JPH0462265B2 - - Google Patents

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Publication number
JPH0462265B2
JPH0462265B2 JP60097278A JP9727885A JPH0462265B2 JP H0462265 B2 JPH0462265 B2 JP H0462265B2 JP 60097278 A JP60097278 A JP 60097278A JP 9727885 A JP9727885 A JP 9727885A JP H0462265 B2 JPH0462265 B2 JP H0462265B2
Authority
JP
Japan
Prior art keywords
raw material
foam
molded body
foam raw
fiber molded
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.)
Expired - Lifetime
Application number
JP60097278A
Other languages
Japanese (ja)
Other versions
JPS61254338A (en
Inventor
Senichi Okuyama
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
IG Technical Research Inc
Original Assignee
IG Technical Research Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by IG Technical Research Inc filed Critical IG Technical Research Inc
Priority to JP60097278A priority Critical patent/JPS61254338A/en
Publication of JPS61254338A publication Critical patent/JPS61254338A/en
Publication of JPH0462265B2 publication Critical patent/JPH0462265B2/ja
Granted legal-status Critical Current

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Description

【発明の詳細な説明】 〔産業上の利用分野〕 本発明はフエノールフオームの弱点である脆
性、強度と接着不良を繊維成形体を利用すること
によつて改善した心材を表、裏面材でサンドイツ
チしたフエノールフオームを連続して製造する複
合板の方法に関するものである。
Detailed Description of the Invention [Field of Industrial Application] The present invention uses a core material that improves the brittleness, strength and poor adhesion, which are the weak points of phenol foam, by using a fiber molded product, and uses a sandwiched core material as front and back materials. The present invention relates to a method for manufacturing a composite plate by continuously manufacturing phenolic foam.

〔従来の技術〕[Conventional technology]

一般に、フエノールフオーム(以下、単にフオ
ームという)は防火性にすぐれた発泡体である。
しかしながら、フオーム自体は脆性があり、強度
が弱く、その上、フオーム形成時に他部材との接
着が反応時に縮合水が生ずる関係で大きく阻害さ
れる欠点があつた。さらに、フオームは高熱に曝
されるとクラツクが入り、形状が破壊する等の欠
点もあつた。これを改善する方法としてはネツト
状のシート複数枚をフオーム間に介在させるこ
と、あるいは長、短繊維をフイラーとして混在さ
せたフオームである。
Generally, phenol foam (hereinafter simply referred to as foam) is a foam with excellent fire retardant properties.
However, the foam itself is brittle and has low strength, and furthermore, when the foam is formed, adhesion to other members is significantly inhibited due to the formation of condensed water during the reaction. Furthermore, the foam had other drawbacks such as cracking and destruction of its shape when exposed to high heat. A method for improving this is to interpose a plurality of net-like sheets between the foams, or to create a foam in which long and short fibers are mixed together as filler.

〔発明が解決しようとする問題点〕[Problem that the invention seeks to solve]

しかしながら、この種方法によつて形成した発
泡体はフエノールフオームでなく、ポリウレタン
フオーム、ポリイソシアヌレートフオームなどで
あり、これらはフエノールフオームの性状、反応
系、物性が全く異なるもので、フオーム原料とフ
イラーの均一混合が装置的に困難で不均一混在発
泡体となり、本来の防火性が発揮できず大きくク
ラツクが入つたり形状が大きく変形して破壊した
りし、かつ、フオーム原料を有効に発泡させるこ
とができず、コストアツプとなり、しかも他部材
との接着性も改善できないものであつた。
However, the foams formed by this type of method are not phenol foams, but polyurethane foams, polyisocyanurate foams, etc., and these are completely different in the properties, reaction systems, and physical properties of phenol foams, and the foam raw materials and fillers are completely different from each other. It is difficult to mix uniformly with the equipment, resulting in a non-uniformly mixed foam, which cannot exhibit its original fire-retardant properties and may crack or break due to large deformation of the shape. This resulted in an increase in costs and also made it impossible to improve adhesion to other members.

