JP3438835B2 - Fireproof insulation panel - Google Patents

Description

Description: BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an exterior wall material for a building or a building,
In particular, the present invention relates to a fire-resistant and heat-insulating composite panel in which resole type phenol foam is used as a core material, and peeling between a resole type phenol foam and a metal substrate is significantly reduced. [0002] Generally, according to the Building Standard Law, the size of a building,
Buildings that require a fire-resistant structure or fire-resistant structure are specified depending on the application and fire prevention area. Among them, a member that can withstand one hour of fire resistance especially in the case of an outer wall has a thickness of 100 mm.
Rock wool having a thickness of 35 mm was sprayed on the inner surface of a lightweight cellular concrete plate (hereinafter simply referred to as ALC) of 35 mm or a fire prevention structure (steel frame). [0003] However, ALC
The plate has a heavy specific gravity of 0.7 and a large plate thickness, and has disadvantages such as requiring a special sash or the like. Further, when rock wool was sprayed, there were inconveniences such as poor workability, lack of aesthetic appearance, peeling, and weakness against water. Further, as a composite panel in which these disadvantages of the outer wall material are improved, there is, for example, Japanese Patent Application Laid-Open No. 6-87183. Although this composite panel substantially solved the conventional drawbacks, the composite panel sometimes peeled off at the contact surface between the resol type phenol foam (hereinafter simply referred to as phenol foam) and the metal plate. This is because when the phenol foam raw material reacts, foams, and cures, the acid curing agent as a curing agent, methylene chloride as a foaming agent breaks the coating film of the metal plate and peels off, and the phenol foam peels off from the metal plate. Also, the condensed water during the reaction causes the foamed structure of the phenol foam to shift the optimal timing of adhesion in the reaction system, and the residual gas in the foamed structure expands due to solar radiation, and the phenol foam and the metal plate are partially peeled off. ,
In some cases, this portion protrudes over an area due to the expansion pressure. [0005] This seriously impairs the appearance of the decorative surface, and furthermore, there is a disadvantage that the repair of a middle-rise or high-rise building is extremely expensive. SUMMARY OF THE INVENTION In order to eliminate such a drawback, the present invention provides a method for improving the surface (inner surface) between a phenol foam and a metal substrate, in particular, the surface of the metal substrate which comes into contact with the phenol foam. , Net-like material, non-woven fabric, etc.
Suppression layer containing fine cellulose fiber in sheet
In addition to removing the phenol foam from the metal substrate and removing the adverse effect of the adhesion inhibitor remaining on the above boundary, the mechanical strength of the composite board is improved and the metal substrate and the phenol foam are brought into contact with each other. The present invention proposes a fire-resistant and heat-insulating composite panel which does not cause swelling (projections) of a decorative surface caused by a decrease in force and is excellent in appearance. An embodiment of a fire-resistant and heat-insulating composite panel according to the present invention will be described below in detail with reference to the drawings. 1 and 2 are a perspective view and a partially enlarged sectional view showing a fire-resistant and heat-insulating composite panel A according to the present invention, wherein 1 is a phenol foam, 2, 3 is a metal substrate, 4 is a base, 5 is an undercoat layer, 6
Is an inhibitory layer, 7 is an adhesive, 8 is an intervening sheet, 9 is a fine cellulose fiber, 10 is an overcoat layer, 11 is a fluorine coating, and 12 is an auxiliary agent. More specifically, phenol foam 1
Mainly functions as a core material, heat insulating material, bulking material, and refractory material
The density is about 50 to 300 kg / m ³ . In addition, aluminum hydroxide powder is used as a flame retardant enhancer.
An appropriate amount, such as 1
