JP4825489B2 - Laminated panel and wall structure using the laminated panel - Google Patents

Description

  The present invention relates to a laminated panel, and more particularly to a laminated panel having excellent heat insulation performance and sound insulation performance.

  A gypsum board and a foamed synthetic resin board may be used in combination as an inner wall material of a building. The gypsum board is suitable as an interior base material for attaching wallpaper or painting. On the other hand, the foamed synthetic resin board is excellent in heat insulation performance. Therefore, a wall structure is implemented in which a foamed synthetic resin board and a gypsum board are sequentially attached to a concrete frame wall on a wall surface of a building, and the surface of the gypsum board is finished with wallpaper or the like.

  In order to improve the construction workability of such a wall structure, gypsum board and foamed synthetic resin board are pasted together using adhesive etc. at the manufacturing stage in the factory, and this laminated panel is built at the construction site It is proposed to carry it in and install it (for example, Patent Document 1).

  This technology saves labor on site construction and can be bonded together under strict quality control in the factory, improving the unity between the gypsum board and the foamed synthetic resin board. Further, the heat insulation performance is further improved, and the problem of dew condensation occurring between the gypsum board and the foamed synthetic resin board can be solved.

JP-A-8-232368

However, the laminated panel composed of the gypsum board and the foamed synthetic resin board as described above has a medium and high frequency range (250 to 8000 Hz) which is annoying to human ears when the laminated panel is attached to the housing wall via an adhesive or the like. In this case, the sound insulation defect was caused and the sound insulation performance was not always sufficient.
This is thought to be due to the fact that the natural vibration of the laminated panel is in the mid-high range, causing a resonance phenomenon with the incident sound in the mid-high range and causing a sound insulation defect.

  The present invention has been made in view of the circumstances of the background art described above, and an object of the present invention is to provide a laminated panel that is excellent not only in heat insulation performance but also in sound insulation performance.

As a result of repeated testing and research to achieve the above object, the present inventors used a styrenic resin foam in which the ratio of bending elastic modulus and bending strength, which is a bending physical property value, is within a predetermined range. Surprisingly, it was found that the laminated panel hardly causes a resonance phenomenon with respect to the incident sound in the middle and high range, and exhibits excellent sound insulation performance, and the present invention has been completed.
That is, the present invention comprises an in-mold molded body of styrene resin foam beads, the density is 18 to 35 kg / m ³ , the thickness is 20 to 150 mm, the bending strength is 25 N / cm ² or more, the bending elastic modulus and bending strength. A styrene-based resin foam having a thickness ratio of 38 to 52 was laminated and adhered to a face material made of gypsum board .

Moreover, this invention made it the wall structure which attached the said laminated panel to the concrete frame wall of the building.

  According to the above-described laminated panel according to the present invention, the laminated panel is excellent not only in heat insulation performance but also in sound insulation performance.

  Hereinafter, embodiments of the above-described laminated panel according to the present invention will be described in detail.

The present invention has the greatest feature in a laminated panel obtained by laminating and bonding a styrene resin foam having a ratio of bending elastic modulus and bending strength of 38 to 52 to a face material made of gypsum board , The laminated panel is excellent not only in heat insulation performance but also in sound insulation performance.

  Here, the bending elastic modulus is a physical property value indicating the rigidity of the material, and the bending strength is a physical property value indicating the material strength in consideration of the rigidity and flexibility of the material. Therefore, the ratio of the flexural modulus to the bending strength is considered to indicate the balance between the rigidity and flexibility of the material. The smaller this ratio, the higher the flexibility and the balance between the rigidity and the flexibility. It can be said that it is a high material. The rigidity of the resin foam is attributed to the rigidity of the closed cells themselves constituting the resin foam, and the flexibility is considered to be due to the fusibility between the expanded particles. It is considered that a material in which one of rigidity and flexibility is dominant is likely to cause a resonance phenomenon with respect to an incident sound in a mid-high range. The present inventor believes that the styrene resin foam having a bending elastic modulus to bending strength ratio of 38 to 52 hardly causes a resonance phenomenon with respect to an incident sound in a mid-high range and exhibits excellent sound insulation performance. I found. From such a viewpoint, the ratio between the flexural modulus and the flexural strength is preferably 39 to 51, and more preferably 40 to 50.