〔問題点を解決するための手段〕[Means for solving problems]

本発明はこのような問題点を解決するために、
所要厚さに近い形状の繊維成形体を補強材兼接着
性改善材として用い、これにフオーム原料を未発
泡状態で吐出し、これらを表、裏面材でサンドイ
ツチし、それをフオーム原料が繊維成形体の空隙
にほぼ含浸された状態まで圧縮後、徐々に圧縮を
解除してフオーム原料の発泡速度に応じて繊維成
形体を復元させると共に、表、裏面材との接着性
は繊維によつてフオーム原料反応発泡時の縮合水
の一部を吸水して強化され、かつ、繊維成形体の
空隙にフオームを充填一体化し、短時間に硬化、
養生して脆性を改善し、さらに機械強度、耐クラ
ツク性のある防火性を有する複合板を連続して製
造する複合板の製造方法を提供するものである。
In order to solve these problems, the present invention has the following features:
A fiber molded body with a shape close to the required thickness is used as a reinforcing material and an adhesion improving material, and the foam raw material is discharged into this in an unfoamed state, and these are sandwiched with front and back materials, and the foam raw material is fiber-molded. After being compressed until it is almost impregnated into the voids of the body, the compression is gradually released to restore the fiber molded body according to the foaming speed of the foam raw material, and the adhesion with the front and back materials is determined by the fibers. It is strengthened by absorbing some of the condensed water during raw material reaction foaming, and the foam is filled into the voids of the fiber molded product to integrate it and harden in a short time.
The present invention provides a method for manufacturing a composite plate, which continuously produces a composite plate having improved brittleness through curing, mechanical strength, crack resistance, and fire retardant properties.

〔実施例〕〔Example〕

以下に、図面を用いて本発明に係る複合板の製
造方法の一実施例について詳細に説明する。
An embodiment of the method for manufacturing a composite plate according to the present invention will be described in detail below with reference to the drawings.

本発明において繊維成形体とは、不燃性繊維を
厚さ5〜50mm、密度4〜10Kg/m3位として長方
形、あるいは帯状に形成したものであり、不燃性
繊維とはガラス繊維、ロツクウールを嵩高の連通
組織状に、短繊維、あるいは長繊維を単体、もし
くはバインダーを介して形成したものである。な
お、厚さ、密度を前記のように設定したのは下記
する原料の含浸の可能性と有効発泡を補強材とし
ての必要度から選択したものである。また、フオ
ームとはフエノールフオームで、レゾール型、あ
るいはベンジリツクエーテル型のいずれか1種か
らなるものであり、液状で吐出後に反応→発泡→
硬化しうるものである。さらに、本発明において
表、裏面材とはクラフト紙、アスベスト紙、石こ
う紙、ガラス繊維不織布、金属箔(Al,Pb,
Cu,Fe)、金属薄板(Al,Pb,Fe,Cu)の1種
以上からなるものである。
In the present invention, the fiber molded article refers to noncombustible fibers formed into a rectangle or band shape with a thickness of 5 to 50 mm and a density of 4 to 10 kg/ m3 . Short fibers or long fibers are formed singly or through a binder in a continuous structure. The thickness and density were set as described above based on the possibility of impregnation of the raw materials described below and the necessity of effective foaming as a reinforcing material. In addition, the foam is phenol foam, which is either a resol type or a benzyl ether type, and is liquid and after being discharged, it reacts → foams →
It can be hardened. Furthermore, in the present invention, front and back materials include kraft paper, asbestos paper, gypsum paper, glass fiber nonwoven fabric, metal foil (Al, Pb,
Cu, Fe), thin metal plate (Al, Pb, Fe, Cu).

