JPH04284240A - Light-weight composite panel - Google Patents

Abstract

PURPOSE:To provide a lightweight composite material, which has the large degree of freedom of molding and is utilized particularly as wall material and flooring matreial. CONSTITUTION:A lightweight composite material is composed of double layer structure constituted of a surface layer mainly comprising reinforcing fibers, inorganic powder and a thermosetting resin and a core layer consisting of granular rock wool covered with a composition mainly comprising inorganic powder and the thermosetting resin.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight composite panel that is excellent in dimensional stability, fire resistance, and light weight and is used for wall materials, floor materials, etc.

0002

[Prior Art] Generally, as a composite building material used for walls and floors of buildings, a lightweight molded body consisting of a core layer mainly made of pumice and a surface layer reinforced with glass fiber is known (especially known). Publication number 59-13473). but,
With this method, it is difficult to obtain pumice in stable quality because it is a natural material, and there are physical limitations on density and strength. However, in order to produce a product with a constant thickness, raw material management is complicated, and the thickness accuracy cannot be improved.

0003

[Problems to be Solved by the Invention] It is an object of the present invention to solve the problems arising from the use of pumice as described above, and to provide a composite panel that is lighter in weight and has a greater degree of freedom in shaping. .

0004

[Means for Solving the Problems] In order to solve the above-mentioned problems, the present invention has conducted research and has developed a granular material whose surface is coated with an inorganic powder and a thermosetting resin in place of the conventionally used inorganic lightweight aggregate. By using rock wool as the aggregate of the core layer and integrating it with the surface layer mainly consisting of reinforcing fibers, inorganic powder, and thermosetting resin, it has excellent lightness, workability, and thickness accuracy. It was discovered that it can be used as a layered composite material.

The present invention will be explained in detail below with reference to the drawings. In FIG. 1, numerals 1 and 1' are a mixture of inorganic powder and thermosetting resin constituting the respective surface layers, 2 is a reinforcing fiber, and 3 is granular rock wool. Note that these constitute the surface layer 4 and the core layer 5. Therefore, the inorganic powders 1 and 1' according to the present invention include calcium carbonate, silica sand, alumina, mica, glass powder, glass balloon, fly ash, sea sand, etc., which are generally used as thermosetting resin fillers. These inorganic powders can be used alone or in combination. Further, the thermosetting resin may be a general-purpose one such as phenol resin, urea resin, melamine resin, epoxy resin, or unsaturated polyester resin. The amount of thermosetting resin added varies somewhat depending on the type of inorganic powder and resin used, and should be set according to each individual case, but from the viewpoint of required performance and economic efficiency, surface layer mixture 1' The thermosetting resin is desirably in a range of 10 to 50 parts per 100 parts by weight of the inorganic powder. Further, in the mixture 1 forming the core layer, inorganic powder is blended in an arbitrary ratio to the thermosetting resin. Additives such as a water repellent and a lubricant may be added to 1 and 1' if necessary.

Next, as for reinforcing fibers 2, there are inorganic fibers such as glass fiber, rock wool, carbon fiber, and metal fiber, and organic fibers such as nylon fiber, polyester fiber, vinylon fiber, and aramid fiber. From the viewpoint of molding operations, converged strand-like fibers are preferred. Furthermore,
Granular rock wool is cotton-like rock wool cut to a specified length.
A spherical agglomerate obtained by applying vibration, rocking, rotation, etc. to a mold, and the particle size can be adjusted as necessary before use.

Next, an example of the means for manufacturing the panel of the present invention will be described. As a raw material for the surface layer, a thermosetting resin is blended with an inorganic powder, and both are mixed, stirred, or kneaded. In the case of liquid resin, adjust the solvent by evaporation until the required fluidity is achieved.
A dry mixture 1' of inorganic powder and thermosetting resin is prepared. Next, reinforcing fibers 2 are blended into this mixture 1, and a certain amount of the reinforcing fibers 2 are sprinkled onto a suitable release sheet to form a mat for the surface layer. At this time, especially when strand-shaped fibers are used, the mixture 1' is sprinkled on the release sheet without mixing the mixture 1' and the reinforcing fibers 2 in advance, and then the strands are The reinforcing fibers 2 are dispersed by scattering the reinforcing fibers 2
A mat can be formed in which the inorganic powder and the thermosetting resin are dispersed in the mixture 1'. Depending on this method, the fibers are not mechanically damaged and at the same time the degree of freedom in blending amount can be increased.

