JPH01234232A - Fire resistant building material - Google Patents

Abstract

PURPOSE:To obtain a lightweight fire resistant building material excellent in cutting processability and sound blocking properties and especially reduced in the lowering of strength under high temp. environment, by providing a protective layer consisting of a particulate material mainly composed of a carbon component and a thermosetting synthetic resin to the surface of a base material. CONSTITUTION:A protective layer consisting of a particulate material mainly composed of a carbon component and a thermosetting synthetic resin is provided to the surface of a base material. As the base material, a wooden material such as plywood or a particle board and a hydraulic inorg. material such as a gypsum board or a calcium silicate board are used. The particulate material composed of the carbon component is obtained by decomposing and baking grasses such as wheat, paddy or foxtail millet other than wood, for example, chaff and tar pitch under heating. As the thermosetting synthetic resin, a precondensate of a phenol or melamine resin is pref. The protective layer is formed by a method wherein alcohol is added to carbon particles and the solid thermosetting resin, for example, a precondensate of a resole type phenol resin to perform kneading and the resulting kneaded mixture is subjected to extrusion molding, dried and ground to obtain a self-curable carbon particulate material which is, in turn, scattered on the surface of the base material and compressed under heating.

Description

[Detailed description of the invention] Industrial applications The present invention relates to a construction material with excellent fire resistance and sound insulation properties.

Prior art and problems to be solved by the invention Conventionally, in general,
For base materials such as partition walls and ceilings, we use gypsum boards, wood cement boards, etc. that use a hydraulic substance as a binder, or metal plates that are integrated with the surface of base materials such as plywood or particle board. It is used.

The former is made of noncombustible material, so it has some degree of fire resistance, but when exposed to flame, the water contained in the crystals is liberated, and the resulting vapor causes the crystal to explode or its strength to drop rapidly. There is a drawback of doing so.

On the other hand, in the latter case, since the metal plate has a large coefficient of heat transfer and thermal expansion, when exposed to high temperatures, thermal stress is generated at the interface between the base material and the metal plate, resulting in peeling and warping.

For this reason, when the above-mentioned conventional construction materials are used for partition walls and ceilings, problems have been pointed out, such as the materials suddenly collapsing in the event of a fire, or the door not being able to open due to deformation of the door. .

On the other hand, wood materials with a large cross-sectional area only carbonize on the surface, and even in the event of a fire, the flame damage does not progress to the inside, and the thermal stress is small, so they have excellent fire resistance. There is a report.

In addition, partition walls and ceilings are required to have sound insulation properties, but the above-mentioned construction materials do not have a good sound insulation effect unless their weight and thickness are increased, so it is possible to improve sound insulation performance while maintaining machinability and workability. The problem was that it could not be done.

In view of the problems mentioned above, the present invention has been developed to provide a structure that is lightweight and has excellent cutting workability, and also has excellent sound insulation and fire resistance, and in particular, has fire resistance with little loss of strength in high temperature environments. Party B's purpose is to provide materials.

Means for Solving the Problems The gist of the present invention is, in order to achieve the above-mentioned objects, to provide a fire-resistant material having a protective layer on the surface of a base material consisting of powder grains mainly consisting of a carbon component and a thermosetting synthetic resin. It is a building material that has properties.

Furthermore, in order to achieve the same object, the present invention provides a protective layer on the surface of the base material consisting of powder grains mainly consisting of a carbon component and a thermosetting synthetic resin, and further provides a decorative layer on the surface. It may also be a construction material with fire resistance.

The base material is plywood or particle board.

In addition to wood materials such as LVL and thin wood boards, there are also water-curable inorganic materials such as gypsum board, calcium silicate board 1 wood chip cement board, and slag gypsum board, but the base material is not necessarily in the form of a plate. It may be columnar or rod-shaped.