次に本発明の実施に供する装置について説明す
ると、第1図はその構成略図であり、1はアンコ
イラ、2はピンチローラ、3は搬送部、4はフオ
ーム原料吐出部、5はリール、はニツプロー
ル、7は押圧ローラ、はキユアオーブン、21
はサイドカツタ、22は走行カツタである。さら
に説明すると、アンコイラ1は表面材Aを装着す
るものであり、搬送部3は原動輪3aと従輪3b
とバツクアツプローラ3cとからなり、繊維成形
体Bを定速度で送給するためのものである。ま
た、フオーム原料吐出部4はフエノール樹脂、発
泡剤、硬化剤からなるフオーム原料Cを一挙に混
合し、ノズルから扇状パターンでフイルムのよう
な厚さで吐出するものである。ニツプロール
上ローラ6aと下ローラ6bとからなり、表面材
Aと裏面材D間に繊維成形体Bとフオーム原料C
とをサンドイツチした状態で、かつ、フオーム原
料Cが繊維成形体Bの空隙に含浸するように圧縮
すると共に、送給するものである。好ましくはニ
ツプロールの外表面を平坦面より凹凸に形成
し、くい込みをよくするのに役立つものである。
また、押圧ローラ7はフオーム原料Cの反応、発
泡に対応して傾斜状に配列し、繊維成形体Bの復
元とフオーム原料Cの発泡とをマツチするように
し、フオーム内にストリーク等が発生しないよう
に、かつ、均質発泡組織となるように機能するも
のである。前記キユアオーブンは上、下の型材
となるスチールベルト9,10と、言動輪11,
12と、従動輪13,14と、バツクアツプロー
ラ15,16と、ヒータ17,18と、カバー1
9と型20とからなり、フオーム原料Cを型20
内で所定形状に成形すると共に、硬化、キユアし
て連続した複合帯としてその出口8aから送出す
るものである。なお、キユア温度は80〜110℃位
であり、型入口8bから出口8aまで約1〜5分
間の短時間で送出するためのものである。
Next, to explain the apparatus used for implementing the present invention, FIG. 1 is a schematic diagram of its configuration, and 1 is an uncoiler, 2 is a pinch roller, 3 is a conveying section, 4 is a foam raw material discharge section, 5 is a reel, and 6 is a reel. Nitpro roll, 7 is a pressure roller, 8 is a cure oven, 21
2 is a side cutter, and 22 is a running cutter. To explain further, the uncoiler 1 is for mounting the surface material A, and the conveying section 3 has a driving wheel 3a and a trailing wheel 3b.
and a back-up roller 3c for feeding the fiber molded body B at a constant speed. Further, the foam raw material discharge section 4 mixes the foam raw material C consisting of a phenol resin, a foaming agent, and a hardening agent all at once, and discharges the mixture from a nozzle in a fan-shaped pattern to a film-like thickness. The nip roll 6 consists of an upper roller 6a and a lower roller 6b, and a fiber molded body B and a foam raw material C are placed between the surface material A and the back material D.
The foam raw material C is compressed and fed in a sandwiched state so that the foam raw material C is impregnated into the voids of the fiber molded body B. Preferably, the outer surface of the nip roll 6 is formed to have an uneven surface rather than a flat surface, which helps to improve the biting.
Further, the pressing rollers 7 are arranged in an inclined manner in response to the reaction and foaming of the foam raw material C, so that the restoration of the fiber molded body B and the foaming of the foam raw material C are matched, and streaks etc. do not occur within the foam. It functions to form a homogeneous foam structure. The cure oven 8 has steel belts 9 and 10 that serve as upper and lower mold members, a speech wheel 11,
12, driven wheels 13 and 14, backup rollers 15 and 16, heaters 17 and 18, and cover 1
9 and a mold 20, the foam raw material C is molded into the mold 20.
It is molded into a predetermined shape inside, hardened and cured, and sent out from the outlet 8a as a continuous composite band. The cure temperature is about 80 to 110° C., and the mold is delivered from the mold inlet 8b to the outlet 8a in a short time of about 1 to 5 minutes.

