JPH01168411A - Method for manufacturing resol-type phenol resin foaming charge building material - Google Patents

Abstract

PURPOSE:To manufacture a building material with an excellent heat insulation, heat resistance and flame resistance by applying adhesive agent on a surface material prior to the injection of resol-type phenol resin. CONSTITUTION:Resol-type phenol resin is foamed and cured under the existence of foam stabilizer, foaming agent and oxidizing curing agent so as to manufacturing a building material integrated with the surface material. At this time, the adhesive agent is applied on the surface material prior to the injection of the resol-type phenol resin. The adhesive resin used herein may be of polyurethane resin, epoxy resin, vinyl acetate resin, polyacryl resin and SBR latex. The surface material may also be of an iron plate, aluminum plate, aluminum foil, gypsum board, rock wool hard plate, calcium silicate plate, veneer plate, non woven fabric, concrete, paper and vinyl chloride cloth, and the surface material is used as a layer or layers. As an applying method of the adhesive agent to the surface material, a roll coating method, spraying method, brush coating method, flow coating method and the like are applied after removing oils and fats or the dust on the surface agent, and a thermocompression method, cold pressing method and roll compression method and the like are applied as the adhesive method between the foam and the surface material.

Description

[Detailed description of the invention] [Industrial application field] The present invention has good adhesion to the surface material and heat insulation properties.

The present invention relates to a method for producing a resol-type phenolic resin foam-filled building material that has excellent heat resistance and flame retardancy.

(Prior art) Resole type phenolic resin foam is used as a heat insulating material for building materials due to its various excellent properties such as fire resistance and heat insulation, but when it is integrally molded with a surface material, its adhesiveness is extremely poor. It was inferior.

A method for improving the adhesion between foam and surface material is disclosed in Japanese Patent Application Laid-open No. 5
9-=F19343, JP-A-60-130628, JP-A-60-188431, JP-A-60-236740, and Utility Model JP-A-60-119531, etc., but even if these methods are used, the adhesion is still excellent. It was not possible to obtain a resol-type phenolic resin foam-filled building material.

[Purpose of the invention]

The present invention was completed as a result of various studies on manufacturing methods for improving the adhesion when integrally molding a resol type phenolic resin foam and a surface material.

The purpose is to have good adhesion to the surface material,
The object of the present invention is to provide a method for producing a resol-type phenolic resin foam-filled building material that has excellent heat insulation, heat resistance, and flame retardancy.

[Structure of the invention]

The present invention is a method for manufacturing a building material in which a resol type phenolic resin is foamed and cured in the presence of a foam stabilizer, a foaming agent, and an acidic curing agent, and is integrated with a surface material. It is characterized by applying an adhesive to the surface.

Adhesives used in the present invention include polyurethane resin, epoxy resin, vinyl acetate resin, polyacrylic resin and SB.
It is R latex. In addition, the surface materials are iron plates, aluminum plates, aluminum foil, gypsum boards, hard rock wool plates, calcium silicate plates, plywood boards, nonwoven fabrics, concrete, paper, and vinyl chloride cloth, and the surface material layers can be used in one layer or in multiple layers. .

Here, when the surface material is metal such as iron plate, aluminum plate, aluminum foil, etc., the adhesive used is preferably polyurethane resin, epoxy resin, vinyl acetate resin, plasterboard, rock wool hard plate, calcium silicate, etc. For inorganic materials such as, epoxy resins and vinyl acetate resins are preferably used, and for plywood boards, paper, etc., vinyl acetate resins are preferably used.

To apply the shoulder adhesive to the surface band, first remove the oil, fat bones, dust, etc. from the surface agent, and then use the generally known methods such as roll coating, spraying, brush coating, and flow coating. It is commonly used. Further, as a method of adhering the foam and the surface material, a hot press method, a cold press method, a roll press method, etc. are applied. In addition to the method of integrally molding the foam and the surface material continuously using a double conveyor line, the resol type phenolic resin foam molded into a block is cut into slices and then one or both of the front and back surfaces are coated with the present invention. Apply the adhesive described,
It also applies to methods of laminating surface materials.

The resol type phenolic resin used in the present invention is produced by reacting phenols and aldehydes, for example, in the presence of an alkali catalyst at a ratio of 1 to 2.5 moles of the latter to 1 mole of the former, and then After neutralization (for example, pH-
6-8) It is obtained by dehydration, has a number average molecular weight in the range of 140 to 450, and usually has a viscosity of 4 to 200 voids at 25°C. number average molecule ff11
If it is smaller than 40, a foam with a dense cell structure cannot be obtained;
When it is larger than 450, the curing reaction becomes slow and cannot be put to practical use.

As the phenols, phenol, cresol, xylenol, ethylphenol, propylphenol, resorcinol, catechol, hydroquinone, bisphenol F2, bisphenol A, etc. can be used. Formaldehyde, acetaldehyde, furfural, etc. are used as aldehydes. As the alkaline catalyst, lithium hydroxide, sodium hydroxide, potassium hydroxide, calcium hydroxide, barium hydroxide, etc. can generally be used.

As the acid used for neutralization, hydrochloric acid, sulfuric acid, phosphoric acid, boric acid, oxalic acid, acetic acid, lactic acid, phenolsulfonic acid, p-toluenesulfonic acid, etc. can be used.

