JPH0257329A - Panel for building material - Google Patents

Abstract

PURPOSE:To improve heat insulation, flame resistance and shape retentivity by filling inorganic foamable particles mixed with aqueous sodium silicate solution in the hollow part of a honeycomblike inorganic sheet core made by coating a raw sheet containing as a main material aluminum hydroxide with the sodium silicate, and refractorily applying a metal plate or glass wool to the face thereof. CONSTITUTION:An inorganic sheet 1 is manufactured by using 70 - 90wt.% of aluminum hydroxide and 30 - 10wt.% of pulp, cut in a square shape, coated linearly with adhesive at a predetermined interval on one side face of each sheet, and a hexagonal honeycomb structure at the time of development is formed. The laminated sheet 2 is cut in a rod shape, and a developed honeycomb structure is obtained by a rodlike laminated sheet 3. It is contained in a container, dipped in aqueous sodium silicate solution, coated therewith, and an inorganic sheet core 6 of the honeycomb structure is obtained. Then, inorganic foamed particles mixed with the aqueous sodium silicate solution are dropped from a hopper on the core 6, the particles are forcibly filled in the hollow part of the core by pressing rolls to be filled under compression without gap. Metal plates 18 adhere to the front and rear faces of the structure 17.

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention involves filling the hollow portion of a honeycomb-shaped inorganic sheet core with an inorganic filler to create a honeycomb structure, and
This invention relates to a panel for building materials in which metal plates or fireproof boards are adhered to the front and back sides of a cam structure.

<Prior Art> A vapor core is generally inserted into building panels such as doors, partitions, and exterior wall panels in order to reduce weight. In recent years, flame-retardant vapor cores have been developed from the viewpoint of fire prevention, and vapor cores are made using flame-retardant paper mixed with asbestos, aluminum hydroxide, and valves as base paper.

However, such a honeycomb-structured vapor core has a hollow part, which reduces sound insulation, heat insulation, mechanical strength, etc., so the hollow part of the vapor core is filled with nonflammable or flame-retardant filler. There are many things.

<Problems to be Solved by the Invention> Therefore, in the past, in Japanese Patent Publication No. 62-27216, etc., a non-combustible sandwich panel in which the hollow part of a honeycomb is filled with inorganic foam particles and metal face plates are bonded to both sides has been proposed. It has been proposed that a phenolic resin is mixed with the inorganic foamed beads as a binder in order to improve the adhesion between the filled inorganic expanded beads and the honeycomb. For this reason, this type of honeycomb structure normally poses no problems, but in the event of a fire, etc., when the panel is exposed to high temperatures and the internal honeycomb structure reaches several hundred degrees, the phenolic resin releases harmful gases due to the high temperature. When this phenolic resin is used for adhesion to the metal face plate, the filler loses its shape retention and its adhesion to the honeycomb structure.If this phenolic resin is also used for adhesion to the metal face plate, the core and face plate may become charred due to a fire. There was a problem with the loss of adhesiveness, which combined with the thermal deformation of the metal plate, caused the entire panel to become significantly deformed.

Means for Solving the Problems> In order to solve the above problems, the present inventors have made extensive efforts in research and development, and as a result, have developed a construction material that has good heat insulation properties, fire resistance, and shape retention under high temperatures. I came up with the idea of a panel.

That is, the building material panel of the present invention uses a honeycomb-shaped inorganic sheet core made of base paper made from aluminum hydroxide as the main raw material and coated with sodium silicate. A honeycomb structure is made by filling inorganic foam particles mixed with an aqueous sodium solution, and on at least one of the front and back sides of the honeycomb structure, a fireproof board formed into a plate shape mainly made of metal plate or glass wool is injected with heat-resistant inorganic foam. Constructed by bonding with adhesive.

<Example> Embodiments of the present invention will be described below based on the drawings.

First, the honeycomb-shaped inorganic sheet core that becomes the core of a building material panel will be explained. FIG. 1 shows an explanatory diagram of the manufacturing process of the inorganic sheet core, and 1 is an inorganic sheet that becomes the base paper of the inorganic sheet core.

This inorganic sheet! is aluminum hydroxide 70~90f
Ifi% and 30 to 101i% of pulp are used for papermaking, and polyvinyl alcohol is added as a binder during papermaking.

If the proportion of aluminum hydroxide is greater than 90% by weight, the bending strength of the seal will be weakened, and if the proportion of the valve is greater than 30% by weight, the flammability will deteriorate.

The inorganic sheet formed in this way is a sheet mainly made of aluminum hydroxide, but by using a binder and sizing with a sizing roller, it has a strength that does not interfere with the subsequent honeycomb formation process (strain strength). ).

The inorganic sheet 1 is cut into squares of a predetermined size, and adhesive is applied linearly to one side of each sheet at predetermined intervals. The adhesive used is sodium silicate, aluminum phosphate or vinyl acetate.