次に本発明に係る複合板の製造方法について説
明する。まず、表面材Aをアンコイラ1からピン
チローラ2を介して搬送部3に送給する。そし
て、表面材Aが搬送部3に到達した際に、厚さ25
mm、密度7.7Kg/m3で幅300mm、長さ1800mmの繊維
成形体Bを第2図aに示すように連結し、次工程
に送給する。上記成形体Bがフオーム原料吐出部
4の直下に到達すると、第3図に示すようにノズ
ルから未発泡のフオーム原料Cが吐出され、第2
図bに示すように繊維成形体Bの表面に未発泡の
フオーム原料Cが積層される。その直ぐ後に、裏
面材Dがフオーム原料C上に案内、積層されると
共に、第2図cに示すようにニツプロールで全
構成材を圧縮する。この際のギヤツプΔGは1〜
3mm程度である。なお、ギヤツプΔGはフオーム
原料Cの吐出量によつて異なるものであり、好ま
しくは繊維成形体の全空隙を充填するに必要な料
である。次に、そのサンドイツチ構造体は押圧ロ
ーラ7に送給され、押圧ローラでは第2図dに示
すようにフオーム原料Cの発泡に対応して規制す
る。その後にキユアオーブンに送給する。キユ
アオーブンは第4図に示すような複合板Eの厚
さHに対応する間隔で配した上、下型材9,10
で、かつ、型温が90℃に加温されているため、反
応、発泡、硬化が早く、養生もほぼ完了してその
出口8aから連続帯として送出される。なお、型
20における横断面は第2図eに示す。これをサ
イドカツタ21で両側縁を切断し、次に走行カツ
タ22で定尺に切断し、複合板Eとするものであ
る。このように製造した複合板Eは密度が43.1
Kg、圧縮強度が0.67Kg/cm2であつた。また、表、
裏面材A,DとフオームC′との接着性は90°、ピ
ーリング試験で1.53Kgf/10cmであり、準不燃試
験(JIS−A−1321)のボツクス試験に合格し、
かつ、有害な亀裂も認められなかつた。なお、比
較例としては長さ5mmのガラス繊維を実施例と同
重量だけフオーム原料Cとミキサーで混合し、型
材に吐出し、実施例と同じ厚さ、密度に形成した
複合板を製造した。その結果は、圧縮強度が平均
して0.56であつて多数のサンプルでのバラツキが
多かつた。また、接着性は0.6(Kgf/10cm)であ
り、準不燃試験は総発熱量が52000KJで、燃焼中
に爆裂して防火上の有害な燃焼を呈したため、不
合格となつた。しかも本発明では生産速度が15〜
20m/minであるのに対し、比較例では9〜
11m/minが限度であつた。
Next, a method for manufacturing a composite plate according to the present invention will be explained. First, the surface material A is fed from the uncoiler 1 to the conveying section 3 via the pinch rollers 2. Then, when the surface material A reaches the conveyance section 3, the thickness is 25
The fiber molded bodies B having a density of 7.7 kg/m 3 and a width of 300 mm and a length of 1800 mm are connected as shown in FIG. 2a and sent to the next process. When the molded body B reaches directly below the foam raw material discharge section 4, the unfoamed foam raw material C is discharged from the nozzle as shown in FIG.
As shown in Figure b, an unfoamed foam raw material C is laminated on the surface of the fiber molded body B. Immediately thereafter, the backing material D is guided and laminated onto the foam material C, and the entire component is compressed with nip rolls 6 , as shown in FIG. 2c. The gap ΔG at this time is 1~
It is about 3mm. Incidentally, the gap ΔG varies depending on the discharge rate of the foam raw material C, and is preferably the amount necessary to fill all the voids in the fiber molded body. The sandwich structure is then fed to a pressure roller 7, where it is regulated in accordance with the foaming of the foam material C, as shown in FIG. 2d. After that, it is fed to the cure oven 8 . The cure oven 8 has upper and lower mold members 9 and 10 arranged at intervals corresponding to the thickness H of the composite plate E as shown in FIG.
Moreover, since the mold temperature is heated to 90° C., the reaction, foaming, and curing are quick, and curing is almost completed, and the product is sent out as a continuous band from the outlet 8a. The cross section of the mold 20 is shown in FIG. 2e. This is cut at both side edges with a side cutter 21, and then cut into a fixed length with a running cutter 22 to obtain a composite plate E. Composite board E manufactured in this way has a density of 43.1
kg, and the compressive strength was 0.67 kg/cm 2 . In addition, the table,
Adhesion between backing materials A and D and foam C' is 90°, 1.53Kgf/10cm in peeling test, and passed the box test of semi-flammability test (JIS-A-1321).
Moreover, no harmful cracks were observed. In addition, as a comparative example, glass fibers having a length of 5 mm were mixed with foam raw material C in the same weight as in the example using a mixer, and the mixture was discharged into a mold material to produce a composite plate having the same thickness and density as in the example. The results showed that the average compressive strength was 0.56, with large variations among the many samples. In addition, the adhesiveness was 0.6 (Kgf/10cm), and the total calorific value was 52,000 KJ in the quasi-nonflammability test, which exploded during combustion and caused harmful combustion in terms of fire protection, so it failed. Moreover, with the present invention, the production speed is 15~
While it is 20m/min, in the comparative example it is 9~
The limit was 11m/min.

以上説明したのは本発明に係る複合板の一実施
例にすぎず、第1図において2点鎖線で示す位置
に吸水樹脂粉末を散布し、フオーム原料Cが反応
する際に生ずる縮合水を吸水し、接着性を向上し
たり、1点鎖線で示す位置に界面活性剤を塗布
し、よりフオーム原料Cの繊維成形体Bへの浸透
をよくすることもできる。
What has been described above is only one embodiment of the composite plate according to the present invention, and the water-absorbing resin powder is sprinkled at the position shown by the two-dot chain line in FIG. However, it is also possible to improve the adhesion or to apply a surfactant to the position shown by the dashed line to improve the penetration of the foam raw material C into the fiber molded body B.

