JPH03258539A - Composite and its manufacture - Google Patents

Abstract

PURPOSE:To obtain a composite whose heat resistance is favorable, by a method wherein a metallic coating layer is formed on a base obtained by molding unitarily an organic matter fiber to an inner wall surface and the outer circumferential surface of which an incombustible inorganic chemical compound is stuck through an adhesive substance containing the incombustible inorganic chemical compound. CONSTITUTION:To perform incombustibility treatment by a method wherein an incombustible inorganic chemical compound is filled into or caused to adhere to or stuck to the inside of a cellular hole and/or an inner wall surface of a ligneous fiber obtained by performing degreasing and softening treatment of lumber chips by steam boiling and the incombustible inorganic chemical compound is stuck to also the outer circumferential part of the ligneous fiber. After formation of an incombustible ligneous fiber mat by mixing an adhesive substance to which the incombustible inorganic chemical compound is compounded with the ligneous fiber which is made incombustible, compression molded and unified and an incombustible ligneous fiber plate is manufactured. Then after a metal is sprayed to at lest one surface of the foregoing fiber plate, a metallic coating layer is formed by cooling the same and a composite is manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a composite material and a method for manufacturing the same, and more particularly to a composite material in which a metal coating layer is formed on a noncombustible organic fiberboard and a method for manufacturing the same.

<Prior art> Japanese Patent Application Laid-open No. 50i2948 discloses hardboard, plywood,
900 on the surface of base materials such as wood, slate, ceramics, etc.
A heat-resistant board is disclosed in which a metal or alloy having a melting point of 1,000 to 16,000 C is thermally sprayed, and a metal or alloy having a melting point of 1,000 to 16,000 C is thermally sprayed thereon. This conventional board is thermally sprayed in two layers and is said to have excellent heat resistance and ice resistance.

<Problems to be Solved by the Invention> Although the heat resistance of the board according to the above-mentioned prior art is improved by the metal layer covering the surface of the base material, if the base material is an organic material such as hardboard, plywood, or wood, The base material itself gradually deteriorates or becomes carbonized due to the influence of heat transmitted through the metal layer, and there is a risk that it will eventually catch fire. For this reason, at present it has not been used as a building material, furniture, or construction member in places such as kitchens.

<Means for Solving the Problems> The present invention was completed through intensive efforts to solve the problems in view of the shortcomings of the prior art. 3. A noncombustible organic fiberboard is obtained, and a metal coating layer is formed by thermally spraying metal onto at least one surface of the noncombustible organic fiberboard and then cooling.

The organic fibers used in the present invention are, for example, softwood materials such as pine, cedar, and cypress, or lauan, capor, chestnut, poplar, etc.
Wood chips are made by appropriately mixing one or more types of hardwood materials such as willow, which are steamed under high-temperature and high-pressure steam to be defatted and softened, and then defibrated using a defibration device, The length of the fiber is 1 to 30 mm, the thickness is 2 in diameter.
The majority are about ~30μ. This organic fiber has the shape of several to dozens of cell pores formed from wood cells, conduit pores, or board duct pores, and the cell walls on the outer periphery of the fiber are torn or cracked. It often occurs. Bayas obtained by defibrating sugar cane, corn stalks, coconut shells, etc. into chips can also be used as an organic fiber.

The obtained organic fibers are dried to reduce their moisture content, so that the inside of the pores and/or the inner wall surface of the cell pores is filled with, adhered to, or fixed with a nonflammable inorganic compound, and the nonflammable inorganic compound is also added to the outer periphery of the organic fiber. A non-combustible organic fiberboard is used as a substrate, which is formed by integrally molding organic fibers to which is attached or fixed via an adhesive substance mixed with a non-combustible inorganic compound that is the same as or different from the above-mentioned non-combustible inorganic compound; This is a composite material characterized by having a metal coating layer formed on at least one surface thereof by a thermal spraying method.

