JPH037312A - Manufacture of phenol resin foam of core member-reinforcing resol type - Google Patents
Manufacture of phenol resin foam of core member-reinforcing resol typeInfo
- Publication number
- JPH037312A JPH037312A JP1142429A JP14242989A JPH037312A JP H037312 A JPH037312 A JP H037312A JP 1142429 A JP1142429 A JP 1142429A JP 14242989 A JP14242989 A JP 14242989A JP H037312 A JPH037312 A JP H037312A
- Authority
- JP
- Japan
- Prior art keywords
- resol type
- phenolic resin
- type phenolic
- core member
- core
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000006260 foam Substances 0.000 title claims abstract description 50
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 239000005011 phenolic resin Substances 0.000 title abstract description 22
- 229920003987 resole Polymers 0.000 title abstract description 9
- 238000005187 foaming Methods 0.000 claims abstract description 35
- 239000007788 liquid Substances 0.000 claims abstract description 19
- 239000011248 coating agent Substances 0.000 claims abstract description 7
- 238000000576 coating method Methods 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims abstract description 7
- 239000011134 resol-type phenolic resin Substances 0.000 claims description 46
- 239000000463 material Substances 0.000 claims description 40
- 239000011162 core material Substances 0.000 claims description 37
- 239000011550 stock solution Substances 0.000 claims description 23
- 239000003795 chemical substances by application Substances 0.000 abstract description 6
- 229920005989 resin Polymers 0.000 abstract description 5
- 239000011347 resin Substances 0.000 abstract description 5
- 238000002156 mixing Methods 0.000 abstract description 4
- 239000000203 mixture Substances 0.000 abstract description 4
- 239000003381 stabilizer Substances 0.000 abstract description 4
- 238000007599 discharging Methods 0.000 abstract description 3
- 239000004088 foaming agent Substances 0.000 abstract description 3
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 13
- 229920001568 phenolic resin Polymers 0.000 description 13
- 239000000123 paper Substances 0.000 description 11
- 239000000843 powder Substances 0.000 description 6
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 5
- 239000000243 solution Substances 0.000 description 5
- 229920003986 novolac Polymers 0.000 description 4
- 239000010680 novolac-type phenolic resin Substances 0.000 description 4
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 239000006071 cream Substances 0.000 description 3
- 239000004604 Blowing Agent Substances 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- ADCOVFLJGNWWNZ-UHFFFAOYSA-N antimony trioxide Chemical compound O=[Sb]O[Sb]=O ADCOVFLJGNWWNZ-UHFFFAOYSA-N 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 239000012774 insulation material Substances 0.000 description 2
- 239000002985 plastic film Substances 0.000 description 2
- BOSAWIQFTJIYIS-UHFFFAOYSA-N 1,1,1-trichloro-2,2,2-trifluoroethane Chemical compound FC(F)(F)C(Cl)(Cl)Cl BOSAWIQFTJIYIS-UHFFFAOYSA-N 0.000 description 1
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 1
- 239000010425 asbestos Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000003610 charcoal Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 125000000853 cresyl group Chemical class C1(=CC=C(C=C1)C)* 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- GYZLOYUZLJXAJU-UHFFFAOYSA-N diglycidyl ether Chemical compound C1OC1COCC1CO1 GYZLOYUZLJXAJU-UHFFFAOYSA-N 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- NBVXSUQYWXRMNV-UHFFFAOYSA-N fluoromethane Chemical compound FC NBVXSUQYWXRMNV-UHFFFAOYSA-N 0.000 description 1
- 239000011888 foil Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012948 isocyanate Substances 0.000 description 1
- 150000002513 isocyanates Chemical class 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000007522 mineralic acids Chemical class 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 239000002736 nonionic surfactant Substances 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 235000006408 oxalic acid Nutrition 0.000 description 1
