JP3659364B2 - Architectural panel - Google Patents

Description

[0001]
[Industrial application fields]
The present invention can be used as an inner wall material, an outer wall material, a roof material, a ceiling material, a floor material, a partition material, a fire door, or the like of a building or a structure, and has no deformation such as swelling and warping after production, and is also fireproof. The present invention relates to a building panel having excellent fire resistance and mechanical strength.
[0002]
[Prior art]
In general, a large number of architectural panels in which a core material made of a synthetic resin foam is sandwiched between a thin plate-like surface material and a back surface material have been invented and marketed.
[0003]
[Problems to be solved by the invention]
However, in a building panel using a synthetic resin foam as a core material as described above, it is generally inferior in fire resistance and fire resistance, and when the building panel is exposed to high temperatures in the event of a fire, etc. The core material, particularly the front surface material, and the boundary surface between the back material and the core material, are likely to become weak points of fire resistance and fire resistance.
[0004]
[Means for Solving the Problems]
In order to eliminate such drawbacks, the present invention uses a flame retardant aggregate in the core as a core, and a building panel in which phenol particles coated with a resol type phenol resin around the core are mixed, At least the back surface of the surface material is laminated with a sheet-like material through an adhesive layer, and the fine carbon pieces that form a heat insulating layer by foaming at a high temperature are mixed in the sheet-like material. The present invention proposes a building panel that foams and fills the thinned defect portion, and has improved fire resistance and fire resistance at the interface between the surface material, the back material and the core material.
[0005]
【Example】
Hereinafter, an embodiment of a building panel according to the present invention will be described in detail with reference to the drawings. That is, as shown in FIG. 1A, which is a cross-sectional view, and FIG. 1B, which is an enlarged view of the portion A in FIG. A panel A for construction in which a core 3 made of a body as a main raw material is sandwiched and formed integrally by the self-adhesive property of the core 3, and phenol particles 4 are mixed in the core 3, and at least a surface material A sheet-like material 8 is laminated between 1 and the core material 3 via an adhesive layer 7.
[0006]
The surface material 1 and the back material 2 are thin metal plates such as iron, aluminum, copper, stainless steel, titanium, aluminum / zinc alloy plated steel plate, galbarium steel plate, enamel steel plate, clad steel plate, laminated steel plate (PVC steel plate, etc.), sandwich steel plate (control) Corrugated steel sheets, etc.), vinyl chloride resin, polycarbonate resin, etc. (including color plates coated with various colors, of course) formed into various shapes by roll molding, press molding, extrusion molding, etc., or inorganic materials Formed into various arbitrary shapes by extrusion molding, press molding, autoclave ripening, etc., as well as aluminum evaporated paper, asbestos paper, craft paper, asphalt felt, metal foil (Al, Fe, Pb, Cu), synthetic Resin sheet, rubber sheet, cloth sheet, gypsum paper, aluminum hydroxide paper, glass fiber nonwoven fabric, etc. Those that have been laminated species, or two or more, or waterproofing, is made of a flame-retardant treated sheet.
[0007]
The core material 3 functions as a bulking material, a heat insulating material, a fireproofing material for the building panel A, and a binder for the phenol particles 4 to be described later. It is made of a synthetic resin foam formed by mixing a flame retardant and heating, curing and curing. Examples of the synthetic resin foam include those made of phenol foam, polyurethane foam, isocyanurate foam and the like.
[0008]
Furthermore, an arbitrary proportion of phenol particles 4 is mixed in the core material 3. The phenol particles 4 are substantially spherical as shown in FIG. 2, and the outer periphery of the core 5 serving as a flame retardant aggregate is coated with a resol type phenol resin 6.
[0009]
As the core 5, for example, one or more of pearlite grains, glass beads, gypsum slag, talc stone, shirasu balloon, aluminum hydroxide, thermally expandable graphite, etc. are used, and the core material 3 has fire resistance and fire resistance. It is to be added. In addition, it is preferable to use aluminum hydroxide powder having good compatibility with the phenol resin as the core 5.
[0010]
The resol-type phenol resin 6 formed on the outer periphery is an uncured (unreacted) resol-type phenol or a fully-cured (reaction completed) resol-type phenol solid, which is foamed or not foamed. But it can be used. The resol type phenolic resin 6 mainly adds fire resistance and fire resistance to the core material 3 in the same manner as the core 5 described above.
