-combustible paper such as calcium carbonate paper or aluminum hydroxide paper and a glass fiber non-woven fabric bonded to phenol foam, leaching of phenol resin onto the surface of the surface material can be prevented, but different types of phenol resin can be prevented. The surface material must be relatively expensive as the surface material to be bonded and laminated, and when a flammability test is performed,
The pass is difficult because of the burning of pulp in noncombustible paper.

[0007] The present invention uses a soft facing material as a lightweight and excellent flame-retardant heat-insulating material which does not cause phenol resin to seep into the surface material and does not adversely affect the human body. It is an object to provide a relatively inexpensive flame-retardant insulation board to be used.

[0008]

SUMMARY OF THE INVENTION The present invention relates to a heat insulating board comprising a phenol foam as a core material and a soft face material integrally molded on one or both sides thereof, wherein the glass fiber is made of 50%.
-80% by weight, 10-30% by weight of aluminum hydroxide, and 10-30% by weight of polymer latex (however, calcium silicate is not included). It is a flame-retardant heat-insulating board characterized by being made. The soft face material used in the present invention is composed of 50 to 80% by weight of glass fiber, 10 to 30% by weight of aluminum hydroxide, and 10 to 30% by weight of polymer latex (excluding calcium silicate). It is a non-woven fabric. That is, in order to improve the flame retardancy of the soft face material, it is necessary that the compounding ratio of the glass fiber is 50% by weight or more. On the other hand, the phenol foam board obtained by the continuous laminator has sufficient mechanical strength. It is necessary that the content be 80% by weight or less in order to maintain the folding resistance which can facilitate the integral molding.

The polymer latex is blended for the purpose of uniformly dispersing the glass fiber and the aluminum hydroxide and providing a sealing property for preventing the phenol resin from seeping into the surface of the surface material. Rubber latex, acrylic latex and the like are used. In order to make the dispersion of the glass fiber and the aluminum hydroxide uniform and to make the surface material satisfactory, the amount of the polymer latex needs to be 10% by weight or more. In order to maintain this, it is necessary that the blending ratio be 30% by weight or less.

Aluminum hydroxide is blended for the purpose of imparting flame retardancy. To maintain sufficient flame retardancy, the blending ratio is required to be 10% by weight or more. On the other hand, in order to maintain the viscosity of the slurry made of glass fiber, polymer latex, and aluminum hydroxide so that the slurry can be formed into a nonwoven fabric by a paper machine, the mixing ratio must be 30% by weight or less.

The slurry containing the above-mentioned glass fiber, polymer latex and aluminum hydroxide is supplied to a wet paper machine and paper-made by a conventional method to obtain a soft face material which is a nonwoven fabric. The basis weight of the soft face material used in the present invention is to obtain sufficient mechanical strength as a face material, and also, when integrally forming a phenol foam board by a continuous laminator, because the face material can be molded without breaking. Has a basis weight of 50 g / m
^It is preferably ² or more. On the other hand, in order to obtain good folding properties of the face material, the basis weight is preferably 200 g / m ² or less.

The phenol foam referred to in the present invention is a resol type phenol foam. The flame-retardant heat-insulating board of the present invention comprises a foaming agent such as a silicone-based surfactant in a resole-type phenol resin, a hydrocarbon-based foaming agent containing chlorine such as 1,1,3 freon, phenolsulfonic acid, and toluene. A sulfonic acid-based curing agent such as sulfonic acid and other additives are added and mixed as needed to form a creamy reaction mixture, which is then supplied to a continuous laminator together with the above-mentioned face material, or formed together with the above-described face material. By heating and foaming and hardening in the frame, it is possible to obtain a flame-retardant heat-insulating board in which a soft surface material is integrally molded on the surface with the self-adhesive force of phenol foam.

[0013]

The present invention will be described more specifically below with reference to examples.

[0014]

Example 1 Glass fiber (average diameter 9 μm, average length 10
mm) 65% by weight, acrylic latex (solid content conversion)
A slurry consisting of 15% by weight and 20% by weight of aluminum hydroxide was supplied to a wet paper machine to make paper, and the basis weight was 75 g / m2.
² was obtained. This non-woven fabric is 35cm in length and width
Cut into stainless steel molds (internal method, 35c each in vertical and horizontal directions)
m), the mold is preheated to 70 ° C. in advance, and 100 parts by weight of resole type phenol resin is
1 part by weight of a silicone-based surfactant as a foaming agent, 15 parts by weight of 1,1,3 freon as a foaming agent, and 15 parts by weight of phenolsulfonic acid as a curing agent were added, and the mixture was stirred at a high speed for 30 seconds to obtain a cream. The mixed solution was poured onto the mixture, fixed with a stainless steel upper lid covered with the nonwoven fabric as the other surface material via a spacer so as to have a predetermined thickness, and hot-pressed at 80 ° C. (high-temperature high-pressure The mixture was heated and foamed and hardened for 10 minutes with a molding apparatus), and after curing, the mold was released from the mold frame to obtain a flame-retardant heat-insulating board in which soft surface materials were integrated on both surfaces.

Table 2 shows the results of conducting an evaluation test on the fireproof performance of the obtained heat-insulating board in accordance with Japanese Industrial Standards, JIS A 1321 for the second-class flame retardant. It passed when judged by the acceptance criteria shown in Table 1.
It can be seen that the flame-retardant heat board obtained according to the present invention has the second-class flame retardancy.

[0016]

Comparative Example 1 A heat insulating board having soft surface materials integrated on both surfaces was obtained in the same manner as in Example except that a commercially available glass fiber nonwoven fabric having a basis weight of 100 g / m ² was used. However, this board had no value as an industrial product because the phenolic resin leached from the surface of the face material.

[0017]

[Table 1]

[0018]

[Table 2]

[0019]

The flame retardant heat insulating board of the present invention has the following effects. Since it is lightweight and does not use an inorganic hard surface material such as a gypsum board or a calcium silicate plate, it is easy to handle the heat insulating board during transportation and construction. Since the soft surface material containing no asbestos is used, there is no adverse effect on the human body during and after construction of the heat insulating board. Since the phenol resin can be prevented from seeping out to the surface of the surface material without laminating different types of surface materials, the resulting heat insulating board is relatively inexpensive. Since it has the second-class level of flame-retardant performance, it is not necessary to further perform a fire-resistant treatment on the surface of the heat insulating board.

Claims (1)

(57) [Claims] 1. A heat insulation board comprising a phenol foam core material and a soft surface material integrally molded on one or both surfaces.
A is 50 to 80 wt% glass fiber, aluminum hydroxide 10 to 30 wt%, the polymer latex 10
~ 30% by weight ( excluding calcium silicate)
I) The nonwoven fabric-like soft surface material is the adhesive force of the phenol foam.
Flame retardant insulation board, characterized in that it is integrally molded by.