JP3230207B2 - Fire resistant composite board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention is useful as an inner wall material, an outer wall material, a roof base material, a fire door, a partition material, etc. of a building or a building required to have fire resistance.
The present invention relates to a fire-resistant composite plate having mechanical strength.

[0002]

2. Description of the Related Art In general, heat-resistant composite boards for outer walls are disclosed in Japanese Utility Model Laid-Open No. 57-185535, Japanese Utility Model Laid-Open No. 58-1538, Japanese Utility Model No. 63-15444, and Japanese Patent Publication No. Hei. No. 18230 is known.

[0003]

However, these composite plates have major drawbacks in the following points. That is, in the above-described composite plate, the nonwoven fabric is a thin nonwoven fabric such as glass fiber, and the phenol foam leaks to the opposite surface, that is, the surface to be bonded to the non-combustible substrate, and has a disadvantage that the function of the adhesive cannot be exhibited. Further, in the above-mentioned composite board, a lightweight aggregate is laid finely, and this is integrated with a non-combustible base material using phenol foam to improve the fire resistance, but the adhesive strength of the phenol foam itself serving as the core material is not so high. There was a drawback that the phenol foam as a core material was peeled off from the non-combustible base material because it was not strong. Further, the composite board shown above is a building board in which a non-combustible sheet impregnated with sodium borate and a phenol foam are integrally fixed, and a non-combustible air-impermeable layer is integrally fixed on the non-combustible sheet via an adhesive. However, the impregnation of the raw material of the phenol foam into the nonwoven fabric is liable to occur only on the surface, and the reaction system of the alkali and the acid impedes the foam formation, resulting in a decrease in the adhesive strength. In addition, the composite plate has a structure in which the face material and the phenol foam containing the aggregate are integrated, and since the fusion of the face material and the core material is utilized, there is an anxiety in the adhesive strength. . Furthermore, the above-mentioned composite plates have a drawback that they lack adhesive strength for integrating the phenol foam and the face material. In addition, the condensed water during the formation of the phenol foam inhibits the reaction system for forming the foam, making it difficult to form a uniform foamed structure, and has problems in heat insulation, adhesion to a substrate, and strength.

[0004]

According to the present invention, there is provided a composite plate in which a core material is formed between non-combustible base materials, wherein the core material is made of a resol type phenol foam resin chaff. The core material is formed by mixing and laminating at least one layer of lath material and integrally formed, and the non-combustible base material and the core material are integrally formed. The present invention proposes a fire-resistant composite plate fixed by self-adhesion during phenol foam formation.

[0005]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of a fire-resistant composite plate according to the present invention. That is, FIG.
(A) to (e) are cross-sectional views showing a typical example of a fire-resistant composite plate according to the present invention, where α is a fire-resistant composite plate, 1, 2 is a non-combustible substrate, 3 is a core material, and 4 is a resol type. Phenol foam, 5 is a fine powder made of rice hulls, 6 is a lath material.

More specifically, the non-combustible substrates 1 and 2 include, for example, aluminum, iron, copper, stainless steel, titanium, aluminum / zinc alloy-plated steel plate, galvalume steel plate, galfan, enamel steel plate, fluororesin coated steel plate, clad steel plate, Sandwich steel plate (vibration damping steel plate) etc., or these color coated metal plates, kraft paper, aluminum evaporated paper, aluminum foil, plastic sheet, non-woven fabric, etc.
Alternatively, it is made of at least one kind of an inorganic plate such as a gypsum board, and is formed into an arbitrary shape as shown in FIGS. 2 (a) to 2 (f) by roll forming, press forming, extrusion forming or the like. It may be something. Note that the lath member 6 is not shown in FIGS.

The core material 3 is made of a foam in which fine particles 5 composed of rice hulls are mixed in a resol type phenol foam 4 and a lath material 6 is laminated.

[0008] Resol type phenol foam (hereinafter referred to as
The phenol foam 4 is mainly manufactured by a continuous foam molding method, and has nonflammability, low smoke emission, and low toxicity compared to other synthetic resin foams (plastic foam). Things.