[0011]
The size of the phenol particle 4 is a fine particle having a diameter of about 50 to 1000 μm (preferably, any one of 50 μm, 100 μm, 300 μm, 500 μm, and 800 μm), and has the same particle size or a particle size. The phenol grains 4 having different sizes are mixed. The mixing ratio of the core material 3 is 30 to 500 parts by weight when the weight ratio of the core material 3 is 100. In addition, as content of the nucleus 5 component of the phenol grain 4, it is a thing of about 8 to 80%.
[0012]
The phenol particles 4 are close to true spheres and have few secondary agglomerates, so they have good fluidity and are useful for uniform distribution in the core material 3, and the outer periphery is coated with a resol type phenol resin 6. Therefore, it is easy to mix and blend with the synthetic resin raw material that is the raw material of the core material 3, and a large amount of the phenol particles 4 that serve as the fireproofing material is mixed without increasing the viscosity of the synthetic resin that is the main raw material of the core material 3. Therefore, it is easy to handle and can easily improve the fireproof performance and fireproof performance.
[0013]
Further, when the core material 3 is made of phenol foam, the bulk volume of the phenol particles 4 reduces the reaction of the resol type phenol resin 6 that becomes the core material 3 to some extent, reduces the generated gas, and also the dry phenol particles. 4 prevents reaction gas and water vapor from being absorbed and confined in the cell, thereby preventing the adverse effects of gas bulging and warping on the surface material 1 and the back material 2 of the building panel A. Furthermore, when polyurethane foam or isocyanurate foam is used as the core material 3, the resol type phenolic resin 6 forming the phenol particles 4 and the flame retardant aggregate as the core 5 improve the fireproof performance and fireproof performance, It becomes the panel A for construction excellent in mechanical strength.
[0014]
In addition, the sheet-like material 8 is formed by laminating and bonding at least on the back surface side of the surface material 1 of the building panel A, that is, the boundary portion with the core material 3 through the adhesive layer 7. The adhesive is applied to the back surface of the surface material 1, the sheet material layer 8 is laminated, dried and cured, and formed integrally.
[0015]
For example, as shown in FIG. 3, the sheet 8 is made of polyester, nylon, boron, carbon, alumina, silicon carbide, aramid fiber, or various synthetic resins. It consists of a sheet-like material mainly composed of refractory, or a refractory sheet-like material in which various inorganic materials are mixed, and improves the mechanical strength of the building panel A. Therefore, the bending strength and wind pressure strength of the building panel A are improved. In addition, it is possible to lengthen the mounting pitch to the housing during construction. Moreover, the unevenness | corrugation of the surface of the sheet-like object 8 produces the anchor effect, and strengthens the adhesiveness of the surface material 1, the back surface material 2, and the core material 3. FIG. Further, the sheet-like material 8 has a function of improving the flatness of the front surface material 1 and the back surface material 2.
[0016]
Further, as shown in FIG. 1, the sheet-like material 8 is a mixture of carbon micro-pieces 9 which foam at an arbitrary ratio and form a heat insulating layer at a high temperature. The carbon fine piece 9 is made of, for example, graphite, carbon black or the like, and has a shape of one or more arbitrary shapes such as a scale shape, a needle shape, a fiber shape, a cotton shape, and a granular shape. Further, the carbon micropiece 9 is foamed at a high temperature to form a heat insulating layer. That is, the carbon fine piece 9 is made of a carbon-generating raw material (foaming raw material) selected from carbohydrates and polyhydric alcohols and a coloring pigment, a film-forming resin, and the like. Carbon generating raw materials are carbonized and foamed in contact with a flame to form a heat insulating layer. The carbon-generating raw materials have an acid group and generate an inorganic acid and an ester, and the inorganic acid is made of phosphoric acid. This is produced by thermal decomposition of catalysts and fire retardants.
[0017]
Furthermore, since the carbon micro-piece 9 foams and fills the defective portion of the core material 3 burned by heat and thinned in the event of a fire, it is exceptional when used in combination with the core material 3 made of synthetic resin foam. It improves the fire resistance and fire resistance. In addition, when the carbon fine pieces 9 are scaly and flat and are arranged in parallel with the surface material 1, the carbon fine pieces 9 are particularly effective in preventing heat from diffusing in the lateral direction and reaching the inside of the core material 3. Is.