At this time, the bending strength of the styrene-based resin foam, and 25 N / cm ² or more. This is because when the bending strength is less than 25 N / cm ² , the fusion is poor and the natural vibration of the foam cannot be constrained, and the ratio of bending elastic modulus to bending strength is 38 to 52, for example. Even if it is a thing, since sound insulation performance is somewhat inferior, it is not preferable. From this viewpoint, the bending strength of the styrenic resin foam, more preferably 26N / cm ² or more, and particularly preferably 27N / cm ² or more. Further, if the bending strength of the styrene resin foam is too large, it may be difficult to make the ratio of bending elastic modulus and bending strength to be 38 or more. Therefore, the bending strength of the styrene-based resin foam is preferably at 65N / cm ² or less, more preferably 60N / cm ² or less.
The flexural modulus is the apparent flexural modulus as defined in JIS K 7221-2: 1999, and the flexural strength is the flexural strength (maximum load) as defined in JIS K 7221-2: 1999. Means. The bending elastic modulus and the bending strength employ the test apparatus B described in JIS K 7221-2: 1999, the size of the test piece is 300 × 75 × 25 mm, the fulcrum is 200 mm, and the test speed is 10 mm. Measured as / min.

Both the bending strength and the flexural modulus of the styrene resin foam show larger values as the density of the foam is higher and the closed cell ratio is higher. In particular, it is preferable to employ a bead method for heat foam molding, which will be described later, because the ratio of the flexural modulus and the flexural strength can be easily adjusted by adjusting the density of the foam and the fusion property between the foam particles during molding. . The styrene resin foam plate used in the panel of the present invention having a flexural modulus / bending strength ratio of 38 to 52 employs a bead method, and the density of the obtained foam is 18 to 35 kg / m ^3. It can be easily obtained by increasing the degree of fusion between the expanded particles. In order to increase the degree of fusion between the expanded particles, the pre-expanded particles are sufficiently preheated at the time of molding, and then the molding steam pressure for fusion is 0.5 to 0.7 kg / cm ² (G), It is preferable to hold this pressure for 10 to 20 seconds.

In addition to the gypsum board and plywood, the face material used in the present invention includes those conventionally used as interior boards such as calcium silicate boards, cement boards, and synthetic resin boards. However, among them, gypsum board is used in the present invention because gypsum board is inexpensive, has high strength, is resistant to fire, and is difficult to crack during curing during production.
The plate thickness of the face material is usually set in a range of 5 to 15 mm, although it varies depending on the material used, purpose of use, construction conditions, and the like.

Moreover, the styrenic resin foams used in the present invention, density of 18~35kg / ^{m 3.} Moreover, it is preferable that a closed cell rate is 80% or more. If the density is less than 18 kg / m ³ , the strength may be lowered, and the natural vibration cannot be restrained, and the sound insulation performance may be lowered. If the density exceeds ³ 5 kg / ^m 3 Conversely, there is a possibility that the heat insulating performance is lowered. Moreover, when the closed cell ratio is less than 80%, the heat insulation performance may be reduced. For the same reason, the density is more preferably from 19~34kg / ^{m 3,} particularly preferably 22~33kg / ^{m 3.} The closed cell ratio is more preferably 85% or more, and particularly preferably 90% or more.
In addition, the density of a foam means the density shown by 5.6 term of JIS A 9511: 2005. In addition, the closed cell ratio is obtained by cutting a test body of about 30 × 30 × 20 mm from a styrene resin foam and obtaining the test body volume obtained by an air comparison type hydrometer (air comparison type hydrometer 1000 model manufactured by Tokyo Science). V1 (cm ³ ), the specimen volume determined by the water displacement method is V2 (cm ³ ), and the weight W (g) of the specimen and the density d (g / cm ³ ) of the synthetic resin are measured, It is a value calculated by the following formula.
Closed cell ratio (%) = (V1−W / d) ÷ (V2−W / d) × 100