For example, about 200 to 400 inorganic sheets of a predetermined size coated with linear adhesive are glued together in a melon shape. At this time, in order to form a hexagonal honeycomb structure when stretched, each sheet is Glued by alternating the lines of adhesive.

The laminate assembly 2 to which the inorganic sheets 1 are laminated is then placed in a press and compressed with an appropriate load for a period of time until the adhesive dries. Then, the dry-bonded m-area bonded body 2 is then passed through a precision cutter and cut into a bar shape with predetermined exact dimensions.

After the cut rod-shaped melon stack assembly 3 undergoes intermediate inspection for adhesion defects and dimensional tolerances, two workers or both ends 3A
, 3B is held and stretched, or by applying it to a stretching machine, a stretched body 4 having a honeycomb structure similar to a finished product is produced.

Next, the expanded body 4 is placed in a container whose length and width are regulated in order to fix its expanded shape, and is soaked in a sodium silicate aqueous solution (for example, a 45% aqueous solution). This immersion is only carried out for a very short time, and the surface of the spread body 4 is thereby coated with sodium silicate.

Since sodium silicate only needs to be coated on the surface of the spread body 4, it is possible to apply it with a brush, spray, etc. in addition to crushing it.

The spread body 4 whose surface is coated with sodium silicate is dried at room temperature, and the sodium silicate hardens to complete the inorganic sheet core 6 with a honeycomb structure having high compressive strength and rigidity. The shape of the inorganic sheet core 6 is completely fixed by the sodium silicate, resulting in a core with sufficient flame retardancy, strength, and moisture resistance.In particular, its compressive strength and bending strength are Greatly improved. Furthermore, since the surface is coated with sodium silicate and the main material is aluminum hydroxide, it does not thermally decompose even in high temperature conditions and the core shape does not collapse.

The inorganic sheet core 6 is then cut to a desired size using a sizing cutter and sent to the next filler filling step.

FIG. 3 shows a process diagram for filling the hollow portion of an inorganic sheet core with a filler.

10 and 11 are conveyors on which the above-mentioned inorganic sheet core 6 is horizontally placed and conveyed, and 12 is a hopper arranged above the next stage of the conveyor 10, in which an inorganic material mixed with an aqueous sodium silicate solution is Foam beads can be added. The ratio of sodium silicate aqueous solution (for example, 45% aqueous solution) and inorganic foamed granules is 10 to 20ffii% sodium silicate.
, the amount of inorganic foamed particles is 80 to 901i%.

As the inorganic foamed particles, inorganic balloons such as pearlite particles and shirasu balloons are used.

Below the hopper 12, a support plate 13 is provided with an inorganic sheet core 6.
Immediately after the hopper 12 and the support board 3, press rolls 14 and 15 are arranged so as to rotate while pressing the front and back surfaces of the inorganic sheet core 6 from above and below. The pressure rolls 14, 15 are made of soft rubber, and are driven to rotate at approximately the same speed as the conveyor 1O5it.

Reference numeral 16 denotes a heating drying oven installed next to the pressure rolls 14 and 15, in which the honeycomb structure 1 is transported by the conveyor 11.
7 (Inorganic sheet core 6 filled with inorganic foam particles)
Heat and dry. Note that carbon dioxide gas is supplied into this heating and drying oven 16 to accelerate hardening of the sodium silicate.

Next, to explain the operation of the filling process, the inorganic sheet core 6
is placed horizontally on the conveyor 10 and conveyed, and reaches the top of the support plate 13. Then, the inorganic foam particles mixed with the sodium silicate aqueous solution are dropped from the upper hopper 12 onto the inorganic sheet core 6, and when this inorganic sheet core reaches between the next press rolls 1415, the press rolls 14.15
The inorganic foam particles are pushed into the hollow part of the inorganic sheet core and compressed and filled without any gaps.At this time, since the press rolls 14% and 15 are made of soft rubber, the inorganic sheet core does not buckle. , the inorganic foam particles are reliably pushed into at least the front and back surfaces of the inorganic sheet core.

In this way, the honeycomb structure 17 in which the hollow portions of the inorganic sheet cores are filled with inorganic foam particles is then sent to the heating drying oven 16 by the conveyor 11, and is heated and dried in a carbon dioxide atmosphere. As a result, the sodium silicate in the filler hardens, and the sodium silicate reliably bonds between the inorganic foam particles and between the inorganic sheet core and the inorganic foam particles.
A honeycomb structure 17 as shown in FIG. 4, which is lightweight and has the necessary strength, is completed.

Next, metal plates 1 are placed on the front and back sides of the honeycomb structure 17.
The 6 metal plate 18 to which 8 is bonded (Fig. 5) should be made in such a way that it will not undergo deformation due to structural transformation, etc., or deformation due to release of residual stress up to the normal fire temperature (at least 6° 0°C). It is preferable to use titanium, titanium alloys, and austenitic stainless steel for the former, and well-annealed mild steel and various alloys for the latter. As the adhesive, a heat-curable inorganic adhesive 19 whose main component is alumina, which has good heat resistance, is used.

