JP6407630B2 - Method for manufacturing non-combustible laminated board - Google Patents

Description

The present invention relates to incombustible production how the laminated board.

  In order to make a building have a certain fireproof structure, “non-combustible material” defined in the Building Standard Law is used as a building material. When used as interior materials such as inner wall materials and ceiling materials, incombustible materials may be required to have design properties. Examples of such incombustible materials include non-combustible base materials such as gypsum board and calcium silicate board. A non-combustible laminated board is known in which a thin single plate obtained by slicing a natural wood very thinly (sometimes referred to as a “projection plate”) is laminated on the surface (see, for example, Patent Document 1). A thin veneer forms a decorative layer in which the grain of natural wood appears. In addition, this decorative layer is flammable, but because it is very thin, it is burned out in a very short time by a flame. Therefore, the nonflammability which a base material has is exhibited without being impaired.

  However, when natural wood is sliced thinly, a large number of thin veneers having substantially the same grain are formed. Therefore, if a building is constructed by arranging building materials with these thin veneers as a decorative layer, the same pattern will be repeated, giving an artificial impression while using natural wood, and monotonous and not interesting. There was a tendency to give.

Japanese Patent Publication No. 7-76485

The present invention has been made in view of the above circumstances, to provide a manufacturing how more design property noncombustible laminated board elevated, it is an issue.

  In order to solve the above-mentioned problems, a method for producing a non-combustible laminated board according to the present invention is described as follows: “A plant that is formed by coating a small piece of grass wood with an adhesive and press-molding, and not impregnated with a flame retardant. By sticking a piece board to at least one surface of a non-combustible substrate and grinding the stuck plant piece board to a plant piece layer having a thickness of 0.2 mm to 0.4 mm as a whole, It shall be a laminated board that exhibits nonflammability.

  “Non-combustible” in “non-combustible substrate” and “laminated board showing non-combustible as a whole” is the same as that of Building Standard Act Article 2-9 and Article 108-2, 1st through 3rd It means that it conforms to the specified non-combustible performance and its technical standards and is certified by the Minister of Land, Infrastructure, Transport and Tourism. As the “non-combustible substrate”, a non-combustible substrate based on a volcanic glassy multilayer board, gypsum board, calcium silicate board, fiber reinforced cement board, rock wool board, glass wool board, steel sheet, etc. Can be used.

  As “grass timber pieces”, wood strands, chips, flakes and wafers (JIS A5908), wood fibers (fiber) (see JIS A5905), crushed pieces and crushed pieces of wood skin (bark), rush Examples include cut pieces, crushed pieces, and crushed pieces of plant stems such as straw and hemp, tea leaves, and tea leaves after extracting drinking tea from tea leaves.

  In order to improve the design of the non-combustible laminated board, the present inventors have adopted a means of using a plant piece board in which small pieces of plant wood are used as a decorative layer. In the sapwood board, the shape, size, and orientation of the timber pieces are not uniform, but the appearance is diverse, so a thin veneer with thin slices of timber with uniform grain in the thickness direction is artificial. This is because, unlike giving a monotonous impression, it was possible to make a decorative layer with high design that made use of the natural beauty of grass wood.

  However, when trying to slice thinly in order to use the plant piece board as a decorative layer, the small piece of grass wood becomes the resistance of the blade and difficult to process, and if sliced to a thickness that can meet the nonflammability standard However, there was a problem that a piece of grass wood was peeled off and became a plate material full of peeling marks. On the other hand, when processed so as to have a uniform thickness, even if it is sliced as thinly as possible, it has a certain thickness, so if it is used as a decorative layer as it is, a nonflammable substrate is used as the base material However, since the thick flammable decorative layer continues to burn, the laminated board as a whole does not meet the nonflammability standards.

  Therefore, as a result of various studies to realize nonflammability, the present inventors have come up with the idea that the flake board is thinned by grinding instead of slicing, contrary to the common sense of those skilled in the art. That is, after laminating a flake board with a thickness of several mm to several tens of mm on a non-flammable substrate, by grinding it into a flake piece layer with a thickness of 0.2 mm to 0.4 mm, the nonflammability is improved as a whole. The present inventors have found that the laminated board shown can be obtained and have reached the present invention. Conventionally, grinding has been performed for the purpose of smoothing the surface. After finding out the means conceived by the present inventors, it may be considered that thinning by grinding is an extension of smoothing by grinding, which is “post-wisdom”. In the present invention, non-flammability and high design have been achieved by adopting a means that has not been conceived so far by those skilled in the art of wooden board materials and laminated boards, that is, grinding to 1/10 or less of the initial thickness. It is possible to produce a non-combustible laminated board that has both properties.