[0009] The fine-grained material (hereinafter simply referred to as rice husk) 5 composed of rice hulls is obtained by finely pulverizing rice husks to form fine particles (about 10 to 200 mesh). It has a function as a material, a raising material, a heat insulating material, and the like. When the phenol foam 4 is formed by being mixed with a resin as a raw material of the phenol foam 4, a reaction inhibition preventing material of the phenol foam 4 and a non-combustible base material Reinforcement material for bonding with cores 1 and 2; reinforcement material for core material 3; refractory material (formation of carbonized layer)
And the like.

More specifically, the rice hulls 5 are uniformly mixed in the phenol foam 4 in the figure as shown in a partially enlarged view in FIG. Then, by removing moisture that inhibits the formation of the foamed structure of the phenolic foam 4, and by homogenizing the foamed structure of the phenolic foam 4, the mechanical strength (enhancement of compressive strength, reduction of brittleness) of the core material 3 is improved, In addition to improving the heat insulating property, the amount of expensive phenol foam 4 used is reduced to reduce the cost.

In addition, since the rice husk 5 has a homogeneous foam structure, the adhesive strength between the non-combustible base materials 1 and 2 and the core material 3 is improved.
The mechanical strength of the refractory composite plate α is also improved.

Further, the rice hulls 5 are carbonized at the time of fire and
A carbonized layer is formed in the inside to help improve fire resistance.

The lath material 6 functions as a reinforcing material for the core material 3 and also functions to prevent the core material 3 from expanding or contracting in the event of a fire. This lath material 6
Materials include iron, zinc, iron, brass, copper, phosphor bronze,
It is made of stainless steel, monel metal, nickel, titanium, aluminum, glass fiber, boron fiber, ceramic fiber, etc. The woven type is plain weave, twill, tatami, tatami tatami, matte weave, stranded wire weave, triple weave , Crimp weave,
They are rhombic, tortoiseshell, round or the like, or formed in a honeycomb structure. Further, the lath material 6 can be disposed substantially at the center of the core material 3 as shown in the figure, can be laminated on the back surfaces of the non-combustible base materials 1 and 2, or can be laminated in plural layers. Of course, since a large number of voids are formed in the lath material 6, the phenol foam 4 passes through the lath material 6, and the phenol foams 4 and the phenol foam 4 and the non-combustible substrate 1,
The two are firmly bonded.

Next, FIG. 4 shows an example of a method for manufacturing a refractory composite plate according to the present invention. First, a non-combustible substrate 1, for example, a color steel plate (thickness 0.35 mm) is fed from a feeding step A (uncoiler, lifter, etc.) to a raw material discharging step B,
40 to 60 parts by weight of the fine particles of the rice husks 5 are mixed into 100 parts by weight of the unfoamed resol-type phenol foam stock solution, and the stock solution 3 a of the core material 3 uniformly stirred is discharged from the discharging machine C to the non-combustible base material 1. Discharge onto back surface 1a, lath material 6 is laminated on it by feeder D, and undiluted solution 3a is further discharged from discharge device C thereon, and non-combustible substrate 2, for example, color steel plate (0.27 mm thick) Are laminated through a feeding step E (uncoiler, lifter, etc.) and fed to a predetermined type of curing oven F, and are continuously or multi-stage pressurized (press) foamed to about 7 times.
After curing at 30 to 100 ° C. for about 15 minutes, foaming and curing, and then cutting to a predetermined size with a cutter G, a packing process H
Is to be sent to

A ₁ and E ₁ indicated by dotted lines are molding machines for the non-combustible base materials 1 and 2.
This is for forming into a predetermined shape as shown in FIG.

[0016]

Other Embodiments The above is only one embodiment of the fire-resistant composite plate according to the present invention, and a lightweight filler 7 can be formed as shown in FIGS. 5 (a) to 5 (g). . That is, FIG. 5A shows a refractory composite plate α in which the pearlite grains 7a having a large grain size and the pearlite grains 7b having a small grain size are densely packed as the lightweight filler 7 to increase the density, and FIG. This is a fire-resistant composite plate α in which pearlite grains 7a and expandable graphite 7c that expands and foams at high temperature are mixed as the material 7, and fire resistance is enhanced.

