JPH04357178A - Non-flammable foamable molding material and non-flammable foamed molded product - Google Patents

Abstract

PURPOSE:To provide a non-flammable foamable material not producing an injurious gas and capable of being readily molded and foamed into desired three-dimensional shapes such as a wave-form basic shape in response to various shapes having various dimensions, and to provide a non-flammable foamed and molded product thereof. CONSTITUTION:An inorganic fiber reinforcing material comprising a non-woven fabric, woven fabric or knitted fabric using glass fibers or carbon fibers as a material is impregnated with a liquid binder containing an alkali metal silicate salt comprising sodium silicate, potassium silicate or lithium silicate, a filler such as zeolite, magnesium oxide or calcium carbonate, a foaming agent and a gelating agent such as glyoxal, ethylene glycol, diacetate, triethanolamine or acetic acid amine to produce a non-flammable foamable molding material. The non-flammable foamable molding material is thermally foamed and molded into a non-flammable foamed and molded product.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to noncombustible foam molding materials and noncombustible foam moldings used as noncombustible interior/exterior building materials or general-purpose fireproof coatings.

0002

[Prior Art] In general, foam molded products are classified into organic foams and inorganic foams depending on their materials.Among these, foams made of organic materials include foamed polystyrene, foamed polyurethane, etc. It is well known as a material for food containers and insulation. These organic foams are lightweight,
It has excellent heat insulation and cushioning properties, and is relatively easy to mold, but it has poor thermal decomposition resistance, that is, fire resistance, and generates harmful gas when burned, so it cannot be used in applications that require nonflammability. Can not.

On the other hand, foam glass and lightweight aerated concrete (ALC) are known as foams made of inorganic materials, and these have excellent heat decomposition resistance and generate almost no harmful gases, so they are nonflammable. It has favorable properties as a foam.

0004

[Problems to be Solved by the Invention] However, the above-mentioned foams made of inorganic materials are produced by adding a foaming material to the main inorganic material in a melted or dissolved state, similar to the foam molding of organic materials. Since it is an inorganic material, its physical properties are that of an inorganic material, and its moldability is poor, making it particularly difficult to mold it into small and complex shapes.

The present invention solves the problems of foams made of inorganic materials, is nonflammable, does not generate harmful gases, can be used in a wide range of applications, and can be formed into various sizes and shapes. Correspondingly, the object of the present invention is to provide a nonflammable foam material and a nonflammable foam molded article that can be foam-molded into a desired three-dimensional shape relatively easily using a web-like basic mold.

[0006]

[Means for Solving the Problems] In order to solve the above problems, the present invention employs a structure in which an inorganic fiber reinforcing material is impregnated with a foamable binder containing an alkali metal silicate.

[0007] Alternatively, the nonflammable foamed molded article may be formed by heating and foaming the nonflammable foamed molding material having the above structure.

[0008] The details will be described below.

[0009] First, the inorganic fiber reinforcing material used in the present invention is a nonwoven fabric, a knitted fabric, or a short fiber made of an inorganic material with excellent heat decomposition resistance, and preferred materials include glass fiber and carbon fiber. Moreover, rock wool, metal fiber, etc. may be used as necessary.

[0010] Examples of the alkali metal silicate used in the present invention include sodium silicate, potassium silicate, and lithium silicate, which have excellent handling properties in that they are soluble in cold or hot water.

The foamable binder containing the alkali metal silicate is mainly composed of water or a water-absorbing synthetic resin emulsion or other liquid material that is highly compatible with the alkali metal silicate. Although the foamable binder foams when heated depending on the composition described above, it is preferable to use a mixture of an extender, a foaming agent, and a gelling agent as additives.

[0012] Examples of the above-mentioned extenders and blowing agents include zeolite, magnesium oxide, and calcium carbonate, and examples of gelling agents include glyoxal, ethylene glycol, diacetate, triethanolamine, and acetate amine.

[0013] When impregnating the inorganic fiber reinforcing material with the expandable binder, it may be impregnated at room temperature (15 to 25°C), but at 50°C.
Impregnation can be carried out more efficiently at a temperature of ~80°C.