- 150000002989 phenols Chemical class 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000005057 refrigeration Methods 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 229910052895 riebeckite Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- JOXIMZWYDAKGHI-UHFFFAOYSA-N toluene-4-sulfonic acid Chemical compound CC1=CC=C(S(O)(=O)=O)C=C1 JOXIMZWYDAKGHI-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/20—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of indefinite length
- B29C44/32—Incorporating or moulding on preformed parts, e.g. linings, inserts or reinforcements
- B29C44/326—Joining the preformed parts, e.g. to make flat or profiled sandwich laminates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/60—Multitubular or multicompartmented articles, e.g. honeycomb
- B29L2031/608—Honeycomb structures
Landscapes
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【発明の詳細な説明】
［産業上の利用分野］
本発明は、芯材強化レゾール型フェノール樹脂発泡体の
製造方法に関する。本発明の方法により得られた芯材強
化レゾール型フェノール樹脂発泡体は、車輌、船舶、航
空機等の内装材、冷凍、冷蔵倉庫のパネル、天井材、ク
リーンルーム用パネル、ドア、ふすま、床下地断熱材、
内装間仕切材、屋根下地断熱材、屋上断熱材等に好まし
く用いられる。DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method for producing a core-reinforced resol type phenolic resin foam. The core-reinforced resol type phenolic resin foam obtained by the method of the present invention can be used as interior materials for vehicles, ships, aircraft, etc., panels for refrigeration and refrigerated warehouses, ceiling materials, clean room panels, doors, sliding doors, and floor insulation. wood,
It is preferably used for interior partitioning materials, roof base insulation materials, rooftop insulation materials, etc.
［従来の技術］
芯材強化フェノール樹脂発泡体として、芯材がハニカム
形状のセル構造を有し、このセル内にフェノール樹脂発
泡体が充填されているものが知られており、この公知の
芯材強化フェノール樹脂発泡体は、芯材の前記セル内に
、粉末状の発泡性ノボラック型フェノール樹脂を、得ら
れる発泡体の所望密度に応じた量だけ充填し、加熱プレ
ス間で発泡硬化させることにより得られている。[Prior Art] As a core material reinforced phenolic resin foam, one in which the core material has a honeycomb-shaped cell structure and the cells are filled with a phenolic resin foam is known. The material-reinforced phenolic resin foam is obtained by filling the cells of the core material with a powdered expandable novolac type phenol resin in an amount corresponding to the desired density of the resulting foam, and then foaming and hardening it between heated presses. It is obtained by
［発明が解決しようとする課題］
粉末状の発泡性ノボラック型フェノール樹脂を使用する
場合、芯材のハニカム構造の各セル内に均一にノボラッ
ク型フェノール樹脂の粉末を分配する困難さや粉末の周
辺への飛散等の問題があった。[Problems to be Solved by the Invention] When using powdered foamable novolac phenolic resin, there are difficulties in uniformly distributing the novolac phenolic resin powder within each cell of the honeycomb structure of the core material, and problems surrounding the powder. There were problems such as scattering of water.
またノボラック型フェノール樹脂の粉末を芯材の各セル
内に均一に分配することができないことから、得られた
発泡体の密度が均一でないという問題があった。Furthermore, since the powder of the novolac type phenolic resin cannot be uniformly distributed within each cell of the core material, there is a problem that the density of the obtained foam is not uniform.
従って本発明の目的は、粉末状のノボラック型フェノー
ル樹脂を用いる上述の従来方法の諸問題点を解消した芯
材強化フェノール樹脂発泡体の製造方法を提供すること
にある。Accordingly, an object of the present invention is to provide a method for producing a core-reinforced phenolic resin foam that eliminates the problems of the above-mentioned conventional methods using powdered novolac-type phenolic resins.
［課題を解決するだめの手段］
粉末状のノボラック型フェノール樹脂の代りに液状のレ
ゾール型フェノール樹脂を用いれば、粉末状のノボラッ
ク型フェノール樹脂を用いた場合に認められる粉末の周
辺への飛散の問題は解消できるが、液状のレゾール型フ
ェノール樹脂を芯材の各セル内に均一に分配することは
、液状のレゾール型フェノール樹脂を直接セル内に注入
するという通常の方法では粉末状のノボラック型フェノ
ール樹脂を用いる場合と同様に困難であった。[Means to solve the problem] If a liquid resol type phenolic resin is used instead of a powdered novolac type phenolic resin, scattering of the powder to the surroundings, which is observed when using a powdered novolac type phenolic resin, can be avoided. Although the problem can be solved, it is difficult to uniformly distribute the liquid resol type phenolic resin into each cell of the core material. The difficulty was similar to that when using phenolic resin.