[0018]
The components of the adhesive layer 7 include elastomeric epoxy resins, isocyanates such as emulsion types such as methylene diisocyanate (abbreviated as MDI), hot melt types, and modified isocyanates such as urethane modified, burette modified isocyanate, and isocyanurate modified. One type such as isocyanate is used.
[0019]
Moreover, as an example of the overall shape of the building panel A, as shown in FIG. 4, a front surface material 1 made of a metal long thin plate, a back surface material 2 and a male connector 10 formed at one end in the width direction, It is formed from a female connecting part 11 formed at the other end and a decorative surface 12. Also, in the figure, the inorganic board 13 and the inorganic packing material 14 are interposed in the joint portion generated by the connection between the building panels A in particular to further improve the fire resistance and fire resistance, and JIS-A-1304 (building structure This is a building panel A that passes the fire resistance 1 hour test of the partial fire resistance test method).
[0020]
[Other examples]
What has been described above is one embodiment of the building panel A according to the present invention, and the building panel A as shown in FIGS. That is, FIG. 5A shows an example of a building panel A in which a sheet-like material 8 is formed on the back surface of the back material 2 via an adhesive layer 7, and FIG. FIG. 5C shows an example of a building panel A in which two or more layers are aggregated in the central portion, and FIG. 5C is an example of the building panel A in which a plurality of breathable string-like objects 15 are interposed in the core material 3.
[0021]
This breathable string-like material 15 is made of a breathable string-like member such as a kite string as shown in FIGS. 6 (a) to 6 (c), for example. This breathable string-like material 15 is obtained by producing an excess gas component (chlorine, which has caused a chemical reaction in the core material 3 due to the influence of the residual acid component of the curing agent and the foaming agent used for the core material 3 after the core material 3 is manufactured. Gas for releasing steam gas such as carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen) or condensed water at the time of reaction to the outside from the cross-sectional portion of the building panel A by the breathable string 15 It will be a distribution channel.
[0022]
For this reason, the front and back surfaces of the building panel A after manufacture are free from deformation such as swelling and warping due to internal gas, and the building panel A is excellent in strength and fire resistance. Of course, as shown in the figure, it may be formed not only on the surface material 1 side of the core material 3 but also in an intermediate portion, or on the back material 2 side, or in a plurality of rows.
[0023]
Further, the breathable string-like material 15 forms a very small gap in the core material 3, for example, fibers of cocoon, cotton, hemp, hair, etc. (plant fiber, animal fiber, synthetic resin fiber, etc.) It is the one that has been stretched by stretching it long and thin. More specifically, the minimal gap formed in the breathable string 15 is an excess gas component (chlorine, carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen) in the core material 3 or a gas such as condensed water during the reaction. The communication structure is formed up to the end portion of the building panel A so that the air can be ventilated. In addition to the linear shape shown in FIG. 6 (a), the multiple pieces shown in FIG. 6 (b), the twisted shape shown in FIG. 6 (c), the shape is formed in a rod shape, tape shape, coil shape, or the like. It is.
[0024]
More specifically, the breathable string-like material 15 is formed by being inserted together when the core material 3 is formed, and is buried by the core material 3. In addition, since the synthetic resin foam of the core material 3 does not penetrate into the breathable string-like material 15 and is formed only on the outer surface portion of the breathable string-like material 15, In the portion, a communication minimal gap is formed.
[0025]
Moreover, the enlarged view of FIG. 7 is an example in which the carbon fine pieces 9 are mixed in the adhesive layer 7 at an arbitrary ratio, and is an example of the building panel A with improved fire resistance and fire resistance.
[0026]
FIGS. 8A and 8B are explanatory views showing other examples of the sheet-like material 8, and FIG. 8A is a sheet in which a plurality of hollow holes 16 are formed in the sheet-like material 8 to form a mesh. FIG. 8B is an example of the sheet-like material 8, and FIG. 8B is an example of the sheet-like material 8 in which a plurality of raised portions 17 are applied to the sheet-like material 8. This is an example of the sheet-like material 8.