[0014]Also, the nonflammable foam material before foam molding can be commercialized as a web-like fire-resistant material as it is, but
Furthermore, it may be formed by heating and foaming with a mold, hot press, or the like. The molding temperature at this time is 150-200℃
is appropriate, and the foaming density depends on the binder concentration, impregnation (
It can be adjusted by the coating amount and the molding temperature. Further, the thickness of the foam molded product may be appropriately set depending on the distance between the hot plates of the hot press.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Examples of the present invention will be described below with reference to the drawings.

[0016] The nonflammable foam molding material P' which is an example is as follows:
Glass fiber nonwoven fabric P was impregnated with an aqueous sodium silicate solution and predried, and a nonflammable foam molded article A was obtained by stacking one or more of these, heating, and foam-molding.

The details of the above manufacturing process will be explained based on FIGS. 1 and 2. First, a web-shaped glass fiber nonwoven fabric P is unwound from a roll 1 at a constant speed and passed through a melting tank 2. This dissolution tank 2 contains a solution in which sodium silicate and water as a diluent are mixed at a weight ratio of approximately 1:1.5. The foaming density of the molded product described below can be adjusted by changing the mixing ratio of the solution. Further, an appropriate amount of a foaming agent such as calcium carbonate related to the foaming density may be added and mixed. The glass fiber nonwoven fabric P in the dissolving tank 2 is transferred between rolls under tension, and in that state is immersed in a sodium silicate solution to achieve uniform impregnation.

The glass fiber nonwoven fabric P impregnated with the sodium silicate solution is taken up from the dissolving tank 2 and introduced into the hot air circulation dryer 3 to remove excess moisture. The temperature of the hot air circulation dryer 3 is set in a range of, for example, 50 to 80°C so that the temperature gradually increases from the inlet to the outlet, and an appropriate amount of moisture necessary for foaming remains at the outlet. It is supposed to be done. The glass fiber nonwoven fabric P thus dried is cut into a predetermined size (1000 m
It was cut into a rectangular shape (m square) to obtain a nonflammable foam molding material P'.

Next, the above nonflammable foam molding material P' was subjected to foam molding using a heating molding machine 5. The heating molding machine 5 has a structure in which a plurality of heating discs 6 are stacked, and is used to place the nonflammable foam molding material P' between each, heat and foam the material, and take it out after cooling.

As shown in FIG. 2, when molding a thick molded product, convert the sheet-like nonflammable foam molding material P' into the desired molded product by weight, and add a number of noncombustible sheets corresponding to the converted amount. The foamed molding materials P' are stacked and placed between the heating plates 6 and heated. At this time, if it is necessary to further improve the flatness precision of the molded product, the molded product is clamped between hot platens 6 with a mirror plate 7 interposed therebetween. Moreover, if a heat-resistant synthetic resin film with excellent frictional properties is interposed between the mirror plate 7 and the nonflammable foamed molding material P', the releasability between the molded product and the mirror plate 7 will be improved.

[0021] If a spacer 8 is interposed between the upper and lower heating plates 6, the distance between the heating plates 6 can be kept constant, so that a molded product with stable dimensions can be obtained.

The nonflammable foam molded article A, which has been subjected to heat foam molding by the heat molding machine 5 in this manner, is cut into a predetermined size by a cutter 9 to obtain a final product.

[0023]

[Effects] As explained above, since the foamed molded product of this invention is made of inorganic material, it is nonflammable and
Moreover, a nonflammable foamed molded article that does not generate harmful gases and can be adapted to the size and shape of structures and utensils can be obtained. Furthermore, when a foamed molding material is used by coating or laminating a material, it can exist as a required nonflammable foam when heated. Therefore, it has an excellent use as a non-combustible auxiliary material for structures used inside and outside buildings and building equipment-related equipment and appliances, especially for improving the heat resistance required for crime prevention in warehouses, safes, etc. It can be said that the industrial utility value of the invention is extremely high.

[Brief explanation of drawings]

[Figure 1] Explanatory diagram of the manufacturing process of the example

[Figure 2] An explanatory diagram of the main parts of the heat forming machine same as above

[Explanation of symbols]

P’ nonflammable foam molding material A Nonflammable foam molded product 2 Dissolution tank 3 Hot air circulation dryer 5　Heating molding machine 6 Heat plate

Claims (2)

[Claims] 1. A nonflammable foam molding material obtained by impregnating an inorganic fiber reinforcing material with a foamable binder containing an alkali metal silicate. 2. A nonflammable foam molded article obtained by heating and foam molding the nonflammable foam molding material according to claim 1.