  Here, if the thickness of the vegetation piece layer is smaller than 0.2 mm, the design may be deteriorated due to peeling of the small pieces of vegetation wood when grinding. On the other hand, if the thickness of the vegetation piece layer is larger than 0.4 mm, the standard of the non-combustible material is not satisfied as will be described later. Furthermore, if the thickness of the vegetation piece layer is set to 0.25 mm to 0.30 mm, it is preferable because the design is higher and the nonflammability is higher.

  In addition, as a common sense of those skilled in the art, it is considered that impregnation with a flame retardant in the decorative layer will increase the non-combustibility performance. It has been found that non-impregnated flame retardant has higher non-flammability performance.

  The manufacturing method of the nonflammable laminated board concerning this invention shall be "the said plant piece board is a non-oriented strand board" in the said structure.

  Conventionally referred to as “strand board” is an oriented strand board (hereinafter referred to as “OSB”). OSB is a material in which strands of wood having a width of 13 mm to 19 mm, a length of 70 mm to 130 mm, and a thickness of 0.6 mm to 0.7 mm are oriented so as to be orthogonal to each other, and the mechanical strength is high. Generally, it is used as a core material of a structural material, a base material, or a laminated board. On the other hand, in this configuration, a “non-oriented strand board” (hereinafter referred to as “RSB”) is used as a plant piece board. RSB is formed by coating an adhesive on a strand smaller in size than OSB and accumulating it without orientation, and then pressing and molding the strand. The strand has a width and length of 20 mm to 40 mm, and a thickness of 0.3 mm to 0.3 mm. 0.4 mm.

  In this configuration, a strand board using strands larger in size than chips and fibers as “small pieces of grass wood” is used as the grass piece board. Therefore, the diversity of the appearance of the plant piece layer that is exhibited when the shape, size, and orientation of the plant pieces are not uniform, and the design of the laminated board is further enhanced. In addition, although a strand having a large size is used, since the strand size of RSB is not as large as that of OSB, it provides a laminated board that gives a delicate and calm impression as compared to the case where OSB is used as a plant piece board. There are advantages that can be made.

  In addition, since the strands of RSB are smaller and thinner than those of OSB, the strands are not easily peeled off when forming a plant fragment layer by grinding, and can be made thinner by grinding more easily. RSB can make the density constant throughout the board because the strands are small and thin. Since the density is constant, the amount of grinding with respect to the grinding force is constant, so that grinding is easy. Furthermore, since the OSB has a structure in which three or more layers in which the strands are oriented are stacked while the strand directions are orthogonal to each other, the board has a certain thickness (about 12 mm) or more, whereas the RSB has the strands. Since it is the structure laminated | stacked non-oriented, the thing about 3 mm thick can be manufactured. Therefore, the RSB that can reduce the initial thickness is suitable for the manufacturing method of the present invention in which the flake board is thinned by grinding.

Next, the non-combustible laminated board manufactured by the manufacturing method of the present invention is “a plant piece layer having a thickness of 0.2 mm to 0.4 mm and containing no flame retardant, wherein small pieces of grass wood are joined with an adhesive. Is laminated on at least one surface of the non-combustible substrate and exhibits non-combustibility as a whole. "

Noncombustible laminated board this is intended to be manufactured by the above manufacturing method. A novel manufacturing method of thinning a flake board laminated on a non-combustible substrate by grinding, a novel flake flake layer having a very thin thickness of 0.2 mm to 0.4 mm, which is inherently difficult to thin. It is now possible to provide a laminated board having a configuration for the first time.

As described above, as an effect of the present invention, more design property is enhanced noncombustible laminated board production how, can be provided.

It is process drawing of the manufacturing method of the nonflammable laminated board which is one Embodiment of this invention. It is sectional drawing of the nonflammable laminated board manufactured by the manufacturing method of the nonflammable laminated board of FIG.