When the base material is wood, since the wood itself has low thermal conductivity, a carbonized layer is generated by thermal decomposition at the interface with the protective layer (described later), and this carbonized layer or the heat insulating material Therefore, internal thermal decomposition is effectively prevented. Further, since the carbonized layer relieves the stress generated between the base material and the protective layer, it has the advantage that surface layer peeling and cracking are less likely to occur.

On the other hand, when the base material is an inorganic material, the protective layer described below prevents the base material from being directly exposed to flames, so there is less decomposition of crystal water, which makes explosions less likely to occur, further improving the fire resistance of the base material. There is an advantage.

In addition to wood, the powder grains mainly composed of carbon components include seeds, rinds, trunks, branches, leaves, etc. of plants of the genus family such as kolyan, wheat, sugarcane, rice, and millet, for example, rice hulls, and TT such as tar pitch. It is obtained by thermally decomposing and sintering n-compounds, and the higher the processing temperature, the more suitable it is. For example, if the treatment temperature is 300°C to 500°C, carbonization will not progress, but if fired at a temperature of 1000°C or higher, the charcoal will shrink, the specific surface area will become smaller, and a carbon ridge will form. , which is even more preferable because it becomes difficult to burn.

In addition to artificially produced charcoal and graphite, naturally occurring graphite and various types of charcoal can be used as carbon powder. If you use scaly carbon powder among these,
Since they overlap when forming the protective layer, there is an advantage that a dense protective layer can be formed. The particle size of this carbon powder is 3
0-2000 microns is preferred.

In addition to the above, mica can be cited as a flake-like powder. Furthermore, silica, alumina, magnesia, etc. may be mixed into the powder particles. Particularly, rice husk, such as a plant belonging to the Phytophyllaceae family, contains a large amount of sorrel, and when fired, a mixture with carbon powder can be formed at once, making it suitable.

In addition, '48; (e-shaped materials, lightweight aggregates, etc.) may be added as reinforcing materials and bulking agents.

On the other hand, as the thermosetting synthetic resin, an initial condensate of, for example, a novolac type or resol type phenol resin or a melamine resin is suitable in order to improve wettability with carbon powder particles. In particular, since the Tubonol resin has a large amount of fixed carbon, it has the advantage of being carbonized through thermal decomposition and further improving its fire resistance.

There are various methods for forming the protective layer, but the first method is to form a self-hardening carbon powder made of carbon powder and a thermosetting low molecular weight material. There is a method of spraying it on the surface of the material and then pressing it under heat.

That is, as a method for obtaining self-curing carbon powder, carbon powder and a solid thermosetting synthetic resin, for example, an initial condensate of a resol type phenol resin, are charged into a Nigu,
After kneading these with an alcohol solvent, etc., the kneaded material is taken out of the Nigu, and in order to further improve the mixing, the extruded and formed molded product is dried, and then pulverized to obtain self-hardening carbon powder. be.

Another method for obtaining self-curing carbon powder in which resin is uniformly adhered to the surface of carbon powder is to place these carbon powder in a reaction vessel in advance when synthesizing phenolic resin. There is a method in which a resin is uniformly adhered to the surface of carbon powder by reaction, and the self-hardening carbon powder is obtained by drying the resin after being distributed from house to house.

A protective layer is formed by scattering this self-hardening carbon powder onto the surface of the base material and then heating and pressing it.

According to the above-mentioned method, self-hardening carbon powder to which a thermosetting synthetic resin is attached can be obtained even from materials that are difficult to wet, such as carbon powder. As a result, by spraying a predetermined amount of this self-hardening carbon powder onto the surface of a base material and heat-pressing it, a protective layer can be easily obtained, which has the advantage that there will be no variation in the fire resistance of the base material. .

Incidentally, during heat pressing, a decorative layer may be integrated by disposing paper, cloth, nonwoven fabric, or a resin sheet on the self-curing carbon powder.

The second method is to uniformly spread the self-hardening carbon powder, press it with a roll at a temperature of 50°C to 100°C, and partially press it to form a self-hardening sheet material of a predetermined thickness. obtained,
There is a method of forming a protective layer on the surface of the base material by coating the surface of the base material with this self-curing sheet material and then pressing under heat.