そこで本発明者らは、液状のレゾール型フェノール樹脂
を芯材の各セル内に均一に分配させた後、発泡硬化させ
て、密度の均一な芯材強化レゾール型フェノール樹脂発
泡体を製造する方法を見い出すべく検討を重ねた。Therefore, the present inventors have developed a method for producing a core-reinforced resol-type phenolic resin foam with uniform density by uniformly distributing liquid resol-type phenolic resin into each cell of the core material and then foaming and curing the resin. We conducted repeated studies to find out.
その結果、面材の一面に液状のレゾール型フェノール樹
脂を含有する発泡性原液をコーティングした後、面材の
レゾール型フェノール樹脂発泡性原液コーティング面を
、所定形状のセル構造を有する芯材の上面に当接して押
圧し、一方、前記所定形状のセル構造を有する芯材の下
面には別の面材を圧接し、前記レゾール型フェノール樹
脂発泡性原液を、前記芯材のセル内で発泡硬化させるこ
とにより、前記の液状樹脂の分配の問題が解消し、密度
の均一な芯材強化レゾール型フェノール樹脂発泡体が得
られることを見い出した。As a result, after coating one side of the face material with a foaming stock solution containing liquid resol type phenolic resin, the surface coated with the resol type phenolic resin foaming stock solution of the face material was coated on the top surface of the core material having a cell structure of a predetermined shape. On the other hand, another surface material is pressed against the lower surface of the core material having a cell structure of a predetermined shape, and the resol type phenolic resin foaming stock solution is foamed and hardened within the cells of the core material. It has been found that by doing so, the above-mentioned problem of liquid resin distribution can be solved and a core-reinforced resol type phenolic resin foam with uniform density can be obtained.
従って本発明の芯材強化レゾール型フェノール樹脂発泡
体の製造方法は、面材の一面に液状のレゾール型フェノ
ール樹脂を含有する発泡性原液をコーティングした後、
面材のレゾール型フェノール樹脂発泡性原液コーティン
グ面を、所定形状のセル構造を有する芯材の上面に当接
して押圧し、一方、前記所定形状のセル構造を有する芯
材の下面には別の面材を圧接し、前記レゾール型フェノ
ール樹脂発泡性原液を、前記芯材のセル内で発泡硬化さ
せることを特徴とする。Therefore, the method for producing a core-reinforced resol-type phenolic resin foam of the present invention involves coating one side of the face material with a foaming stock solution containing a liquid resol-type phenolic resin, and then
The surface of the face material coated with a resol-type phenolic resin foaming solution is brought into contact with and pressed against the upper surface of the core material having a cell structure of a predetermined shape, while the lower surface of the core material having a cell structure of a predetermined shape is coated with another The method is characterized in that the face material is pressed against the surface material and the resol type phenolic resin foamable stock solution is foamed and hardened within the cells of the core material.
以下、本発明の芯材強化レゾール型フェノール樹脂発泡
体の製造方法を第１図に基いて説明する。Hereinafter, a method for producing a core-reinforced resol type phenolic resin foam according to the present invention will be explained with reference to FIG.
液状レゾール型フェノール樹脂に整泡剤等を加えたレゾ
ール型フェノール樹脂組成物１、発泡剤２および硬化剤
３の所定量を混合吐出機４に供給混合して発泡性原液５
を得た後、混合吐出機４の吐出口から発泡性原液５を、
上面材６の一面に吐出し、ドクターナイフ７により均一
に所望の幅まで素早く延展して所定量の発泡性原液５を
上面材６の一面にコーティングする。その後、受はロー
ル８を経た上面材６をコーティング面を下にして、支持
ロール１１および１２によって支持されっつ運搬される
芯材９の上面に加圧ロール１０によって当接させる。芯
材を構成するセル形状上しては、ハニカム（六角形）、
正方形、長方形、三角形等の形状が挙げられる。A predetermined amount of resol type phenolic resin composition 1, foaming agent 2, and curing agent 3, which is a liquid resol type phenolic resin added with a foam stabilizer, etc., is supplied to a mixing and discharging machine 4 and mixed to form a foaming stock solution 5.