  Hereinafter, a method for producing a nonflammable laminated board 1 according to an embodiment of the present invention (hereinafter, simply referred to as “manufacturing method”), and a nonflammable laminated board 1 produced by the production method, This will be described with reference to FIGS.

  In the manufacturing method of the present embodiment, a piece of grass wood board 10 not coated with a flame retardant is formed on one surface of a nonflammable substrate 20 by coating a small piece of grass wood with an adhesive and press-molding the piece. The non-flammable laminated board 1 which shows nonflammability as a whole by grinding the pasting step S1 and the pasted plant piece board 10 until it becomes a plant piece layer 11 having a thickness of 0.2 mm to 0.4 mm. And step S2.

  The plant piece board 10 is formed by laminating and pressing a step P1 for processing grass wood into a small piece, a step P2 for coating a small piece of grass wood with an adhesive, and a piece of grass wood coated with an adhesive. It can be manufactured by a manufacturing method comprising: a step P3 for forming into a predetermined size; and a step P4 for cutting the pressure-formed plate material into a predetermined size.

  Hereafter, each process is demonstrated concretely. Process P1 which processes grass wood into a small piece is a process which makes small pieces by giving processing, such as cutting, cutting, crushing, crushing, and defibration, to grass wood. For example, the wood is cut into strands or wafers, the wood is crushed or crushed into chips or flakes, and the steamed wood chips are fibrillated into fibers. In addition, the wood skin is crushed and crushed into small pieces. As the wood as the grass wood, conifers such as cypress, cedar, pine, and hiba, and broad-leaved trees such as oak, birch, beech, and zelkova can be used. By using wood that is difficult to be used as building materials, such as thinned wood and small diameter trees, resources can be used effectively.

  If the grass timber is a plant stem, the stem is cut, crushed, or crushed. The plant stems include the rush of rushes produced in the tatami mat production process, immature short rush that cannot be used in the production of tatami mats, reeds that have been harvested after absorbing organic matter and used for water purification of lakes and marshes. Waste wood, such as sawdust after removing fiber from hemp stalks, can be used effectively.

  In addition, when the grass wood has a size that can be used as a small piece of grass wood, such as tea leaves or tea leaves, the process P1 can be omitted. Tea, green tea, oolong tea, and other teas for beverages such as tea, green tea, and oolong tea can be used as leaves, stems, fibers, and powdered leaves removed from the tea leaves as raw materials. What is discharged | emitted in large quantities after extracting tea in a process can be used.

  Also, when the moisture content is higher than a predetermined value, such as when the grass-wood pieces are strands cut from raw wood or tea husks, a drying step of drying the grass-wood pieces before the next step P2 is performed. Can be provided.

  In the process P2, an adhesive is coated on each piece of grass wood. Examples of coating adhesives include rubber latex adhesives, phenol resin adhesives, melamine resin adhesives, urea resin adhesives, isocyanate adhesives, resorcinol resin adhesives, and epoxy resin adhesives. can do. In step P3, a small piece of grass and wood coated with an adhesive is compressed and formed into a plate material.

  In step P4, the pressure-formed plate material is cut into a predetermined size using a cutting machine. Here, it cuts according to the size of a nonflammable board | substrate. By the above processes P1 to P4, the plant piece board 10 that has not been subjected to the flame-retardant treatment is manufactured.

  In step S <b> 1, an adhesive is applied to one surface of the incombustible substrate 20, and the plant piece board 10 is bonded. As the non-combustible substrate 20, a non-combustible material that has been approved by the Minister of Land, Infrastructure, Transport and Tourism is used. Adhesives include aqueous polymer isocyanate adhesives, vinyl acetate resin emulsion adhesives, vinyl acetate resin solvent adhesives, vinyl copolymer resin adhesives, rubber latex adhesives, urethane resins Examples of such adhesives include acrylic adhesives, acrylic resin adhesives, epoxy resin adhesives, resorcinol resin adhesives, and phenol resin adhesives.

  In step S2, the surface of the plant piece board 10 in a state of being stuck to the non-combustible substrate 20 is ground to reduce the thickness until the thickness becomes 0.2 mm to 0.4 mm, thereby forming the plant piece layer 11. . Here, when the thickness of the vegetation piece layer 11 is thinner than 0.2 mm, the small piece of the vegetation wood is peeled off, and the incombustible substrate 20 which is the base is exposed, and the design property may be deteriorated. Accordingly, the lower limit of the thickness of the plant fragment layer 11 is 0.2 mm. Through the above steps S <b> 1 to S <b> 2, the incombustible laminated board 1 in which a very thin plant piece layer 11 is laminated on the incombustible substrate 20 can be manufactured.