According to this method, since a uniform self-curing sheet material is heated and pressed onto the surface of the base material, the protective layer is uniform even in large-sized construction materials, and there is an advantage that there is no variation in fire resistance.

In addition, in this method, when manufacturing the self-curing sheet material, paper, cloth, nonwoven fabric, or resin sheet may be placed on one side of the sheet material and integrated, and if it is a decorative material, the decorative layer described below may be used. The pasting process can be omitted.

Alternatively, the self-curing sheet material may be superimposed on the surface of a base material coated with an adhesive and then heat-pressed.

A third method is to place the self-curing powder or self-curing sheet material on the top or bottom surface of a forming mat made by kneading small pieces of wood with a binder such as adhesive or cement, and then heat it. There is a method of forming a protective layer at the same time as sheet forming by pressing.

According to this method, a mixed and integrated layer is formed at the interface between the base material and the protective material, which has the advantage of being strongly adhered and less prone to peeling or cracking.

The fourth method is to knead carbon powder and thermosetting low-molecular-weight fluorescent material into a paste through various solvents, and then
This is a method in which the sheet is extruded by applying pressure with a roll, placed on the surface of the base material, and then heated and pressed to form a protective layer. good.

The fifth method is to add a strong acid to graphite to form an intercalation compound, heat this to expand it approximately 10-100 times, and then heat-cure it into a sheet by pressing it with a roll at room temperature. There is a method of forming a protective layer by impregnating a base material with a low molecular weight material, placing it on the surface of a base material, and pressing it under heat.

The fixed content of carbon powder in the protective layer is preferably 50% or more, preferably 60 to 95% by weight, and the specific gravity of the protective layer is 0.8 or more, preferably 1°0 to 1.4. .

In addition, the thickness of the protective layer is 0.5 to 5 cm, preferably 1 to 3 cm.
Am is good.

Furthermore, if a protective layer is provided on the front and back surfaces of the base material, it becomes a so-called sandwich construction, and the physical
Since the mechanical properties are stable, warping is less likely to occur, and the protective layer is thicker, which has the advantage of making it difficult for flames to penetrate in the event of a fire and improving sound insulation.

Further, on the surface of the protective layer formed in advance, a thin wood board 1 is provided.
It is preferable to provide a decorative layer such as a decorative sheet such as a synthetic resin sheet or glass cloth.

Example 1 A scaly carbon powder and a resol type phenol resin were charged in a weight ratio of 65:35 into a double-arm type Nigu, and 30
After stirring and kneading for a minute, this f2 kneaded material is extruded and molded using a continuous kneading extruder, and the molded product is air-dried to remove the solvent.Then, this is crushed using a pulverizer to obtain self-hardening carbon powder. I got it.

Next, this self-hardening carbon powder was made into a powder with a thickness of 17 mm and a specific gravity of 0.
．． 70 particle board (commercially available), and heated and pressed at 160°C for 5 minutes to give a thickness of 1.
A construction material having a protective layer of 5 mm and a specific gravity of l 2 was obtained and used as a sample.

Example 2 Scale-like carbon powder and resol type phenolic resin with a viscosity of 200 poise were added to a double-arm type Nigu at a weight ratio of 100+6.
Pour in at a ratio of 5:5 and stir for 30 minutes.

After mixing and discharging, this paste-like kneaded material is pressurized with a roll to obtain a sheet-like self-hardening protective material, which is placed on the front and back surfaces of a gypsum board, and then passed through wire mesh and punched metal. By heating and pressing at 160°C for 10 minutes while degassing, a construction material with a total thickness of 15 mm and a protective layer with a thickness of 5 mm and a specific gravity of 1.0 on the front and back surfaces was obtained, and this was used as a sample. .

Example 3 770 g of phenol in a 512 four-loop flask.

1,328 g of 37% formalin and 80 g of hexamethylenetetramine were charged, and further, 1,100 g of flaky graphite having an average particle size of 5 μm were charged.