〔発明の効果〕〔Effect of the invention〕

上述したように本発明に係る複合板の製造方法
によれば、フオーム原料を繊維成形体の空隙に
充填できると共に、均質な発泡組織の中に繊維を
補強材として存在させることができるため、防火
性、強度にすぐれ、フオームの脆性も改善でき
る。フオームと表、裏面材の接着性が繊維成形
体の繊維による吸水機能によつて大きく向上す
る。表、裏面材間に繊維成形体入りフオームの
芯材を介在した複合板を連続して高速で生産でき
る。等の特徴がある。
As described above, according to the method for manufacturing a composite board according to the present invention, the foam raw material can be filled into the voids of the fiber molded body, and the fibers can be present as a reinforcing material in the homogeneous foam structure, so that fire prevention is achieved. It has excellent toughness and strength, and can also improve the brittleness of the foam. The adhesion between the foam and the front and back materials is greatly improved by the water absorption function of the fibers of the fiber molded product. It is possible to continuously produce composite plates at high speed, with a core material of foam containing a fiber molded body interposed between the front and back materials. It has the following characteristics.

【図面の簡単な説明】[Brief explanation of drawings]

第1図は本発明に係る複合板の製造方法の実施
に供する装置を示す説明図、第2図a〜eは本発
明に係る製造工程を示す説明図、第3図はフエノ
ールフオーム原料の吐出状況を示す斜視図、第4
図は本発明に係る複合板の製造方法により製造し
た複合板を示す斜視図である。 1……アンコイラ、3……搬送部、4……フエ
ノールフオーム原料吐出部、……ニツプロー
ル、……キユアオープン。
FIG. 1 is an explanatory diagram showing an apparatus for carrying out the method for manufacturing a composite plate according to the present invention, FIGS. 2 a to e are explanatory diagrams showing the manufacturing process according to the present invention, and FIG. Perspective view showing the situation, No. 4
The figure is a perspective view showing a composite board manufactured by the method for manufacturing a composite board according to the present invention. 1... Uncoiler, 3... Conveyance section, 4... Phenol foam raw material discharge section, 6 ... Nipprol, 8 ... Cure open.

Claims (1)

【特許請求の範囲】[Claims] 1 不燃性繊維を厚さ5〜50mm、密度4〜10Kg/
m3のマツト状に形成した切板、もしくはコイル状
の繊維成形体を表面材の裏面に積層し、該繊維成
形体の上にフエノールフオーム原料を未発泡状態
で吐出し、その上に不織布からなるシート状の裏
面材を載せた後、直ちに表、裏面材間に前記原料
と繊維成形体をサンドイツチし、これをニツプロ
ールでフオーム原料を繊維成形体のほぼ全空隙を
充填するように圧縮し、次にフエノールフオーム
原料の発泡パターンにほぼ対応して押圧ローラを
複数個配設し、これを80〜110℃に加温された型
材も兼ねるキユアオーブンに送給して前記原料の
反応、発泡を完了させ、かつ、硬化養生したこと
を特徴とする複合板の製造方法。
1 Non-flammable fibers with a thickness of 5 to 50 mm and a density of 4 to 10 kg/
A pine-shaped cut plate or a coiled fiber molded body of 3 m3 is laminated on the back side of the surface material, the phenol foam raw material is discharged in an unfoamed state onto the fiber molded body, and a non-woven fabric is placed on top of the phenol foam raw material in an unfoamed state. Immediately after placing the sheet-like backing material, the raw material and the fibrous molded body are sandwiched between the front and backing materials, and this is compressed with Nitzprol so that the foam raw material fills almost all the voids in the fibrous molded body, Next, a plurality of pressure rollers are arranged approximately corresponding to the foaming pattern of the phenol foam raw material, and the rollers are sent to a cure oven that also serves as a mold material heated to 80 to 110°C to complete the reaction and foaming of the raw material. A method for producing a composite board, characterized in that it is cured and cured.
JP60097278A 1985-05-07 1985-05-07 Manufacture of composite board Granted JPS61254338A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP60097278A JPS61254338A (en) 1985-05-07 1985-05-07 Manufacture of composite board

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP60097278A JPS61254338A (en) 1985-05-07 1985-05-07 Manufacture of composite board

Publications (2)

Publication Number Publication Date
JPS61254338A JPS61254338A (en) 1986-11-12
JPH0462265B2 true JPH0462265B2 (en) 1992-10-05

Family

ID=14188051

Family Applications (1)

Application Number Title Priority Date Filing Date
JP60097278A Granted JPS61254338A (en) 1985-05-07 1985-05-07 Manufacture of composite board

Country Status (1)

Country Link
JP (1) JPS61254338A (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH074821B2 (en) * 1987-01-12 1995-01-25 株式会社クボタ Method for manufacturing laminated foam board

Also Published As

Publication number Publication date
JPS61254338A (en) 1986-11-12

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