  An incombustible laminated board 1 using RSB as the plant piece board 10 was manufactured. First, the wood was cut into strands each having a width and length of 20 mm to 40 mm and a thickness of 0.3 mm to 0.4 mm. Cypress was used as grass wood that is the raw material wood of the strand. After the strand was dried, the adhesive was sprayed while rolling the strand in a rotating drum, and the surface of the strand was coated with the adhesive. The strands coated with the adhesive were randomly collected and pressed with heating using a heating compressor, and formed into a plate material having a thickness of about 3 mm to obtain RSB. After cutting this RSB according to the size of the incombustible substrate 20, it was stuck on one side of the incombustible substrate 20 with an adhesive.

  The incombustible substrate 20 includes a base material having a thickness of 5 mm to 9 mm in which a fiber layer 22 is laminated on the front and back surfaces of the volcanic glassy plate 21 and an aluminum foil layer 23 attached to one side of the base material. A substrate having a laminated structure (Dailite FAL, manufactured by Daiken Kogyo Co., Ltd.) was used. Here, the volcanic glassy plate 21 is a layer in which volcanic glassy deposits such as shirasu and white clay and inorganic fillers such as aluminum hydroxide and magnesium hydroxide are bonded with a binder, and the fiber layer 22 is This is a layer in which fibers such as rock wool and glass wool are bonded with an inorganic filler and a binder, and the aluminum foil layer 23 is a layer in which thin paper is attached to both surfaces of the aluminum foil.

  The RSB stuck to the surface of the nonflammable substrate 20 on the aluminum foil layer 23 side was ground and thinned to a thickness of 0.2 mm to 0.4 mm using a wide belt sander. Thereby, the nonflammable laminated board 1 of the structure by which the plant piece layer 11 was laminated | stacked on the aluminum foil layer 23 of the nonflammable board | substrate 20 was manufactured (refer FIG. 2).

Hereinafter, in the manufacturing method of the non-combustible laminated board of this embodiment, the grounds which make the plant piece layer 11 the structure which does not contain a flame retardant and make the thickness of the plant piece layer 11 0.4 mm or less will be described.

  Samples E1 to E5 in which the thickness of the plant fragment layer 11 that does not contain the flame retardant laminated on the incombustible substrate 20 is varied in the range of 0.25 mm to 0.50 mm by the same manufacturing method as in the above example. Was made.

  Here, as a common sense of those skilled in the art, it is expected that the non-flammable performance of the laminated board will be further increased by applying a flame retardant treatment for impregnating the flame retardant into the flake board and making the flake piece layer contain the flame retardant. Is done. Therefore, the same RSB as the RSB used for the samples E1 to E5 is subjected to a flame retardant treatment in which a flame retardant mainly composed of ammonium polyphosphate is impregnated, and then the same nonflammable substrate 20 as the samples E1 to E5 is applied. The sample E6 was produced by sticking and thinning by grinding. The thickness of the plant piece layer 11 in the sample E6 was set to 0.30 mm which is 0.40 mm or less. The thickness of the incombustible substrate 20 was 6 mm in any of the samples E1 to E6, and the sample size was 99 mm ± 1 mm × 99 mm ± 1 mm.

About the samples E1-E6, the exothermic test based on ISO5660 was done. In the test, a corn calorimeter was used, and the surface of each sample having the vegetation piece layer 11 was irradiated with radiant heat of 50 kW / m ^{2 with} a radiant electric heater and ignited with a spark plug. Was performed by measuring.