Moreover, it is preferable that the average cell diameter of a styrene resin foam is 20-1000 micrometers. This is because if the thickness is less than 20 μm, the bubble film becomes thin, so that it is easily broken, and the closed cell ratio is lowered, which may lower the heat insulation performance and the sound insulation performance. On the other hand, if it exceeds 1000 μm, the heat insulation performance of the resulting styrene resin foam may be lowered.
Here, the average cell diameter is a diameter per cell (part divided between the walls of the resin), and the styrenic resin foam is cleanly cut with a blade at an arbitrary position. Targeting 20 randomly selected bubbles (cells) on the cut surface, the length of the longest straight line (inner dimensions) connecting the bubble wall and the different bubble wall is determined for each bubble. Let the diameter be the number average value of the diameters of the 20 bubbles. The average cell diameter is preferably 45 to 250 μm. This average cell diameter can be adjusted by changing the amount of the cell nucleating agent such as talc or polyethylene wax or the type and composition of the foaming agent.

Further, the thickness of the styrene-based resin foam is 20 to 150 mm, preferably 20～130Mm, more preferably 20 to 100 mm, 20 to 80 mm is particularly preferred. When the thickness of the styrene resin foam is too thin, the heat insulation performance and the sound insulation performance become insufficient, and the mechanical strength also becomes weak. On the other hand, when the thickness is too thick, the laminated panel to be formed becomes thick, and the wall structure constructed using the laminated panel becomes too thick, which is not preferable.

  Examples of the styrenic resin constituting the styrenic resin foam used in the present invention include polystyrene, rubber-modified polystyrene, ABS resin, AS resin, and AES resin. The above styrenic resins may be used alone or in combination of two or more.

There are no particular restrictions on the type of styrene monomer that is the main raw material for producing the styrene resin, but examples include styrene, α-methylstyrene, o-methylstyrene, m-methylstyrene, and p-methylstyrene. , Vinyltoluene, p-ethylstyrene, 2,4-dimethylstyrene, p-methoxystyrene, p-phenylstyrene, o-chlorostyrene, m-chlorostyrene, p-chlorostyrene, 2,4-dichlorostyrene, p- Examples thereof include n-butyl styrene, pt-butyl styrene, pn-hexyl styrene, p-octyl styrene, styrene sulfonic acid, sodium styrene sulfonate, and the like. In addition, as a monomer component (secondary material) copolymerizable with a styrene monomer, for example, the number of carbon atoms of acrylic acid such as methyl acrylate, ethyl acrylate, propyl acrylate, butyl acrylate, and 2-ethylhexyl acrylate 1-10 alkyl esters, etc .; methyl methacrylate, ethyl methacrylate, propyl methacrylate, butyl methacrylate, alkyl esters having 1-10 carbon atoms of methacrylic acid, such as methacrylic acid-2-ethylhexyl, etc .; acrylonitrile, methacrylate Resins obtained by copolymerizing monomers such as nitrile group-containing unsaturated compounds such as nitrile alone or in combination of two or more with styrenic monomers can be used.
A monomer component (other than the styrene monomer) copolymerizable with the styrene monomer is referred to as a non-styrene monomer.
However, when these non-styrene monomers as auxiliary materials are used in addition to the styrene monomer as the main raw material, the weight of the styrene monomer with respect to the total weight of all monomers when polymerizing the styrene resin. Is preferably 50% or more, more preferably 70% or more, and still more preferably 90% or more.