To bond the metal plate 18, first apply an inorganic adhesive 19 to the contact surface of the honeycomb structure 17, place the metal plate 18 thereon, and dry and harden the adhesive by hot pressing. The adhesive surfaces of the structure 17, that is, its front and back surfaces, are bonded to the soft rubber press roll 14, when filled with inorganic foam particles.
15, and a considerable number of recesses are formed in the cells of the honeycomb, so that the inorganic adhesive 19 penetrates well into these recesses, and sufficient adhesive strength is obtained.

Building material panels constructed in this way are used as external wall panels, screens, or partitions of buildings, but the face plate is a metal plate made of titanium, stainless steel, etc., and the core material is a honeycomb structure. Since it is made from an inorganic sheet core, inorganic foam particles, and sodium silicate, it is lightweight and has sufficient mechanical strength, as well as good corrosion resistance, fire resistance, and heat insulation properties.

That is, if the honeycomb structure 17 is heated to a high temperature via the metal plate 18 in the event of a fire, etc., since the inorganic sheet core 6 is mainly made of aluminum hydroxide and coated with sodium silicate on the surface, Although it carbonizes, it retains its honeycomb shape without thermal decomposition, and the filled inorganic foam particles release crystal water at high temperatures and foam again, and the sodium silicate does not burn out even at high temperatures and functions as a binder. fully accomplish.

Therefore, in the above-mentioned building material panel under Takagata, the filling material of the honeycomb structure 17 is retained in each cell of the honeycomb, and the shape of the entire honeycomb structure is retained without collapsing, and the metal plate of the face plate is 1B is bonded with a heat-resistant inorganic adhesive (for example, a heat-resistant temperature of 1500° C. or higher), so the metal plate 18 will not separate from the honeycomb structure 17 even in the event of a fire, resulting in good heat insulation and fire resistance. It means that they have a sexual nature.

Note that the honeycomb-shaped inorganic sheet core may be coated with aluminum phosphate for reinforcement.

In addition, as a panel surface material, a fireproof board made by forming glass wool into a sheet with low elongation and hardening it with a ceramic coating agent made of adhesive, sodium silicate, aluminum phosphate, etc. can also be used. .

<Effects of the Invention> As explained above, according to the panel for building materials of the present invention,
A honeycomb structure is created by filling the hollow part of a honeycomb-shaped inorganic sheet core made of paper made from aluminum hydroxide as the main raw material and coated with sodium silicate with inorganic foam particles mixed with an aqueous sodium silicate solution. A fireproof board formed into a plate shape mainly made of metal plate or glass wool is adhered to at least one of the front and back sides of the honeycomb structure using a heat-resistant inorganic adhesive, so it is lightweight, has sufficient strength, has heat insulation properties, and is fireproof. It can be made into a panel with a unique character. In particular, even under high temperatures, the inorganic sheet core of the honeycomb structure does not burn out, the sodium silicate sufficiently functions as a binder for the inorganic foam particles, and the metal plate or fireproof board is bonded with a heat-resistant inorganic adhesive. Because of this, in the event of a fire, the metal plates, etc. will not peel off or the honeycomb structure inside the panel will maintain its shape without collapsing, and it has excellent fire resistance and is suitable for use as a panel for external walls of buildings. It can also be used effectively.

[Brief explanation of the drawing]

The figures show examples of the present invention; FIG. 1 is an explanatory diagram of the manufacturing process of an inorganic sheet core; FIG. 2 is a perspective view of the inorganic sheet core; FIG. 3 is an explanatory diagram of the filler filling process; The figure is a plan view of the honeycomb structure, and Figure 5 is a cross-sectional view of the building material panel. 6... Inorganic sheet core, 17... Honeycomb structure, 18... Metal plate, 19... Inorganic adhesive. Patent applicant

Claims (2)

[Claims] (1) A honeycomb structure is created by filling the hollow part of a honeycomb-shaped inorganic sheet core made of base paper made from aluminum hydroxide as the main raw material and coated with sodium silicate with inorganic foam particles mixed with an aqueous solution of sodium silicate. 1. A panel for building materials, characterized in that a metal plate is bonded to at least one of the front and back surfaces of the honeycomb structure using a heat-resistant inorganic adhesive. (2) A honeycomb structure is created by filling the hollow part of a honeycomb-shaped inorganic sheet core made of paper made from aluminum hydroxide as the main raw material and coated with sodium silicate with inorganic foam particles mixed with an aqueous solution of sodium silicate. 1. A building material panel characterized in that a fireproof board made of glass wool and formed into a plate shape is adhered to at least one of the front and back surfaces of the honeycomb structure using a heat-resistant inorganic adhesive.