From the results of the exothermic test, nonflammability is determined according to the following three criteria. The measurement results in the test are shown in Table 1 together with the determination results of nonflammability.
(1) The total calorific value during the test time is 8 MJ / m ² or less (2) Within the test time, the maximum heat generation rate does not exceed 200 kW / m ² continuously for 10 seconds or more (3) After the test, there should be no cracks or holes penetrating to the rear side, which is harmful to fire prevention

As shown in Table 1, the total calorific value and the heat generation rate increase as the thickness of the plant fragment layer 11 increases. In samples E1 to E4, the total calorific values are 4.69, 5.00, 6.27, and 6.64 MJ / m ² , respectively, which are the standard values of 8 MJ / m ² or less, and the condition (1) Met. The maximum heat release rate, and 166.21,185.95kW / ^{m 2} Sample E1 and E2, never exceeding 200 kW / ^{m 2.} Further, the maximum heat release rate for sample E3 and E4 are slightly exceeded 204.61,228.56kW / ^{m 2} and 200 kW / ^{m 2,} 1.0 seconds exceeded duration, respectively, and 6.4 seconds and 10 Less than a second. Therefore, all of the samples E1 to E4 satisfied the condition (2). In addition, all the vegetation piece layers 11 of the samples E1 to E4 are burned out within the test time, but no cracks or holes penetrating to the back surface are formed in the non-combustible substrate 20 as the base, and the condition (3) is satisfied. It was something to satisfy. Therefore, all of the samples E1 to E4 conformed to the nonflammability criterion.

On the other hand, the sample E5 in which the thickness of the vegetation piece layer 11 is 0.5 mm has a total calorific value of 16.10 MJ / m ² and a maximum exothermic rate of 200 kW / m ² exceeding 12.8 seconds as a reference value. The condition (1) and the condition (2) were not satisfied.

In addition, Sample E6 in which a flame retardant was contained in the plant piece layer 11 was contrary to prediction and did not conform to the non-flammability criteria. More specifically, although the maximum heat generation rate was 56.42 kW / m ² , which was small compared to the samples E1 to E5, the total heat generation amount was 9.70 MJ / m ² , which was higher than the reference value. Therefore, the sample E6 did not satisfy the condition (1). This is thought to be because impregnation with the flame retardant suppresses the burning of the vegetation piece layer 11 and suppresses the heat generation rate, but maintains a small heat generation. Further, in the sample E6, heat generation continued for a long time, and damage such as partial peeling was observed on the aluminum foil layer 23 of the non-combustible substrate 20. Therefore, it was considered that the gas diffusion prevention function and the heat radiation function expected for the aluminum foil layer 23 were impaired. Sample E6 meets the criteria for “quasi-incombustibility” required to satisfy the above three conditions with a test time of 10 minutes.

  From the above results, it was confirmed that samples E1 to E4 satisfy the nonflammability standard. Therefore, if the thickness of the vegetation piece layer 11 is at least 0.40 mm or less, a laminated board exhibiting nonflammability as a whole can be obtained. Moreover, from the result of the sample E6, in order to show the incombustibility as a whole, the vegetation piece layer 11 not only has a thickness of 0.40 mm or less, but does not contain a flame retardant contrary to conventional common sense. Turned out to be necessary.

  The present invention has been described with reference to the preferred embodiments. However, the present invention is not limited to the above-described embodiments, and various improvements can be made without departing from the scope of the present invention as described below. And design changes are possible.

  For example, in the above embodiment, RSB was used as a plant piece board, but a plant piece board such as OSB, particle board, medium density fiber board (hereinafter referred to as “MDF”) can be used, The appearance of the decorative layer can be varied depending on the size of the small pieces of grass wood. Specifically, when OSB is used, the strand is rougher than RSB, so that it can be a decorative layer that gives a strong impression. When particle board or MDF is used, a small piece of grass wood than RSB strand. Since it is fine, it can be a makeup layer that gives a modest impression. In addition, by forming a plant piece layer from a plant piece board that uses rushes, straw, brown tea, tea leaves, tea husk etc. as grass wood, it is not only non-combustible with a decorative layer that has not only high design but also a natural refreshing fragrance The laminated board can be made.

1 Non-combustible laminated board 10 Grass chip board 11 Grass wood layer 20 Non-flammable substrate

Claims (2)

A piece of grass and wood that is not impregnated with a flame retardant, formed by coating an adhesive on a small piece of grass and pressure-molding, is stuck to at least one surface of a non-flammable substrate, and is stuck A method for producing a non-combustible laminated board, characterized in that a laminated board that exhibits non-combustibility as a whole is obtained by grinding the chopped board until a vegetated piece layer having a thickness of 0.2 mm to 0.4 mm is obtained. The method of manufacturing a non-combustible laminated board according to claim 1, wherein the vegetation piece board is a non-oriented strand board.

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