0-70% (by weight) may be added. In the phenol foam 1, the amount of the acid curing agent for controlling the reaction system is reduced, the amount of the condensed water is significantly reduced during the reaction, or the fine cellulose fiber is contained in the raw material of the phenol foam 1. It was added an appropriate amount (about 10% or less-position), Nonfu as an alternative blowing agent
Or by adding some alternative chlorofluorocarbon
It can be, fire structural testing, a phenolic foam 1 that can pass the fire structural testing. The metal substrates 2 and 3 are nonflammable, for example, aluminum plate, zinc iron plate, color steel plate, stainless steel plate, titanium, galvalume steel plate, galfan, clad steel plate, etc.
Consists of one or more, these plate members at least one surface of the phenolic foam 1, or is intended to cover the two surfaces, the sectional shape of a roll forming machine, in which can be molded by a pressing machine or the like. More specifically, when metal substrates 2 and 3 are used, as a specific example, a color steel plate, as shown in FIG. 2, a base 4 composed of a main body 2a, a zinc coating 4a, a chemical conversion coating 4b, and an undercoat layer 5, an overcoat layer 10, and a fluorine coating 11 provided if necessary. Note that FIG. 2 shows a case where the undercoat layer 5 on the surface (inside) contacting the phenol foam 1 is formed in two layers. The undercoat layer 5 (base coat) is formed in one or two layers to a thickness of about 5 to 30 μm (dry) on the surface in contact with the phenol foam 1, and has an adverse effect on the formation of the phenol foam 1, for example, the main body 2a. The undercoat layer 5 can be prevented from being destroyed or dissolved by an acid curing agent, a catalyst, or the like, thereby preventing the undercoat layer 5 from peeling off from the main body 2a, and having a good adhesion to the phenol foam 1. For example, it is composed of one kind of epoxy resin, polyester resin, phenol resin, acrylic resin and the like. The suppression layer 6 is interposed between the undercoat layer 5 and the surface layer of the phenol foam 1, and is integrally fixed to both members via an adhesive 7 provided as required.
That is, the suppression layer 6 is formed on the intervening sheet 8 made of one of a net-like material and a non-woven fabric made of a material such as cloth, paper, resin, glass fiber, carbon fiber, and rock wool fiber.
The fiber 9 is placed on one side, the whole surface, a gap, a gap, or a tissue.
The metal bases 2 and 3 and the pheno
By providing it in the middle of the tool form 1, it is useful to further strengthen the bonding between the two . More specifically, the fine cellulose fiber 9 has a length of about 10 to 50 μm and a thickness of about 0.5 to 1 μm.
At about 0 micron, the water absorbing agent, foaming agent, reinforcing agent, and lignin in the fine cellulose fiber 9 mainly function as a reaction and neutralization catalyst, helping to enhance the adhesive strength at the interface and homogenize the foamed structure. is there. To explain further, the distribution of the fine cellulose fibers 9 in the interposition sheet 8 is, for example, shown in FIG.
To (c). That is,
(A) shows the case where the fine cellulose fiber 9 is attached to the outer peripheral surface of the fiber 8a, and (b) shows the case where the fine cellulose fiber 9 is contained in the resin fiber system.
The figure shows a case where the fine cellulose fiber 9 is attached to the cloth. The auxiliary agent 12 causes at least one or more of a water-absorbing agent, a neutralizing agent, and a flame retardant to be present in the voids of the intervening sheet 8 of a net-like material, and suppresses the “badness” at the time of formation of the phenolic foam 1 at these interfaces. It is useful for. Here, for the sake of specific description, it is assumed that a fire-resistant and heat-insulating composite panel A as shown in FIG. 1 is manufactured. The metal substrates 2 and 3 are colored steel plates (the undercoat layer 5 and the overcoat layer 10 are polyester resin of about 30 microns), and the back surface of the metal substrate 2 is the undercoat layer 5 (about 10 microns), especially phenol foam 1 Is a resol type, and it is assumed that aluminum hydroxide, an acid curing agent, ammonium polyphosphate (flame retardant) and methylene chloride (blowing agent) form a total thickness of about 50 mm and a density of 150 kg / m ³ . The suppression layer 6 is made of a polyester resin fiber and formed in a net shape at 150 g / m ² .
(B) As shown in FIG.
This is a mesh in which fibers having a thickness of 0.5 mmφ and a space of 5 mm square are added. The adhesive 7 was integrated with the undercoat layer 5 via an epoxy resin. Therefore, in order to confirm the adhesive strength, JIS-