After obtaining the foaming stock solution 5 from the discharge port of the mixing discharge machine 4,
It is discharged onto one surface of the top material 6 and quickly spread uniformly to a desired width using a doctor knife 7 to coat one surface of the top material 6 with a predetermined amount of the foaming stock solution 5. Thereafter, the receiver brings the top material 6 which has passed through the rolls 8, with the coating side down, into contact with the top surface of the core material 9, which is supported and conveyed by support rolls 11 and 12, by means of a pressure roll 10. The cell shapes that make up the core material are honeycomb (hexagonal),
Examples include shapes such as square, rectangle, and triangle.
一方、別の面材１３を芯材９の下面に支持ロール１２に
よって当接させる。上下両面に面材を当接させた芯材を
、上下２個の回動式エンドレスベルト１４．１５に挟圧
固定したまま硬化炉１６に導入し、上面材にコーティン
グされた発泡性原液５を、芯材９のセル内の下方に移行
させつつ、発泡硬化し、レゾール型フェノール樹脂発泡
体をセル内に充填させる。硬化炉１２を出た芯材強化レ
ゾール型フェノール樹脂発泡体をカッター１７で切断し
、所望寸法の芯材強化レゾール型フェノール樹脂発泡体
製品１８を得る。On the other hand, another face material 13 is brought into contact with the lower surface of the core material 9 by the support roll 12. The core material with face materials in contact with the upper and lower surfaces is introduced into the curing furnace 16 while being clamped and fixed between the upper and lower two rotating endless belts 14 and 15, and the foaming stock solution 5 coated on the top material is introduced into the curing furnace 16. , while moving downward into the cells of the core material 9, the foam is cured and the resol type phenolic resin foam is filled into the cells. The core-reinforced resol-type phenolic resin foam that has come out of the curing furnace 12 is cut by a cutter 17 to obtain a core-reinforced resol-type phenolic resin foam product 18 of desired dimensions.
以上説明した本発明の方法によれば、発泡性原液が、上
面材に均一のコーティングされる結果、芯材の各セル内
に均一に分配されるので、得られた芯材強化レゾール型
フェノール樹脂発泡体の発泡状態、密度が均一であると
いう利点がある。また本発明の方法により得られる他の
利点として、芯材強化レゾール型フェノール樹脂発泡体
の連続生産が可能であることが挙げられる。According to the method of the present invention described above, the foaming stock solution is uniformly coated on the top material and is evenly distributed within each cell of the core material, so that the resulting core material reinforced resol type phenolic resin It has the advantage that the foam state and density of the foam are uniform. Another advantage obtained by the method of the present invention is that continuous production of core-reinforced resol type phenolic resin foam is possible.
発泡体の原料である液状のレゾール型フェノール樹脂と
しては、未変性のレゾール型フェノール樹脂を用いても
良く、また未変性のレゾール型フェノール樹脂を、ウレ
タン樹脂、メラミン樹脂、エポキシ樹脂、ポリエステル
樹脂、熱可塑性樹脂等で変性した変性レゾール型フェノ
ール樹脂を用いても良い。このレゾール型フェノール樹
脂を含む発泡性原液の粘度は１，０００〜１５，０００
ｃｐｓの範囲が好ましい。その理由は粘度が１゜０００
ｃｐｓより低いと流動性が高すぎて、発泡性原液を芯材
に均一にコーティングすることが出来ず、また１５．０
００ｃｐｓより高いと流動性が低すぎて、発泡性原液を
均一にコーティングすることがが出来ないので、いずれ
の場合も芯材のセル内に発泡体を均一に充填しにくくな
るからである。好ましい粘度は２，０００〜８，０００
ｃｐｓ、特に好ましい粘度は３，０００〜６，００Ｑｃ
ｐｓである。As the liquid resol type phenolic resin that is the raw material for the foam, unmodified resol type phenolic resin may be used, and unmodified resol type phenolic resin may be used as urethane resin, melamine resin, epoxy resin, polyester resin, A modified resol type phenol resin modified with a thermoplastic resin or the like may also be used. The viscosity of the foaming stock solution containing this resol type phenolic resin is 1,000 to 15,000.