The styrene-based resin foam used in the present invention, Ru is prepared by the following bead method.
As a specific example of the bead method, first, styrene resin particles are dispersed in an aqueous medium in a sealed container, and aliphatic such as propane, normal butane, isopentane, normal pentane, isopentane, neopentane, hexane, etc. in the sealed container. After injecting a foaming agent such as hydrocarbon, cyclobutane, cyclopentane or the like, impregnating the styrene resin particles with the foaming agent, and taking out the styrene resin particles containing the foaming agent from the sealed container, A method may be mentioned in which styrene resin particles containing a foaming agent are heated with steam or the like, pre-foamed at a predetermined foaming ratio, filled in a mold, and again heated and foamed with steam or the like.
At this time, in particular, the heat-foaming molding in the above-mentioned mold is sufficiently performed, the fusion state between the beads is made favorable, the bending strength is 25 N / cm ² or more, and the ratio of the bending elastic modulus to the bending strength is A styrene resin foam of 38 to 52 is obtained.
According to this method, it is possible to produce a styrene-based resin foam that is excellent in heat insulation performance and sound insulation performance and also excellent in dimensional stability.

The laminated panel according to the present invention is obtained by integrally bonding a face material which is the above-described gypsum board and a styrene resin foam having a predetermined bending elastic modulus to bending strength ratio described above with an adhesive. is there.
As the adhesive, synthetic resin emulsion adhesives, synthetic rubber emulsion adhesives, reactive resin adhesives, mortar adhesives, resin mortar adhesives, etc. can be used, preferably over the entire adhesive surface. Apply and integrate the face material and styrene resin foam without gaps. Further, in order to save the adhesive, the face material and the styrene resin foam can be partially integrated by applying to the adhesive surface in a square shape or a square shape.

The wall structure according to the present invention is configured by attaching the above-described laminated panel according to the present invention to a concrete frame wall of a building.
The method of attachment is to fix the laminated panel according to the present invention directly to the concrete frame wall of the building with a tapping screw or the like, and use an adhesive such as mortar dumpling or adhesive resin dumpling on the building wall of the building. A method of sticking the laminated panel according to the invention, and a method of fixing the laminated panel according to the present invention to the guide rail by providing guide rails on the concrete frame wall of the building with screws or the like at regular intervals. Can be mentioned.

  Among the above-described attachment methods, the method of attaching the laminated panel according to the present invention to the housing wall via an adhesive is preferable because it is excellent in workability, reliability, construction cost, and the like. As the adhesive, conventionally known ones such as organic adhesives, cement mortar, resin mortar, etc. can be used, and mortar dumpling can be preferably used from the viewpoint of workability for the concrete wall with large unevenness. .

An example of a preferred embodiment of a laminated panel according to the present invention and a wall structure using the laminated panel is shown in FIG.
In the wall structure shown in FIG. 1, the laminated panel 3 according to the present invention is attached by bonding to the housing wall 1 using an adhesive 2. The laminated panel 3 according to the present invention has a configuration in which a styrene resin foam plate 4 and a face material 5 are integrally attached by an adhesive 6, and the styrene resin foam plate 4 side of the laminate panel 3 is a housing wall. 1 and a surface finishing material 8 such as wallpaper is provided on the surface of the face material 5 via an adhesive material 7.

Below, the Example and comparative example regarding this invention are described.
-Production of styrene resin foam-

Example 1
Using foam polystyrene resin particles made by JSP Co., Ltd., trade name “Styrodia JFN200”, this is 0.2 kg / cm ² (G) with a steam foaming machine (DYH1000 manufactured by Daisen Kogyo Co., Ltd.) for expandable polystyrene. The pre-foamed resin particles having a bulk density of 19 kg / m ³ were obtained by steam heating at a steam pressure of 1 kg / m ³ . The bulk density of the pre-expanded resin particles obtained is controlled by adjusting the filling amount of expandable polystyrene resin particles into the foaming machine so as to fill the space in the foaming machine when the bulk density becomes 19 kg / m ^3. It was done. After this pre-expanded resin particle was aged at room temperature for 24 hours, it was filled in a mold of a molding machine for expanded polystyrene (VS-500 type molding machine manufactured by Daisen Kogyo Co., Ltd.), and then 0 kg / cm ² (G). Of steam from one chamber (drain valve closed) through the mold to the other chamber (drain valve open) for 10 seconds, and then 0 kg / cm ² (G) steam is supplied to the other chamber (drain valve closed). From the inside of the mold, it flows into one chamber (drain valve open) for 10 seconds, thereby preheating the pre-foamed particles and exhausting the air between the pre-foamed particles, and subsequently to both chambers (drain valve open). steam pressure led steam maintains the pressure for 15 seconds upon reaching a 0.6kg / cm ² (G) and foam molding the pre-expanded particles, then cooled, 300 × 200 × 5 to obtain a styrene resin foamed plate mm plate-like density 19 kg / m ^3.
The steam pressure at the time of foam molding was measured in a drain pipe arranged at the lower part of the molding machine. Further, the above-mentioned Styrodia JFN200 contains 3.5% by weight of butane and 1.5% by weight of pentane as a foaming agent in the expandable polystyrene resin particles.