The present invention also provides a method for producing such a composite material, which comprises degreasing and softening wood chips by steaming, then defibrating them to obtain wood fibers, and then obtaining cell pores in the wood fibers. A nonflammable organic fiber is obtained by filling, adhering, or fixing a noncombustible inorganic compound to the inside and/or inner wall surface of the cell pores, and also adhering or fixing the noncombustible inorganic compound to the outer periphery of the organic fiber. A nonflammable organic fiber mat is formed by mixing an adhesive substance mixed with a nonflammable inorganic compound that is the same as or different from the above nonflammable inorganic compound, and then the mat is compressed and molded into one piece and adjusted to about 7 to 15%. be done.

A nonflammable inorganic compound is filled in the voids such as cell pores and conduit pores of the dried organic fiber, or the nonflammable inorganic compound is fixed or adhered in a layer along the inner wall of the cell pore, and then the organic fiber is Nonflammability treatment is performed by fixing or adhering the nonflammable inorganic compound to the outer periphery as well. This nonflammability treatment can be performed, for example, by the following steps. That is, the organic fibers are sufficiently immersed in an aqueous solution of a water-soluble inorganic salt (hereinafter referred to as "first solution") to impregnate it. On this occasion,
It is effective to forcibly accelerate the impregnation treatment by applying reduced pressure or increased pressure. Alternatively, the organic fibers may be brought into a high moisture content state without drying, or after drying, they may be immersed in water or hot water to absorb water to become saturated with water, and then immersed in the first liquid for diffusion impregnation. It's okay. As the first liquid, M
gCQ2゜MgB r! + MgS O4”H20, M
g(N O3)2' 6 H20.

Al2Cl28. Al2Br3. Al22(S 0
4) 31AQ(N Os)a・9 HzO, CaCO2
, CaBr2゜Ca(N Os ) 21 Z n C
(i 2 + B a B r @ + Ba (j22”
Examples include aqueous solutions such as 2H20 and Ba(No3)2.

By immersing the organic fiber in the first liquid, ions of the inorganic salt of the solute diffuse into the cell pores of the organic fiber.

Next, a dewatering process is performed to remove the excess first liquid. The liquid removal treatment is carried out by means such as centrifugal dehydration, java or dobuzuke washing, etc., and by removing the excess first liquid, it is possible to avoid excessive production of nonflammable inorganic compounds on the surface of the organic fibers. suppresses and improves diffusion impregnation of the aqueous solution to be impregnated next. It also prevents nonflammable inorganic compounds from being produced in a free state that is not attached or fixed to organic fibers.

Next, a compound liquid that reacts with the first liquid to produce a water-insoluble, nonflammable inorganic compound (hereinafter referred to as the "second liquid") is added to and mixed with the organic fibers using a blender, spray, etc., or immersed. The organic fibers are impregnated with the second liquid by allowing the organic fibers to soak. As in the case of the first liquid, impregnation of the second liquid into the organic fibers is promoted by a reduced pressure or pressurized treatment.

After the reaction is completed, the excess second liquid is removed by centrifugal deliquidation or by washing with water using a shower, soaking, or the like. The second liquid immersion process and the liquid removal process may be repeated multiple times as necessary. After the liquid removal treatment, it is dried to a moisture content of 25% or less, preferably 7 to 15%. Since this nonflammable inorganic compound is water-insoluble, after drying, it is filled in, adhered to, or fixed to the inside of the cell pores of the organic fiber or the inner wall surface of the cell pore, and is also attached to or fixed to the outer periphery of the organic fiber. As a result, the nonflammable inorganic compound is present in a form that blocks or fills the pores and cracks appearing on the surface of the organic fibers.

It is preferable that the nonflammable inorganic compound is mixed in at a ratio of 33% by weight or more based on the organic fibers, and if it is less than this, sufficient fireproof performance cannot be obtained. Further, in order to increase the reaction efficiency between the first liquid and the second liquid, it is preferable to add and mix the second liquid under a heated atmosphere, particularly at a temperature of 40°C or higher, more preferably 50°C or higher. As the second liquid, Na
2 COs +H2S O4, (NH4)2 CO3
, N a 2 S O4.

(NH4)2sOt, H2POa+ Na2HPO4° (NH4)2HP04+ H3BOs, NaBO2°N
Examples include H, BO2, etc. By applying or dipping the second liquid, the second liquid is diffused and impregnated into the cell pores of the organic fiber, and the first liquid and the second liquid react in the organic fiber to generate a nonflammable inorganic compound. .