Next, as a raw material for the core layer, a mixture 1 of an inorganic powder and a thermosetting resin is mixed with granular rock wool 3, and the mixture is heated or stirred with a small amount of water added, so that the surface is coated with the mixture 1. Make granular rock wool. This granular rock wool is sprinkled onto the surface layer mat. Furthermore, a mat for the surface layer is sprinkled thereon in the same manner as described above, and then heated and compressed for a predetermined period of time using a hot press. By heat compression,
The granular rock wool deforms locally and fills the voids.
Thereafter, the thermosetting resin reacts and hardens due to heat transfer, and the mixture 1
' is hardened around the granular rock wool in a mesh pattern. At the same time, the surface layer is also solidified to form a three-layered composite.

[0009]

[Operation] Thus, the composite panel of the present invention uses granular rock wool instead of pumice. The bulk density of granular rock wool is 0.05 to 0.20 g/cm2, but the volume is reduced by 1/2 to 1/2 due to compaction during compression molding.
Reduce to 10. Because it shows such a large consolidation behavior,
The degree of freedom in setting the product density width can be increased, and the thickness of the product can be easily adjusted. Furthermore, in the dispersed state, the core layer forms a loose packed layer as shown in Figure 2, but when compressed, the rock wool deforms mainly in the compression direction, as shown in Figure 3. The structure is such that the coating layer is a continuous layer. Thereafter, upon heat transfer, the thermosetting resin of the coating layer reacts and hardens, forming a three-dimensional reinforcing layer of cellular structure. By pre-coating granular rock wool with a mixture of thermosetting resin and inorganic powder, it is possible to prevent layer separation of the two materials, which have greatly different densities, and to keep the thickness of the coating layer constant. A core layer exhibiting reasonable strength can be formed.

0010

[Examples] The present invention will be explained in more detail with reference to Examples below. 74 parts by weight of fly ash with a Blaine value of 1500 cm2/g, 13 parts by weight of novolac type phenolic resin
13 parts by weight of chopped glass fiber strands with a length of 25 mm were evenly spread on the mold release sheet at a rate of 1.53 kg per square meter to form a surface layer, and then the particle size was 10 mm. Granular rock powder adjusted to a range of ~3mm
40 parts by weight of oil, 50 parts by weight of fly ash, 9.5 parts by weight of novolac type phenolic resin, 0.5 parts by weight of paraffin.
Mix parts by weight and stir to coat the surface of rock wool. This coated rock wool is sprinkled onto the surface layer to form a core layer. Furthermore, a surface layer is again sprinkled on top of this core layer to form a mat with a three-layer structure. Insert the mat into a heat press at a temperature of 150°C and a maximum pressure of 10kg/cm2.
for 10 minutes to obtain a three-layer composite panel. The composite panel made in this way has the following properties. Thickness 13mm Specific gravity 0.55 Bending strength 75kg/cm2 Water absorption expansion coefficient
0.2% Processing rate Can be cut with a saw and fixed by nailing

[0011]

As described above, in the present invention, granular rock wool whose surface is coated with inorganic powder and thermosetting resin is used as the aggregate of the core layer, and reinforcing fibers and inorganic powder It is a three-layer composite material with excellent lightness, workability, and thickness accuracy by integrating it with a surface layer mainly composed of thermosetting resin.It is especially suitable as a lightweight composite panel for wall materials, flooring, etc. It is found in highly used products.

[Brief explanation of the drawing]

FIG. 1 is a front sectional view showing the structure of a lightweight composite panel obtained by the present invention;

FIG. 2 is a structural cross-sectional view showing the state before compression of granular rock wool whose surface is coated with a mixture;

[Figure 3] Granular rock powder whose surface is coated with the mixture.
FIG. 3 is a structural cross-sectional view showing the state after compression of the module.

[Explanation of symbols] 1.1' Mixture of inorganic powder and thermosetting resin, 2
Reinforcing fiber, 3 granular rock wool, 4 surface layer, 5 core layer.

Claims (1)

[Claims] Claim 1: A core made of granular rock wool covered with reinforcing fibers, a surface layer mainly composed of inorganic powder and a thermosetting resin, and a composition mainly composed of inorganic powder and thermosetting resin. A lightweight composite panel characterized by having a multilayer structure composed of layers.