cps range is preferred. The reason is that the viscosity is 1°000
If it is lower than 15.0 cps, the fluidity is too high and the core material cannot be uniformly coated with the foaming stock solution.
If it is higher than 00 cps, the fluidity is too low and it is impossible to uniformly coat the foaming stock solution, so in either case it becomes difficult to uniformly fill the cells of the core material with the foam. Preferred viscosity is 2,000 to 8,000
cps, particularly preferred viscosity is 3,000 to 6,00Qc
It is ps.
前記フェノール樹脂に添加される整泡剤としては例えば
シリコーン系非イオン界面活性剤が使用される。さらに
必要に応じて他の界面活性剤、充填剤、難燃剤、金属腐
食防止剤等を配合しても良い。フェノール樹脂を発泡さ
せるだめの発泡剤としてはフルオロカーボン等が用いら
れる。また硬化剤としては無機酸、有機酸、多価フェノ
ール、フェノールオリゴマー、イソシアネート等が用い
られる。発泡性原液の調製から発泡が開始されるまでの
時間をクリームタイムと言い、このクリームタイム以内
に、発泡性原液を面材にコーティングする必要があるが
、このクリームタイムは通常短かいので、既に述べたよ
うに発泡剤と硬化剤とは、面材にコーティングする直前
にフェノール樹脂に添加するのが好ましい。As the foam stabilizer added to the phenolic resin, for example, a silicone nonionic surfactant is used. Furthermore, other surfactants, fillers, flame retardants, metal corrosion inhibitors, etc. may be added as necessary. Fluorocarbon or the like is used as a foaming agent for foaming the phenolic resin. Further, as the curing agent, inorganic acids, organic acids, polyhydric phenols, phenol oligomers, isocyanates, etc. are used. The time from the preparation of the foaming stock solution to the start of foaming is called cream time, and it is necessary to coat the surface material with the foaming stock solution within this cream time, but since this cream time is usually short, As mentioned, the blowing agent and curing agent are preferably added to the phenolic resin immediately before coating the facing material.
芯材としては、既に述べたようにハニカム（六角形）、
正方形、長方形、三角形等の所定形状のセル構造を有す
るものが好ましく、特にハニカム形状のセル構造を有す
る芯材、例えばペーパーハニカム、樹脂含浸ペーパーハ
ニカム、無機質ペーパーハニカム、アルミニウムハニカ
ム等が好適に使用される。As the core material, as already mentioned, honeycomb (hexagonal),
Those having a cell structure in a predetermined shape such as a square, rectangle, or triangle are preferred, and core materials having a honeycomb-shaped cell structure, such as paper honeycomb, resin-impregnated paper honeycomb, inorganic paper honeycomb, aluminum honeycomb, etc., are particularly preferably used. Ru.
面材（上面材および下面材）としてはクラフト紙、プラ
スチックフィルム、プラスチックシート等の有機質系面
材や、珪カル紙、アスベスト紙、炭カル紙、ガラスペー
パー、アルミ箔、アルミ蒸着紙、銅板等の無機質系面材
、さらにはこれらの複合積層シート等が使用される。面
材のうち、上面材と下面材とは同種のものであっても異
種のものであってもよい。通常、面材は発泡性原液の発
泡硬化後もそのまま芯材の表面に張着したまま使用され
るが、必要に応じて離型タイプの面材を使用し発泡硬化
後に面材を剥離することもできる。Surface materials (top and bottom materials) include organic surface materials such as kraft paper, plastic film, and plastic sheets, silica paper, asbestos paper, charcoal paper, glass paper, aluminum foil, aluminum vapor-deposited paper, copper plate, etc. Inorganic surface materials, composite laminated sheets of these materials, etc. are used. Among the facing materials, the upper facing material and the lower facing material may be of the same type or different types. Normally, the face material is used while remaining attached to the surface of the core material even after the foaming stock solution has foamed and hardened, but if necessary, a releasable face material can be used and the face material can be peeled off after the foam has hardened. You can also do it.