[0027]
9-12 is sectional drawing which shows the example of the whole shape of the panel A for construction, FIG.9 (a)-(c), FIG.10 (a)-(c), FIG.11 (a)-(c). ) Shows an example of metal siding using a thin metal plate as the front material 1 and aluminum vapor-deposited paper as the back material 2. 12 (a) to 12 (c) are large metal panels using thin metal plates as the surface material 1 and the back material 2, and a fire-resistant 1-hour structure according to JIS-A-1304 (fire resistance test method for building structures). It is an example of the panel A for construction which passes a test. 4 and 9 to 12, the adhesive layer 7 is omitted.
[0028]
【The invention's effect】
As described above, according to the building panel according to the present invention, the conventional defect is solved, and the flame retardant aggregate is used as a core in the core, and the phenol particles in which the periphery of the core is coated with the resol type phenol resin. Because it is a mixed building panel, (1) it functions as a bulk material for the core material, reducing the amount of reaction at the time of core material formation, reducing the generated gas, and the dry phenol particles are converted into reaction gas and water vapor. Can be absorbed and confined in the cell, and the adverse effect of gas bulging or warping on the front and back materials of the building panel can be prevented. (2) Phenol grains are close to true spheres and have few secondary aggregates, so they have good fluidity and are useful for uniform distribution in the core material, and the outer periphery is coated with a resol type phenol resin. Therefore, it blends well with the synthetic resin raw material that is the raw material of the core material, is easy to mix, and can be mixed with a large amount of phenolic particles that serve as a fireproofing material without increasing the viscosity of the resin, so it easily improves fireproofing performance and fireproofing performance And it can be set as the panel for construction excellent in mechanical strength.
[0029]
Further, since the sheet-like material is laminated at least on the back surface of the surface material via the adhesive layer, (3) the mechanical strength of the building panel is improved and the flatness of the surface material is also improved. (4) The adhesive force between the surface material and the core material is greatly improved. (5) The surface material can be protected from the acid component generated from the core material, and the durability of the surface material is improved.
[0030]
In addition, since carbon fine pieces that form a heat insulating layer by foaming at a high temperature are mixed in the sheet-like material, the fire resistance performance and fire resistance performance of the boundary surface between the surface material and the core material are improved. (7) In the unlikely event of a fire, the carbon micro-pieces foam and fill the missing part of the core material that has burnt due to heat, so when used in combination with a core material made of synthetic resin foam, it is exceptionally fire-proof. And fire resistance can be improved. There are features and effects.
[Brief description of the drawings]
FIG. 1 is an explanatory view showing a typical example of a building panel according to the present invention.
FIG. 2 is an explanatory diagram showing an example of phenol particles used in FIG. 1;
FIG. 3 is an explanatory view showing an example of a sheet-like material placed also in FIG. 1;
FIG. 4 is an explanatory diagram showing an example of the overall shape of a building panel according to the present invention.
FIG. 5 is an explanatory view showing another example of a building panel according to the present invention.
FIG. 6 is an explanatory view showing an example of a breathable string used in FIG. 5 (c).
FIG. 7 is an explanatory view showing another example of a building panel according to the present invention.
FIG. 8 is an explanatory view showing another example of a sheet-like material.
FIG. 9 is an explanatory view showing another example of a building panel according to the present invention.
FIG. 10 is an explanatory view showing another example of a building panel according to the present invention.
FIG. 11 is an explanatory view showing another example of a building panel according to the present invention.
FIG. 12 is an explanatory view showing another example of a building panel according to the present invention.
[Explanation of symbols]
A Construction Panel 1 Surface Material 2 Back Material 3 Core Material 4 Phenol Grain 5 Core 6 Resole Type Phenolic Resin 7 Adhesive Layer 8 Sheet Material 9 Carbon Fine Piece 10 Male Linkage 11 Female Linkage 12 Makeup Surface 13 Inorganic Board 14 Inorganic packing material 15 Breathable string 16 Hollow hole 17 Brushed

Claims (1)

In a building panel in which a core material composed mainly of a synthetic resin foam is sandwiched between a surface material and a back material, a sheet material is laminated at least on the back surface of the surface material via an adhesive layer, and the inside of the sheet material In addition to mixing carbon fragments that form a heat insulating layer by foaming at high temperatures, and also containing phenol particles with flame retardant aggregate in the core and core of the core covered with resol type phenol resin Architectural panel characterized by that.

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