A test according to A-1613 yielded the results shown in Table 1. [Table 1] A is simply a primer coat 5 of polyester resin.
This is a sandwich panel in which a raw material of phenol foam 1 is integrated by discharging a raw material of phenol foam 1 onto a commercially available product coated with only a micron (undercoat). Further, after the fire-resistant and heat-insulating composite panel A was manufactured, it was left at room temperature for 3 days, and after repeating a test at 0 ° C.-80 ° C. for 100 hours (4 cycles), it was made to conform to JIS-A-1613. It is the result of the test according to the above.
Shows the degree of adhesion when eggplant-shaped dragon (1 kg) falls from the height of 1.5 m to the center of the decorative surface of the fire-resistant and heat-insulating composite panel A, and then the surface material is peeled off from the phenol foam 1 and visually observed. And shows the peeled area (weight of phenol foam broken). 4 (a) to 4 (j) and FIG.
(A)-(d) is sectional drawing which shows the other Example of the fireproof insulation composite panel A which concerns on this invention. In particular, and FIG. 5 (b)
(D) shows the packing material 1 on at least one of the upper and lower ends.
3. Fireproof and heat-insulating composite panel A with fireproof reinforcing material 14 interposed
It is shown. As described above, according to the fire-resistant and heat-insulating composite panel of the present invention, the adhesive strength between the metal base material and the resol-type phenol foam is greatly enhanced as shown in the above-mentioned numerical values. . Since the adhesive strength is enhanced, there is little peeling between the phenol foam and the metal base material, so that the decorative surface of the panel does not have unevenness and a beautiful appearance can be formed.
Since the expansion and contraction due to heat between the metal base material and the phenol foam is largely suppressed by the suppression layer, peeling of the phenol foam from the metal base material can be greatly reduced. Condensed water, foaming agent, acid curing agent, flame retardant, and other unreacted substances and surplus substances remaining during the reaction generated during the formation of phenol foam destroy the coating film of the metal substrate by the action of fine cellulose fibers and the suppression layer. Therefore, the adhesive strength can be maintained for a long time. The impact resistance is greatly improved by the synergistic effect of the strengthening of the adhesive strength and the suppressing layer. There are features and effects.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view showing one embodiment of a fire-resistant and heat-insulating composite panel according to the present invention. FIG. 2 is an explanatory diagram showing a part of a fire-resistant and heat-insulating composite panel extracted and enlarged. FIG. 3 is an explanatory view showing a part of fibers of an interposed sheet constituting a suppression layer, which is a main part of the present invention, by extracting and enlarging it. FIG. 4 is a perspective view showing another embodiment of the fire-resistant and heat-insulating composite panel according to the present invention. FIG. 5 is a perspective view showing another embodiment of the fire-resistant and heat-insulating composite panel according to the present invention. [Description of Signs] A Fireproof and heat-insulating composite panel 1 Resol type phenol foam 2 Metal substrate 2a Main body 3 Metal substrate 4 Base 4a Zinc coating 4b Chemical conversion coating 5 Undercoat layer 6 Suppression layer 7 Adhesive 8 Intermediate sheet 8a Fiber 9 Fine cellulose fiber 10 Overcoat layer 11 Fluorine coating film 12 Auxiliary agent 13 Packing material 14 Refractory reinforcing material

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int. Cl. ⁷ , DB name) B32B 1/00-35/00

Claims (1)

(57) [Claim 1] In a composite panel in which a resole type phenol foam 1 is integrally interposed between metal base materials 2 and 3, the surface of the base materials 2 and 3 and the resol type phenol are combined. A net-like material made of fiber on the surface that comes into contact with Form 1 , non-woven
A fine cell is provided on the interposition sheet 8 made of at least one kind of cloth or the like.
A fire-resistant and heat-insulating composite panel, wherein a suppression layer 6 containing a loin fiber 9 is integrally provided on at least one surface.