液状レゾール樹脂を面材にコーティングした後、セル内
で発泡硬化する本発明の方法により得られた芯材強化レ
ゾール型フェノール樹脂発泡体は、液状レゾール型フェ
ノール樹脂を芯材のセル内に直接注入した後、発泡硬化
する方法で得られた芯材強化レゾール型フェノール樹脂
発泡体よりも、各セル内における発泡状態が均一であり
、従って密度も均一であるという利点を有する。またレ
ゾール型フェノール樹脂発泡体自身が本来保有する性質
をそのまま保有している。The core-reinforced resol-type phenolic resin foam obtained by the method of the present invention, in which the liquid resol resin is coated on the face material and then foamed and cured within the cells, is obtained by directly injecting the liquid resol-type phenolic resin into the cells of the core material. Compared to a core-reinforced resol type phenolic resin foam obtained by foaming and curing after foaming, this foam has the advantage that the foaming state in each cell is uniform, and therefore the density is also uniform. Furthermore, the resol type phenolic resin foam itself retains its original properties.
［実施例コ 以下、実施例により本発明を更（４説明する。[Example code] The present invention will be further explained below with reference to Examples.
フェノール８４重量部、３７％ホルマリン５５８重量部
および水酸化カルシウム１１．１重量部をフラスコに入
れ９０℃で６０分間等温反応させ、続いて臭素化クレー
ゾールモノグリシジルエーテル８５重量部を添加し、さ
らに２０分間反応させた後、反応液のｐＨが７．０〜７
．３になるようにシュウ酸を添加し、反応液を中和し、
減圧下８０℃で脱水し、固形分８９重量％、３０℃にお
ける粘度５７００ｃｐｓ、遊離フェノール３．０重量％
、遊離ホルムアルデヒド１．９重量％の液状レゾール型
フェノール樹脂液を得た。この樹脂液１００重量部に、
整泡剤（ユニオンカーバイド社製Ｌ５３４０）０．２重
量部、難燃剤（三酸化アンチモン）１０重量部を添加し
て液状レゾール型フェノール樹脂組成物を得た。次にこ
の樹脂組成物に発泡剤（トリクロロトリフロロエタン）
２０重量部、硬化剤（パラトルエンスルホン酸）１５重
量部を添加した。さらに配合物のｐＨがほぼ中性となる
ようにｐＨＦｌ整剤を加えて発泡性原液を得、この発泡
性原液を混合吐出機の吐出口から、上面材（珪酸カルシ
ウム３３重量％、パルプ３０重量％、ガラス繊維３重量
％、水酸化アルミニウム３０重量％、結合剤３重量％お
よび定着剤１重量％からなる無機抄造紙）の−面に吐出
し、発泡硬化後のフオーム密度が４２ｋｇ／ｒｒ？にな
るようドクターナイフにより均一に発泡性原液をコーテ
ィングした。次いで上面材の発泡性原液コーティング面
を、第２図にその斜視図に示すハニカム形状のセル構造
を有する芯材（密度２６ｋｇ／ｒｒｆ’、厚み２０ｍｍ
：昭和飛行機工業■品番９−Ｇ−１０のペーパーハニカ
ム）の上面に加圧ロールにより当接する。一方、下面材
（上面材と同一の無機抄造紙）を同一の芯材の下面にロ
ールにより当接する。84 parts by weight of phenol, 558 parts by weight of 37% formalin and 11.1 parts by weight of calcium hydroxide were placed in a flask and reacted isothermally at 90°C for 60 minutes, then 85 parts by weight of brominated cresol monoglycidyl ether was added, and After reacting for 20 minutes, the pH of the reaction solution is 7.0-7.