(Example 2)
Pre-foaming having a bulk density of 23 kg / m ^{3 in} the same manner as in Example 1 except that the filling amount of expandable polystyrene resin particles (trade name “Styrodia JFN200”) in the pre-foaming machine is larger than that in Example 1. Resin particles were obtained. The obtained pre-expanded particles were aged in the same manner as in Example 1 and then molded and cooled to obtain a styrene-based resin foam plate having a plate shape of 300 × 200 × 50 mm and a density of 23 kg / m ³ . .

(Example 3)
A preliminary having a bulk density of 32 kg / m ^{3 in} the same manner as in Example 1 except that the amount of expandable polystyrene resin particles (trade name “Styrodia JFN200”) in the preliminary foaming machine was further increased than in Example 2. Expanded resin particles were obtained. The obtained pre-expanded particles were aged in the same manner as in Example 1, and then molded and cooled to obtain a styrene resin foam plate having a plate density of 300 × 200 × 50 mm and a density of 32 kg / m ³ . .

(Comparative Example 1)
A 300 × 200 × 25 mm-size plate having no epidermis during production was cut out from an extruded polystyrene foam plate (trade name “Mirafoam MKS”, density 39 kg / m ³ ) manufactured by JSP Co., Ltd. .

(Comparative Example 2)
A preliminary having a bulk density of 28 kg / m ^{3 in} the same manner as in Example 1 except that the filling amount of expandable polystyrene resin particles (trade name “Styrodia JFN200”) into the preliminary foaming machine is slightly larger than that in Example 2. Expanded resin particles were obtained. After aging the obtained pre-expanded particles in the same manner as in Example 1, when the steam pressure during molding reached 0.6 kg / cm ² (G), this pressure was maintained for 1 second to prepare the pre-expanded particles. Except for foam molding, it was molded and cooled in the same manner as in Example 1 to obtain a 300 × 200 × 50 mm plate-like density 28 kg / m ³ styrene resin foam plate.

(Comparative Example 3)
Pre-foaming having a bulk density of 14 kg / m ^{3 in} the same manner as in Example 1 except that the filling amount of expandable polystyrene resin particles (trade name “Styrodia JFN200”) into the pre-foaming machine is less than that in Example 1. Resin particles were obtained. The obtained pre-expanded particles were aged in the same manner as in Example 1, and then molded and cooled to obtain a styrene-based resin foam plate having a plate-like density of 14 kg / m ³ of 300 × 200 × 50 mm. .

(Comparative Example 4)
A preliminary having a bulk density of 16 kg / m ^{3 in} the same manner as in Example 1 except that the filling amount of expandable polystyrene resin particles (trade name “Styrodia JFN200”) into the preliminary foaming machine is slightly larger than that in Comparative Example 3. Expanded resin particles were obtained. After aging the obtained pre-expanded particles in the same manner as in Example 1, when the steam pressure during molding reached 0.6 kg / cm ² (G), this pressure was maintained for 1 second to prepare the pre-expanded particles. Except for foam molding, it was molded and cooled in the same manner as in Example 1 to obtain a 300 × 200 × 50 mm plate-like density 16 kg / m ³ styrene resin foam plate.