The temperature was raised to 90°C over about 60 minutes, and the reaction was continued for 3 hours. After cooling, the mixture was separated. This was air-dried to obtain 1830 g of self-hardening carbon powder having an average particle size of 50 μm.

The content of phenolic resin in the obtained powder was 40%.
Met.

A construction material obtained by operating this self-hardening carbon powder in the same manner as in Example 1 was used as a sample.

Comparative example! A commercially available wood cement board with a specific gravity of 1.15 was used as a sample.

Comparative example 2 The sample was commercially available gypsum board (general purpose product).

Comparative Example 3 A single particle boat with a specific gravity of 0.70 was used as a sample.

And the above-mentioned Examples 1 and 2. , 3 and comparative example 1゜2
．． 3 was subjected to a bending creep test under flame.

The bending creep test under flame is to find out the fireproof bending performance in a high temperature environment, and uses a board bending performance test method and equipment based on JISA5908. The tip of the flame of a Bunsen burner, which is supplied with city gas via a ballast to maintain a constant flow rate, is placed in the same place as 111.

The temperature at the tip of this flame was about 700° C., and a load set to 115, which is the bending fracture strength of the sample, was applied, and the time required to reach fracture and the varying weight at the load point were measured.

The measurement results are shown in Table 1.

As is clear from the measurement results in Table 1 and above, Example 1゜2.3
These are comparative examples! It was found that the fire resistance performance is 6 to 10 times higher than that of , 2.3.

In addition, the sound insulation performance at 5001-rz was measured and 1-Example! was 20 dB and 22 dI3 in Example 2, whereas it was 6 dB in Comparative Example 2.
Although Example 1.2 had almost the same specific gravity as Comparative Example 2, it was found that it had better sound insulation properties than Comparative Example 2.

Effects of the Invention As is clear from the above explanation, according to the present invention, the surface of the base material is coated with a protective layer made of carbon powder and a thermosetting synthetic resin. In particular, if the carbon powder is scaly, the carbon powder overlaps to form a protective layer, so that the carbon powder is covered with a dense protective layer.

The carbon powder that forms the oil and fat protective layer itself has an extender pigment function through the thermosetting synthetic resin, so even if the base material is porous, it can penetrate into the pores of the base material. In addition to being strongly integrated with the base material, the protective layer made of carbon powder has small thermal expansion.

Particularly, if the carbon powder particles have a scaly shape, they are oriented in a certain direction, so that there is a stress relieving effect in the oriented direction. Therefore, the shear stress generated between the base material and the protective layer in high-temperature environments is small, causing warping and peeling.

Cracks are less likely to occur, and sufficient strength can be maintained for a long time even in the event of a fire.

In addition, the construction material of the present application coated with a protective layer made of carbon powder and synthetic resin has a high oxygen index, so it is difficult to ignite and spread flame in the air. In this case, the scaly carbon particles overlap to form a dense protective layer, which blocks oxygen. For this reason, fire resistance is further improved, and for example, even if the base material is wood, the inside will not burn, the flame will not penetrate, and it will not suddenly collapse in the event of a fire, making it useful for fire resistance. There is a certain effect.

Furthermore, the protective layer has excellent sound insulation properties, and especially if the carbon powder particles are scaly, they overlap to form a protective layer with some orientation, so while it has high rigidity, it also has high rigidity. Due to the difference in rigidity between the protective layer and the base material, the protective layer effectively absorbs sound propagation energy, resulting in good sound insulation properties.

Patent applicant: Daiken Kogyo Co., Ltd. (1 person) and patent attorney (1 person and 1 person)

Claims (2)

[Claims] (1) A fire-resistant construction material characterized by providing a protective layer on the surface of a base material consisting of powder grains mainly consisting of a carbon component and a thermosetting synthetic resin. (2) A fire-resistant building characterized by providing a protective layer made of powder mainly composed of carbon components and a thermosetting synthetic resin on the surface of the base material, and further providing a decorative layer on the surface. lumber.