．． Add oxalic acid to a concentration of 3 to neutralize the reaction solution,
Dehydrated at 80°C under reduced pressure, solid content 89% by weight, viscosity at 30°C 5700 cps, free phenol 3.0% by weight
A liquid resol type phenol resin solution containing 1.9% by weight of free formaldehyde was obtained. To 100 parts by weight of this resin liquid,
A liquid resol type phenolic resin composition was obtained by adding 0.2 parts by weight of a foam stabilizer (L5340 manufactured by Union Carbide) and 10 parts by weight of a flame retardant (antimony trioxide). Next, a blowing agent (trichlorotrifluoroethane) is added to this resin composition.
20 parts by weight and 15 parts by weight of a curing agent (para-toluenesulfonic acid) were added. Furthermore, a pHFl adjuster is added to make the pH of the mixture almost neutral to obtain a foaming stock solution, and this foaming stock solution is poured into the top material (calcium silicate 33% by weight, pulp 30% by weight) from the discharge port of the mixing and discharging machine. %, glass fiber 3% by weight, aluminum hydroxide 30% by weight, binder 3% and fixing agent 1% by weight) and the foam density after foaming and curing was 42 kg/rr? The foaming stock solution was coated uniformly with a doctor knife so that Next, the foaming solution coated surface of the top material was coated with a core material (density 26 kg/rrf', thickness 20 mm) having a honeycomb-shaped cell structure shown in a perspective view in FIG.
: Showa Aircraft Industry ■Paper honeycomb of product number 9-G-10) is brought into contact with the top surface of the paper honeycomb by a pressure roll. On the other hand, a lower surface material (the same inorganic paper as the upper surface material) is brought into contact with the lower surface of the same core material using a roll.
上下両面に前記上下面材を当接した、ハニカム形状のセ
ル構造を有する芯材を上下のエンドレスベルトに挟圧し
たまま硬化炉に送り、加熱することにより発泡硬化した
。The core material having a honeycomb-shaped cell structure with the upper and lower surface materials in contact with the upper and lower surfaces was sent to a curing furnace while being compressed between the upper and lower endless belts, and was foamed and hardened by heating.
得られた本実施例のハニカム芯材強化レゾール型フェノ
ール樹脂発泡体の性能を第１表に示す。Table 1 shows the performance of the obtained honeycomb core reinforced resol type phenolic resin foam of this example.
なお、比較例として芯材を使用せずに、発泡性原液を発
泡硬化させて得た、フオーム密度４２ｋｇ／ｒｒｆ’［
この値は前記実施例のハニカム芯材強化レゾール型フェ
ノール樹脂発泡体のフオーム密度と同一である］のレゾ
ール型フェノール樹脂発泡体およびフオーム密度６８ｋ
ｇ／ｒｒｔ’［この値は前記実施例のハニカム芯材強化
レゾール型フェノール樹脂発泡体の全体の密度（但し面
材を除く）と同一である］のレゾール型フェノール樹脂
発泡体を得、それらの性能も第１表に示した。As a comparative example, a foam density of 42 kg/rrf' was obtained by foaming and curing a foaming stock solution without using a core material.
This value is the same as the form density of the honeycomb core-reinforced resol type phenolic resin foam of the above example] and the resol type phenolic resin foam with a foam density of 68k.
g/rrt' [this value is the same as the overall density (excluding the face material) of the honeycomb core-reinforced resol-type phenolic resin foam of the above example] was obtained, and their The performance is also shown in Table 1.
（以下余白）
第１表から明らかなように実施例のハニカム芯材強化レ
ゾール型フェノール樹脂発泡体は、ハニカム芯材で強化
していない、２種の比較例のレゾール型フェノール樹脂
発泡体に比べ、曲げ強度、圧縮強度等の諸物性が優れて
いた。また実施例のハニカム芯材強化レゾール型フェノ
ール樹脂発泡体は発泡状態の均一性が確保され、密度も
均一であった。(Left below) As is clear from Table 1, the honeycomb core-reinforced resol-type phenolic resin foam of the example is compared with the resol-type phenolic resin foam of two comparative examples that are not reinforced with a honeycomb core material. , various physical properties such as bending strength and compressive strength were excellent. Furthermore, the honeycomb core-reinforced resol type phenolic resin foam of the example had a uniform foamed state and a uniform density.