For Comparative Example 1, the foam plate taken out of the mold for Examples 1 to 3 and Comparative Examples 2 to 4 was used for the 300 × 200 × 25 mm size plate that did not have a manufacturing skin on the entire surface. After curing at 60 ° C. for 7 days, the thermal conductivity was measured on a foamed plate (300 × 200 × 25 mm size) having no skin at the time of manufacture on the upper and lower surfaces sliced to a thickness of 25 mm. In addition, the bending elastic modulus and bending strength were measured for each test piece cut to a size of 300 × 75 × 25 mm without the production skin on the upper and lower surfaces, and the ratio of each bending elastic modulus and bending strength was determined. Calculated. The measurement results and calculation results are shown in Table 1.
The thermal conductivity is measured according to the description in Section 4.7 of JIS A 9511: 1995. The plate heat flow meter method described in JIS A 1412: 1994 (two heat flow meters, high temperature side 35 ° C., low temperature side 5 ° C., average Temperature).

-Manufacture of laminated panels-
A gypsum board (Yoshino Gypsum Co., Ltd. product name) cut into 300 × 200 mm size on one side of each 25 mm thick styrene resin foam plate (300 × 200 × 25 mm size) of Examples 1 to 3 and Comparative Examples 1 to 4 “Tiger board” (thickness: 9.5 mm) was adhered to the entire surface with an adhesive (Vinyl acetate wood adhesive 605 manufactured by Cemedine Co., Ltd.) to obtain a 300 × 200 × 35 mm laminated panel.

-Performance test-
In a reinforced concrete building, each laminated panel is adhered to one side of a partition wall (reinforced concrete thickness: 180 mm) with an adhesive (modified silicone resin KMP10S manufactured by Konishi Co., Ltd.) and the laminated panel is attached. Noise (white noise) is generated from a non-existing room, and the surface vibration of the laminated panel is picked up sensor (vibration measuring device: SA-28 1 / N octave band real-time analyzer made by Lion Co., Ltd. acceleration sensor: PV-85 pickup sensor made by Lion Co.) Acceleration measurement was performed in a frequency range of 25 to 10,000 Hz. The acceleration measurement conditions at this time were 1/3 octave analysis, acoustic characteristics: flat characteristics, linear average, and average calculation time of 10 seconds. The charts of these acceleration measurement results are shown in FIGS. 2 to 8, respectively.
The acceleration has a correlation with the vibration and the magnitude of sound radiated therefrom.
Table 1 shows the maximum acceleration of each obtained laminated panel. The density of each styrene resin foam [JIS A 9511 (2005)] is also shown in Table 1.

  From Table 1 above, the laminated panels of Examples 1 to 3 in which the ratio of the flexural modulus to the flexural strength is in the range of 38 to 52 and the styrene resin foam plate bonded to the face material are the flexural modulus and flexural strength. Compared with the laminated panels of Comparative Examples 1 to 4 in which a styrene-based resin foam plate having a ratio of less than 38 or more than 52 is bonded to the face material, the maximum acceleration is as low as about half, and it is understood that the sound insulation performance is excellent. .

It is sectional drawing which showed an example of the preferable aspect of the laminated structure which concerns on this invention, and the wall structure using this laminated panel. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of Example 1. FIG. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of Example 2. FIG. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of Example 3. FIG. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of the comparative example 1. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of the comparative example 2. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of the comparative example 3. It is the figure which showed the chart of the acceleration measurement measured using the laminated panel of the comparative example 4.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Housing wall 2 Adhesive 3 Laminated panel 4 Styrenic resin foam 5 Face material 6 Adhesive 7 Adhesive 8 Surface finish material

Claims (4)

It consists of an in-mold molded product of styrene resin foam beads, density is 18 to 35 kg / m ³ , thickness is 20 to 150 mm, bending strength is 25 N / cm ² or more, and the ratio of bending elastic modulus to bending strength is 38 to A laminated panel, wherein 52 styrene resin foam is laminated and adhered to a face material made of gypsum board . The laminate panel according to claim 1, wherein the ratio of the flexural modulus and the flexural strength of the styrenic resin foam is 40 to 50 . The laminated panel according to claim 1 or 2, wherein the bending strength of the styrenic resin foam is 65 N / cm ² or less . A wall structure, wherein the laminated panel according to any one of claims 1 to 3 is attached to a concrete frame wall of a building.

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