As the foam stabilizer, one or more of known active surfactants such as silicone oil, ethylene oxide adducts of alkylphenols, polyoxyethylene ethers of castor oil or coconut oil, and sorbitan esters are usually used. It will be done. Moreover, these can also be included in the resol type phenolic resin in advance.

As the blowing agent, conventionally known blowing agents for producing resol foam can be used. For example, carbon tetrachloride, petroleum ether, isopropyl ether, n-pentane, trichloromonofluoromethane, dichlorodifluoromethane, monochlorotrifluoromethane, dichloromonofluoromethane. , monochlorodifluoromethane, tetrachlorodifluoroethane, trichlorotrifluoroethane, dichlorotetrafluoroethane or mixtures thereof.

Examples of acidic curing agents include inorganic acids such as sulfuric acid, hydrochloric acid, and phosphoric acid;
Organic acids such as phenolsulfonic acid and paratoluenesulfonic acid can be used.

The production of resol-type phenolic resin foam is carried out using conventionally known procedures, for example, by mixing a resol-type phenolic resin with a certain amount of a foam stabilizer/blowing agent and an acidic curing agent.
Obtained by applying a temperature of 120°C. In this case, perlite, shirasu balloon, calcium carbonate,
Composites can also be made of inorganic particles such as gypsum, clay, hydrated alumina, talc, mica, kaolin, and asbestos as aggregates. Furthermore, known techniques can be applied to flame retardants such as phosphate esters and chlorine, and corrosion inhibitors such as magnesium carbonate.

〔Effect of the invention〕

The resol-type phenolic resin foam-filled building material obtained by the method of the present invention has good adhesion between the foam and the surface material, and has excellent heat insulation, heat resistance, and flame retardancy, so it can be used as an exterior wall material.・Can be used as an excellent building insulation material for interior wall materials, etc.

〔Example〕

Next, the present invention will be specifically explained with reference to Examples, but the present invention is not limited to these Examples. ” indicate “parts by weight” and “% by weight”.

Resol Phenol Hino ゛1 A reaction vessel with a stirrer and a cooler, charged with 1000 parts of phenol and 1380 parts of 37% formalin, then 50%
After adding 30 parts of aqueous sodium hydroxide solution, the temperature was gradually raised,
After reaching 80°C, the reaction was continued for 2 hours. Then 50%
After neutralizing by adding 40 parts of lactic acid, a dehydration reaction was carried out under vacuum until the nonvolatile content was reduced to 80%. A resol type phenolic resin was obtained.

Resol Phenol B Panel.

■ 220 x 220 with oil and fat removed in advance
am, two galvanized steel plates with a thickness of 0.5 tm or 220
Immediately after coating on aluminum of 220 x 220 wta, it was fixed to the upper and lower molds of a 222 x 222 x 35 m openable and freely openable aluminum mold (Fig. 1) whose internal surface temperature was adjusted to 80°C.

Next, resol type phenolic resin 10 obtained in the production example
0 part was adjusted to 20°C, and a foam stabilizer (r T11-5120
4 parts (manufactured by J. Kao ■) and a blowing agent (“Freon-113
Mix 10 parts of ``Mikata DuPont Fluorochemil ■'' with stirring, add 15 parts of a 67% phenol sulfonic acid aqueous solution, and stir vigorously for 20 seconds at a rotation speed of 6.00 rpm.Then, the finished foam density is approximately An appropriate amount of this mixture was injected into the aluminum mold (Figure 2) at a rate of 55 kg/if (Figure 2), the upper mold was immediately closed, and foaming was allowed to harden for 10 minutes. After demolding, it was cured at room temperature for 2 days, and a resol-type phenolic resin foam-filled panel (220
X 220 X 35 m) was obtained.

-35゛ and 220 x 220 x O, 5- galvanized steel plates, etc.
Various adhesives shown in Table 1 were applied, and a resol type phenolic resin foam filled panel (220 x 220 x 35 tm) was obtained based on the manufacturing example of the panel described above and based on the manufacturing example of a resol type phenolic resin foam filled panel. Ta. After curing, an adhesion test between the foam and the surface material and a flame retardant test of the panel were conducted.

[Brief explanation of the drawing]

FIG. 1 is a schematic cross-sectional view of an aluminum mold used in the present invention. The thickness of the mold and the surface temperature can be adjusted. FIG. 2 is a schematic cross-sectional view of the upper mold closed after pouring the mixture in the example. FIG. 3 is a schematic cross-sectional view of a resol-type phenolic resin foam-filled panel obtained in an example. Patent applicant Sumitomo Durez Co., Ltd. Figure 1 Figure 3

Claims (1)

[Claims] 1. In a method for manufacturing a building material in which a resol type phenolic resin is foamed and cured in the presence of a foam stabilizer, a foaming agent, and an acidic curing agent, and is integrated with a surface material, the resol type phenolic resin is injected. A method for producing a resol-type phenolic resin foam-filled building material, characterized in that an adhesive is applied to the surface material in advance. 2. The method for producing a resol type phenolic resin foam filling building material according to claim 1, wherein the adhesive is selected from the group consisting of polyurethane resin, epoxy resin, vinyl acetate resin, polyacrylic resin, and SBR latex. 3. Surface material is iron plate, aluminum plate, aluminum foil, plasterboard,
The resol mold according to claim 1, which is selected from the group consisting of rock wool hard board, calcium silicate board, concrete, plywood board, paper, nonwoven fabric, and vinyl chloride cloth, and has a surface material layer of one or more layers. Method for manufacturing phenolic resin foam-filled building materials.