The nonflammable inorganic compounds produced are magnesium phosphate, calcium phosphate, and barium phosphate.

Aluminum phosphate, magnesium borate, magnesium carbonate, calcium carbonate, zinc phosphate, barium carbonate,
Calcium compounds such as calcium nitrate and barium nitrate,
Examples include magnesium compounds, aluminum compounds, barium compounds, lead compounds, zinc compounds, and silicate compounds. For example, if the reaction is performed using barium chloride as the first liquid and ammonium hydrogen phosphate as the second liquid,
Barium cations and phosphate anions react,
Barium phosphate and barium hydrogen phosphate are recommended. Further, by immersing the organic fibers in the first and second liquids in a warm water state, or by applying electrical or mechanical vibrations using ultrasonic waves, vibrators, etc. when immersing the first and second liquids, Diffusion and reaction of the treatment liquid into the organic fibers are carried out well. Note that the order of processing with the first liquid and the second liquid does not matter, and it goes without saying that the processing with the second liquid may be performed first.

In this way, a nonflammable inorganic compound is fixed within the cell pores or on the inner wall surface, and a nonflammable inorganic compound is also fixed or attached to the outer periphery of the cell pore, thereby obtaining an organic fiber treated to be nonflammable.

Next, this nonflammable organic fiber is put into a mixing device, and an adhesive substance mixed with a nonflammable inorganic compound is added and adhered thereto. The nonflammable inorganic compound mixed into the adhesive substance may be of the same kind as that produced by the reaction of the first liquid and the second liquid, or may be of a different type. (1st liquid if treatment with 2 liquids precedes)
Since the nonflammable inorganic compounds produced in excess are precipitated in the treatment tank, it is efficient and economical to collect them and mix them into the adhesive material. Alternatively, the excess noncombustible inorganic compound that falls off and accumulates during drying after the noncombustibility treatment may be collected, dried and sieved as necessary, and then mixed into the adhesive material.

As the adhesive substance, synthetic resin adhesives such as urea resin, melamine resin, incyanate, urethane resin, epoxy resin, vinyl acetate resin, phenol resin, or modified resins thereof are preferably used.

The noncombustible organic fibers to which the adhesive substance has been attached are conveyed by air to form a noncombustible organic fiber mat, which is then cut and integrated by hot pressure molding to obtain a noncombustible organic fiberboard.

The moisture content of this noncombustible organic fiberboard is preferably 20% or less. The reason for this is that if the water content is 20% or more, the internal water on the sprayed surface side will evaporate and move to the opposite side due to the influence of the heat during metal spraying, causing an internal balance to be disrupted, making it impossible to combust during metal spraying. This is because the organic fiberboard itself tends to warp with the sprayed surface side concave.

After sanding the surface of the obtained noncombustible organic fiberboard (the side on which the metal coating layer will later be formed) as necessary, a necessary amount of molten metal is sprayed using a thermal sprayer.

Metallic spraying can be carried out not only on the front surface of the noncombustible organic fiberboard, but also on necessary parts such as the back surface, end surface, etc., or to cover the entire surface. It is preferable that the temperature of the surface of the noncombustible organic fiberboard on which metal spraying is performed is 40 to 100°0. It is preferable to perform metal spraying after at least warming the temperature of the surface of the noncombustible organic fiberboard on which the metal coating layer is to be formed. If the temperature is below 40°C, the sprayed molten metal will immediately cool and solidify, so that the adhesion force due to the anchoring effect to the coated surface of the noncombustible organic fiberboard will not be sufficiently exerted.

Further, if the temperature is 100° C. or higher, the influence of the temperature of the molten metal is strong, and the surface of the noncombustible organic fiberboard is deteriorated, resulting in a decrease in adhesion. Metals to be thermally sprayed include tin, lead,
zinc, copper, brass, bronze, aluminum, nickel, iron,
Metal alloys such as stainless steel are preferably used. As the thermal spraying method, any of the commonly used electric wire spraying method, gas wire thermal spraying method, and powder spraying method may be employed. The sprayed metal is solidified by subsequent cooling, and a metal coating layer is formed in close contact with the surface of the organic fiberboard.