FIG. 5C shows the use of pearlite particles 7d coated with a superabsorbent polymer as the lightweight filler 7, and FIG. 5D shows the use of the pearlite particles 7a as the lightweight filler 7 and the hydrophilic interface. With the activator 7e interposed, both absorb and retain the condensed water generated when the raw material of the phenol foam 4 is cured, improve the fire resistance by the moisture, improve the foaming reaction, and reduce the curing time during production. It is a refractory composite plate α that can be shortened.

Further, FIG. 5 (e) shows a fire-resistant composite plate α as a lightweight filler 7 in which pearlite grains 7a and glass fibers 7f such as chopped strands are interposed to increase fire resistance and strengthen strength. f) is the non-combustible substrate 1 of the core material 3,
The refractory composite plate α is formed by densely filling pearlite grains 7a having a large grain size and pearlite grains 7b having a small grain size on the two sides. FIG. 5G shows a fire-resistant composite plate α in which a nonwoven fabric 9 such as a hydrophilic polyester fiber is formed between the non-combustible base materials 1 and 2 and the core material 3 with an adhesive 8 interposed therebetween.

Also, the rice husk 5 is mixed into the lightweight filler 7,
Further, fire resistance can be improved.

Further, although not shown, FIGS. 5 (a) to 5 (g)
As shown in FIGS. 1B to 1E, a refractory composite plate α having a lath material 6 formed thereon can also be used.

Of course, in FIGS. 5A to 5G, the lightweight aggregate 5
Is larger than the actual size in the drawing, but is actually smaller.

[0022]

As described above, according to the refractory composite plate of the present invention, a resol type phenol foam is used.
It becomes a fire-resistant composite board having non-flammability, low smoke emission, and low toxicity performance as compared with other synthetic resin foams (plastic foam). The fine powder consisting of rice hulls has a function of a water-absorbing material, a water-retaining material, a raising material, a heat insulating material, and the like.When mixed with a resin that is a raw material of a resol-type phenol foam to form a phenol foam foam, It absorbs the condensed water generated during the reaction, serves as a material for preventing foaming reaction inhibition of the phenol foam, and makes the foamed structure uniform. Has functions such as reducing the amount of raw materials used, improving heat insulation, strengthening the adhesion between the non-combustible base material and the core, and improving the strength of the core (improving the compressive strength and reducing brittleness) by making the foam structure uniform. It becomes a fire resistant composite board. The fine powder and granules composed of the rice hulls serve as a raising material, which reduces the amount of expensive resol-type phenol foam raw materials used and contributes to cost reduction. Fine particles made of rice hulls form a carbonized layer in the event of a fire, improving fire resistance. Improvement of core material strength (improvement of compressive strength,
(Reduced brittleness) and improved fire resistance, resulting in a fire-resistant composite plate that passes a fire-resistant structure test such as fire resistance for one hour. It is very light compared to other inorganic fireproof panels, and the workability is improved. There are features and effects such as.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an example of a refractory composite plate according to the present invention.

FIG. 2 is a sectional view showing an example of a fire-resistant composite plate.

FIG. 3 is an explanatory diagram showing a part of the refractory composite plate used in FIG. 1 in an enlarged manner.

FIG. 4 is an explanatory view showing an example of a process for manufacturing a refractory composite plate according to the present invention.

FIG. 5 is a sectional view showing another example of the refractory composite plate according to the present invention.

[Explanation of symbols]

 α Fireproof composite board 1 Non-combustible base material 2 Non-combustible base material 3 Core material 4 Resol type phenol foam 5 Fine powder and granular material consisting of rice hulls 6 Lath material

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-64-63137 (JP, A) JP-A-59-11339 (JP, A) JP-A-3-88848 (JP, A) 97309 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35/00 E04B 1/62-1/99 E04F 13/00-13/18

Claims (1)

(57) [Claims] 1. A composite board having a core material formed between non-combustible base materials, wherein the core material is formed by mixing and finely foaming fine particles made of rice hulls in a resol type phenol foam resin. In addition, at least one lath material is laminated and integrally formed in the core material, and the integration of the non-combustible base material and the core material is fixed by self-adhesion during phenol foam formation. Refractory composite board.