JP3421707B2 - Composite panel - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior wall material for a building or a building,
The present invention relates to a composite panel that can be used for an outer wall material, a partition material, a fire door, and the like, can prevent deformation such as swelling and warping after manufacturing, and has excellent mechanical strength. 2. Description of the Related Art In general, a large number of composite panels having a synthetic resin foam as a core material between both surfaces have been developed and sold. [0003] However, this type of composite panel, particularly a composite panel manufactured by discharging a core material in a liquid or granular form or the like, has the following disadvantages. That is, phenol foam, polyurethane foam,
Polyisocyanurate foam has an unreacted component of the components used when forming the core material, and the excess gas component generated by the reaction causes the surface of the composite panel to swell or warp over time, which greatly enhances the image of the decorative surface Had been lowered.
In particular, for example, when a raw material for phenol foam (resole type) formed by mixing and discharging a phenol resin stock solution, an acid curing agent, and a foaming agent and reacting and foaming is used as a core material, the phenol foam contains Condensed water retains several tens of percent of its weight, and after the curing period of the product, or after the application of the composite panel, changes in external temperature, etc., cause water to vaporize and, similarly, there is no escape route. Residual material between the backing material and the core material, gas swelling between the surface material of the composite panel and the backing material and the core material, warping, lowering of mechanical strength, etc., the appearance of the composite panel with time However, there is a disadvantage that the strength of the panel is adversely affected. [0004] In order to eliminate such a drawback, the present invention embeds a string or the like in a vertical or horizontal direction or in one direction at an appropriate position of a foam as a core material, or Interposed at the boundary between the surface material, the back surface material and the core material, and as a vent hole for unnecessary gas generated in the core material over time as the hole forming material such as a string is dissolved or shrunk over time. The present invention proposes a composite panel that functions and maintains the original strength and does not impair the aesthetic appearance. An embodiment of the composite panel according to the present invention will be described below in detail with reference to the drawings. That is, FIG.
(A), (b) is a perspective view showing a typical example of a composite panel A according to the present invention, in which a core material 3 integrally interposed between a front material 1 and a back material 2 and an appropriate position of the core material 3. And the hole forming material 4 which is present in the first embodiment is integrally formed. That is, the surface material 1 and the back surface material 2 are made of a thin metal plate, for example, iron, aluminum, copper, stainless steel, titanium, aluminum / zinc alloy plated steel plate, enameled steel plate, clad steel plate, laminated steel plate (PVC steel plate, etc.), sandwich steel plate. (Vibration damping steel plate, etc.), vinyl chloride molded plate, etc. (of course, including colored metal plates coated with various colors) formed into various shapes by roll forming, press forming, extrusion forming, etc., or inorganic Material, vinyl chloride resin, etc. formed into various arbitrary shapes by extrusion molding, press molding, autoclaving, etc., or asbestos paper, kraft paper, asphalt felt, metal foil (A
l, Fe, Pb, Cu), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper, aluminum hydroxide paper, glass fiber non-woven fabric, etc., or a laminate of two or more kinds,
Further, they are made of a sheet-like material subjected to a waterproof treatment and a flame retardant treatment. The core material 3 is made of a synthetic resin foam such as polyurethane foam, polyisocyanurate foam, phenol foam, vinyl chloride foam, polyethylene foam, polystyrene foam, urea foam and the like. In particular, when a phenol foam is used, a resol-type phenol stock solution and an acid curing agent are mixed, and the surface material 1,
Alternatively, it is formed by discharging on the back side of the back material 2 and heating and reacting and foaming. In the core material 3, various types of flame-retardant materials such as lightweight aggregates (pearlite particles, glass beads, gypsum slag, talc stone, zeolites having adsorption capacity, shirasu balloons, etc., and fibrous materials (glass wool, rock wool, Carbon fiber, graphite, etc.),