［発明の効果］
本発明によれば、芯材の各セル内へ液状レゾール型フェ
ノール樹脂を均一に分配することが可能となったので、
発泡状態、密度等が均一な芯材強化フェノール樹脂発泡
体を得ることができる。また本発明によれば芯材強化フ
ェノール樹脂発泡体を連続生産することができる。さら
に本発明によれば、ノボラック型フェノール樹脂粉末を
用いたときに認められる、粉末飛散による問題も解消す
ることができる。[Effects of the Invention] According to the present invention, it has become possible to uniformly distribute the liquid resol type phenolic resin into each cell of the core material.
A core-reinforced phenolic resin foam with uniform foaming state, density, etc. can be obtained. Further, according to the present invention, it is possible to continuously produce a core-reinforced phenolic resin foam. Further, according to the present invention, it is also possible to solve the problem caused by powder scattering, which is observed when using novolak type phenolic resin powder.
第１図は、本発明の芯材強化レゾール型フエノ−ル樹脂
発泡体の製造方法を実施するために好適な装置の模式図
、第２図はハニカム形状のセル（ｊ４造を有する芯材の
一部を示す斜視図である。FIG. 1 is a schematic diagram of an apparatus suitable for carrying out the method for producing core-reinforced resol type phenolic resin foam of the present invention, and FIG. It is a perspective view showing a part.
Claims (2)
含有する発泡性原液をコーティングした後、面材のレゾ
ール型フェノール樹脂発泡性原液コーティング面を、所
定形状のセル構造を有する芯材の上面に当接して押圧し
、一方、前記所定形状のセル構造を有する芯材の下面に
は別の面材を圧接し、前記レゾール型フェノール樹脂発
泡性原液を、前記芯材のセル内で発泡硬化させることを
特徴とする芯材強化レゾール型フェノール樹脂発泡体の
製造方法。(1) After coating one side of the face material with a foaming stock solution containing liquid resol type phenolic resin, the surface coated with the resol type phenolic resin foaming stock solution of the face material is applied to the top surface of the core material having a cell structure of a predetermined shape. On the other hand, another surface material is pressed against the lower surface of the core material having a cell structure of a predetermined shape, and the resol type phenolic resin foaming stock solution is foamed and hardened within the cells of the core material. A method for producing a core-reinforced resol type phenolic resin foam.
状のセル内に充填されていることを特徴とする、請求項
（１）の方法で得られた芯材強化レゾール型フェノール
樹脂発泡体。(2) A core-reinforced resol-type phenolic resin foam obtained by the method of claim (1), characterized in that the resol-type phenolic resin foam is filled in cells of a predetermined shape of the core material.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1142429A JP2720518B2 (en) | 1989-06-05 | 1989-06-05 | Manufacturing method of core material reinforced resol type phenol resin foam |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP1142429A JP2720518B2 (en) | 1989-06-05 | 1989-06-05 | Manufacturing method of core material reinforced resol type phenol resin foam |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH037312A true JPH037312A (en) | 1991-01-14 |
| JP2720518B2 JP2720518B2 (en) | 1998-03-04 |
Family
ID=15315115
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP1142429A Expired - Fee Related JP2720518B2 (en) | 1989-06-05 | 1989-06-05 | Manufacturing method of core material reinforced resol type phenol resin foam |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2720518B2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05222784A (en) * | 1992-01-21 | 1993-08-31 | Nitto Boseki Co Ltd | Heat-sound-fire preventing panel |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01169322U (en) * | 1988-05-21 | 1989-11-29 |
-
1989
- 1989-06-05 JP JP1142429A patent/JP2720518B2/en not_active Expired - Fee Related
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH01169322U (en) * | 1988-05-21 | 1989-11-29 |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05222784A (en) * | 1992-01-21 | 1993-08-31 | Nitto Boseki Co Ltd | Heat-sound-fire preventing panel |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2720518B2 (en) | 1998-03-04 |
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