<Function> Heat resistance is improved by the metal coating layer formed on the surface of the noncombustible organic fiberboard. A noncombustible organic fiberboard has a noncombustible inorganic compound filled in, attached to, or fixed to the cell pores of organic fibers or the inner wall surface of the cell pores, and also has a noncombustible inorganic compound attached to or fixed to the outer periphery thereof. Furthermore, since a nonflammable inorganic compound is mixed into the adhesive material used to form the organic fibers into fiberboard, the heat transmitted through the metal coating layer causes It will not deteriorate or carbonize.

<Example> The wood fibers obtained by steaming lauan chips at 170°C and 7 kg/cm2 for 3 minutes and then defibrating them using a defibrator type refiner were added to an aqueous solution containing barium chloride as the main two components under reduced pressure. After soaking for 15 minutes in
Excess barium chloride was removed by centrifugation between the lines.

Next, the wood fibers are immersed in an aqueous solution containing ammonium phosphate as the main component for 20 minutes under reduced pressure to react with barium chloride, thereby injecting water-insoluble substances into the cell pores and the outer periphery of the wood fibers. A nonflammable inorganic compound made from barium phosphate and barium hydrogen phosphate was filled, adhered, or fixed to make it nonflammable, and then centrifugal deliquification was performed for 30 seconds to remove excess nonflammable inorganic compounds. . The wood fibers were also washed with water at the same time.

The wood fibers were then dried in a hot air drying oven at 130°C to adjust the moisture content of the wood fibers to 10%. The weight increase rate due to the nonflammable inorganic compound produced by this nonflammability treatment was 73%.

The thus obtained non-combustible wood fibers were put into a blender, mixed with 7% melamine resin adhesive containing 5% barium phosphate, blown with air, and formed into a non-combustible wood fiber mat using a forming device. did.

After cutting this non-combustible wood fiber to a certain size, hot press')A
A noncombustible organic fiberboard with a specific gravity of 0.75 was obtained by inserting it into an A-space and hot pressing at 170°C for 3 minutes.

The obtained noncombustible organic fiberboard was subjected to a quasi-nonflammable test according to JIS and passed.

Molten aluminum metal having a melting point of 660°C is sprayed by a powder spraying method while the surface temperature of the noncombustible organic fiberboard is 50°C, and is then cooled to form an aluminum metal coating layer. A composite material was obtained.

<Effects of the Invention> The composite material according to the present invention has excellent heat resistance and water resistance due to the formation of a metal coating layer on the surface of the organic fiberboard, and the organic fiberboard that is the base material is made of organic material treated to make it incombustible. Because it is obtained by integrally molding fibers with a nonflammable adhesive, it will not deteriorate or carbonize due to heat transmitted through the metal coating layer, and there is no risk of ignition over a long period of time. Therefore, it can be suitably used widely as a building material or furniture/building member even in places where fire is used, such as kitchens.

Claims (3)

[Claims] (1) A nonflammable inorganic compound is filled in, attached to, or fixed to the cell pores of the organic fiber and/or to the inner wall surface of the cell pore, and the nonflammable inorganic compound is also attached to or fixed to the outer periphery of the organic fiber. A nonflammable organic fiberboard is used as a substrate, which is formed by integrally molding organic fibers mixed with the same or different nonflammable inorganic compound as the above nonflammable inorganic compound, and on at least one surface of the substrate, A composite material characterized by a metal coating layer formed by thermal spraying. (2) Wood chips are degreased and softened by steaming, then defibrated to obtain wood fibers, and then a nonflammable inorganic compound is filled, attached, or fixed to the cell pores and/or the inner wall surface of the cell pores of the wood fibers. At the same time, the nonflammable inorganic compound is also attached or fixed to the outer periphery of the organic fiber, and the nonflammable organic fiber obtained in this way is mixed with a nonflammable inorganic compound that is the same as or different from the above nonflammable inorganic compound. After mixing to form a noncombustible organic fiber mat, this is pressed and molded into a single piece to form a noncombustible organic fiberboard, and then a metal is sprayed on at least one surface of the noncombustible organic fiberboard and then cooled. A method for producing a composite material, comprising forming a metal coating layer by. (3) The metal spraying is performed at a temperature of the noncombustible organic fiberboard at a temperature of 40 to 100°C.
A method for manufacturing a composite material according to claim 2.