At least 5 to 300 parts by weight of aluminum hydroxide or the like as a heat-absorbing material may be mixed in at least 5 to 300 parts by weight to improve fire resistance and fire resistance. More specifically, the pore-forming material 4 is a foaming agent,
Whether the cross section is circular, polygonal, or any other hollow cross section made of a material that shrinks or dissolves in a period of several days to several months depending on components such as an acid curing agent, a resin component, a flame retardant, and a reinforcing agent. It has a structure in which gas can leak from the gap between the twisted portions of the fibrous material. Specific examples include cotton, glass fiber, starch, animal fiber, and plant fiber which are formed into a linear shape, a net shape, a rod shape, a tape shape, or the like, and have a cross-sectional area of about 0.01 to 10 mm ^2. Rank. 1A shows a state immediately after manufacturing, and FIG. 1B shows a state in which the hole forming material 4 is formed as a hollow portion 14 after manufacturing. The hole forming material 4 is formed, for example, in a configuration as shown in FIGS. 2 (a) to 2 (f). That is,
(A) is a diagram in which fine holes 6 are formed or provided on the outer peripheral surface of the hollow body 5, (b) is a dense body, (c) is a linear object obtained by taking a fiber 7, (d) The figure shows that the filling 9 itself dissolves in the hollow part of the hollow body 5 at a temperature of about 60 to 100 ° C. and also dissolves the hollow body 5 or the entire body shrinks and the hollow part 14 (vent). The filling 9 is starch, about 60 to 80 ° C.
It is made of one or more of low melting point plastic, alginic acid, paraffin, low melting point rubber, styrene resin, etc., which changes to any of melting, shrinking, etc. FIG. 2 (e) shows that the hole forming material 4 is a hollow linear body, and FIG. 2 (f) shows a coil-shaped linear body, which is generated from the center during the reaction and thereafter. This is useful for guiding the generated gas out of the core material 3. In particular, in the case of the coil shape, a gap is easily formed due to the surface tension at a contact portion between the wires, and a structure in which gas easily enters a central portion thereof is provided. In addition, as the material, a coil in which stainless steel or steel is covered with resin, paraffin, or the like, a coil made of resin, or the like is used. More specifically, the hole forming material 4 is not limited to a linear arrangement, but is a sheet-like material knitted in a net shape as shown as an example in FIGS. 3 (a) to 3 (c) or (c).
As shown in the figure, this also includes the case of a lattice shape, and particularly in the case of a lattice shape, the path for discharging the gas in the core material 3 to the outside can be greatly shortened, and there is an exhaust effect. Other Embodiments Described above is one embodiment of the composite panel according to the present invention, as shown in FIGS. 4 (a) to 4 (d) and 10 (a) to 10 (e). Can also be configured. 4 (a) to 4 (d), in FIG. 4 (a), the core material 3 is integrally interposed between the surface material 1 and the back material 2, and the surface material 1, the back material 2 and the core material 3 are in contact with each other. Hole forming material 4
Panel A, (b) shows a composite panel A in which three layers of hole forming materials 4 are interposed in a core material 3, (c).
In the figure, a linear, cloth-like, net-like or lattice-like hole forming material 4 is attached to an intermediate portion of a surface material 1 with an isocyanate-based adhesive thin layer 10.
A composite panel A in which all of the constituent materials are integrated by discharging the core material 3 or the like onto the composite panel A, and FIG.
This is a composite panel A in which a hole forming material 4 formed in a layered lattice is embedded. FIGS. 5A to 5E show modified shapes of the composite panel A, and FIGS. 5A to 5C show that a hole forming material 4 is interposed between the front surface member 1 and the back surface member 2. FIG. Composite panel A,
(D) and (e) show the composite panel A in which the hole forming material 4 is formed on the back surface 1a of the surface material 1. In FIGS. 6 (a) to 6 (d),
(A) to (c) are composite panels A formed by embedding five, three, and two hole forming materials 4, and (d) are unnecessary panels generated between the back surface 1a of the surface material 1 and the core material 3. The gas is led to the outside through the hole forming material 4 to the hollow portion 8, and the gas passes through the through hole 11 through the hollow portion 8.
Is a composite panel A configured to discharge through the panel. FIG. 7 is a partially enlarged cross-sectional view thereof. Further, FIGS. 8A to 8D and FIG.
As shown in (a) to (d), a blind hole 12 having a diameter of about 1 to 5 mmφ is formed from the back surface member 2 to the vicinity of the back surface 1a of the front surface member 1 so that the front surface member 1 and the core member 3 can be formed. Can be prevented from peeling off. Of course, the formation position and the number are arbitrary. FIGS. 10A to 10E show another embodiment showing another composite panel A. FIG.
The surface of the surface is formed unevenly, and the concave portion is mainly 0.1 to 2 mm.
This is a composite panel A in which a large number of through holes 11 in the φ-position are formed at arbitrary intervals, and a hollow portion 14 is formed by bonding a sheet 13 having weather resistance and waterproofness to the surface thereof. (B) The composite panel A in which the through hole 11 is formed after the surface material 1 and the core material 3 are integrated after the surface material 1 and the core material 3 are integrated, and then the sheet 13 is integrally fixed to form the hollow portion 14, (c) to (c). e) The figure shows a composite panel A in which the hole-forming material 4 is filled at the tip of the convex portion 15, and the air-forming hollow portion 14 is formed after the hole-forming material 4 shrinks or melts. . In addition, it also includes those obtained by forming a fibrous material into a string shape and adding paraffin or wax that is melted at a temperature of 150 ° C. or lower to the fiber. In the figure, reference numeral 16 denotes an inorganic packing material, 1
Reference numeral 7 denotes an inorganic plate material, and reference numeral 18 denotes a packing material. As described above, according to the composite panel of the present invention, the gas generated by the reaction of the surface material after the filling of the core material is caused by the shrinkage and dissolution of the pore-forming material. Is formed reliably and with time, gas generated at the boundary between the surface material and the core material can be discharged from the boundary portion to the outside at a ratio of about 5 to 20 times as much as before. The above gas at the boundary,
Since it can be discharged from the core or the like to the outside, deformation of the decorative surface can be prevented, and a beautiful appearance can be maintained for a long time.
Since unnecessary gas generated between the surface material and the core material is discharged to the outside, the integration of the surface material and the core material is not destroyed, and the mechanical strength can be maintained for a long time. There are features and effects.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing one embodiment of a composite panel according to the present invention. FIG. 2 is an explanatory view showing another configuration of a hole forming material which is a main part of the composite panel according to the present invention. FIG. 3 is an explanatory view showing another embodiment of a hole forming material which is a main part of the composite panel according to the present invention. FIG. 4 is an explanatory view showing another embodiment of the composite panel according to the present invention. FIG. 5 is an explanatory view showing another embodiment of the composite panel according to the present invention. FIG. 6 is an explanatory view showing another embodiment of the composite panel according to the present invention. FIG. 7 is an explanatory view showing another embodiment of the composite panel according to the present invention. FIG. 8 is an explanatory view showing another embodiment of the composite panel according to the present invention. FIG. 9 is an explanatory view showing another embodiment of the composite panel according to the present invention. FIG. 10 is an explanatory view showing another embodiment of the composite panel according to the present invention. DESCRIPTION OF SYMBOLS A Composite panel 1 Surface material 1a Back surface 2 Back material 3 Core material 4 Pore forming material 5 Hollow body 6 Micropore 7 Fiber 8 Hollow portion 9 Filler 10 Adhesive thin layer 11 Through hole 12 Drill hole 13 Sheet 14 Hollow part 15 Convex part 16 Inorganic packing material 17 Inorganic plate material 18 Packing material

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Claims (1)

(57) [Claim 1] In a composite panel in which a core material made of a synthetic resin foam is integrally sandwiched between a front material and a back material, the composite material has a core material, a core material, a surface material, and a back material. At least one of the boundaries between the core material, or a hole-forming material such as a string-like material, tape-like material, net-like material, which shrinks or dissolves in volume by itself or is interposed. Composite panel.