JPH05162224A - Flame-retardant heat-insulating board - Google Patents

Abstract

PURPOSE:To provide lightweight heat insulating board, which is excellent in flame retardancy and does not adversely affect people at comparatively low cost. CONSTITUTION:The flame-retardant heat insulating board concerned is obtained through self-bonding force, which develops at the expansion of phenolic foam made of resol-type phenolic resin under the condition the non-woven fabric consisting of 65wt.% of glass fiber, 15wt.% of acrylic latex and 20wt.% of aluminum hydroxide is laid in a form. The obtained heat insulating board has the flame retardant performance of second class flame retardant rating level.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat insulating board having excellent flame retardancy.

[0002]

2. Description of the Related Art A rigid synthetic resin foam has excellent heat insulating performance and material properties, and one of its typical uses is a heat insulating board for construction. Above all, phenol foam, which can be certified as semi-incombustible while taking advantage of the excellent properties of organic materials, has been commercialized as a construction board. However, since phenol foam is an organic material, the material itself burns in the presence of oxygen, and therefore a non-combustible or quasi-incombustible material is generally used as the surface material.

Phenolic foam boards, which have been certified as semi-inflammable, are inorganic materials such as gypsum board and calcium silicate board, metallic materials such as iron and aluminum on the surface of phenol foam, or asbestos paper as a soft surface material. Is a composite.

[0004]

However, when an inorganic material such as a gypsum board or a calcium silicate board is compounded on the surface of the above-mentioned phenol foam, the weight of the board increases, which has recently been required in the construction field. It is not preferable in terms of weight reduction of existing building materials. Also, when compounding metal materials such as iron and aluminum, it is necessary to perform corrosion resistance treatment on the metal surface that is compounded with phenol foam in order to cope with the metal corrosiveness peculiar to phenol foam. It becomes expensive.

On the other hand, when asbestos paper is used as the soft surface material, a lightweight and inexpensive heat-insulating board excellent in fireproofing can be obtained, but there is concern that asbestos may have a bad effect on the human body, and it is a worldwide construction material. It is difficult to use asbestos paper because the asbestos-free method is recommended. Therefore, the development of soft surface materials to replace asbestos paper, for example,
Although there are calcium carbonate paper and aluminum hydroxide paper, when phenol foam and these non-combustible papers are combined as a face material, the pulp contained in the non-combustible paper is flammable. Passing is difficult due to the heat generated by combustion.

Although there is a glass fiber non-woven fabric as a soft surface material that does not contain pulp, when the phenol foam is foam-molded using the glass fiber non-woven material as the surface material, the phenol resin is immersed in the surface material surface due to the large voids between the glass fibers. It will stick out. In such a case, if the basis weight of the glass fiber non-woven fabric is increased, the exudation of the phenol resin can be prevented, but since the face material is less bendable, the phenol foam board cannot be integrally molded by the continuous laminator. In addition, when a non-combustible paper such as calcium carbonate paper or aluminum hydroxide paper and a face material laminated with glass fiber non-woven fabric by adhesion are combined with phenol foam, leaching of phenol resin to the face material surface can be prevented, but As the surface material is laminated by adhesion, it is unavoidable that it will be relatively expensive as a surface material, and when a flammability test is conducted,
After all, it is difficult to pass due to the burning of pulp in non-combustible paper.

The present invention uses a soft surface material, as a heat insulating material for construction, which is not lighted by the phenol resin on the surface of the surface material and has no adverse effect on the human body. The purpose is to provide a relatively inexpensive flame retardant insulation board for use.

[0008]

SUMMARY OF THE INVENTION The present invention relates to a flame-retardant heat insulating board in which a soft foam material made of glass fiber, polymer latex and aluminum hydroxide is integrally molded on one or both sides with a phenol foam as a core material. The soft surface material used in the present invention is a non-woven fabric made of glass fiber, polymer latex and aluminum hydroxide. The mixing ratio is
Glass fiber 50 to 80% by weight, polymer latex 10
30% by weight and 10 to 30% by weight of aluminum hydroxide are desirable. That is, in order to improve the flame retardancy of the soft surface material, it is preferable that the blending ratio of the glass fibers is 50% by weight or more, while sufficient mechanical strength is obtained, and the phenol foam board is integrated with the continuous laminator. It is preferably 80% by weight or less in order to maintain the folding property which can facilitate the molding.

The polymer latex is blended for the purpose of uniformly dispersing the glass fiber and aluminum hydroxide and at the same time, for the purpose of imparting a sealing property for preventing the phenol resin from seeping out to the surface of the surface material, styrene-butadiene. -Rubber latex, acrylic latex, etc. are used. In order to evenly disperse the glass fiber and aluminum hydroxide and to make the surface material have sufficient sealing properties, the blending amount of the polymer latex is preferably 10% by weight or more, and in order to maintain the flame retardant performance, The blending ratio is preferably 30% by weight or less.

Aluminum hydroxide is blended for the purpose of imparting flame retardancy, and in order to obtain sufficient flame retardancy, the blending ratio is preferably 10% by weight or more. On the other hand, the mixing ratio is preferably 30% by weight or less in order to maintain the viscosity of the slurry so that the slurry made of glass fibers, polymer latex and aluminum hydroxide can be made into a nonwoven fabric by a paper machine.

The above slurry containing glass fiber, polymer latex and aluminum hydroxide is fed to a wet paper machine and paper is made by a conventional method to obtain a soft face material which is a non-woven fabric. The basis weight of the soft surface material used in the present invention is sufficient mechanical strength as a surface material, and in the integral molding of the phenol foam board with a continuous laminator, the surface material can be molded without breaking. Has a basis weight of 50 g / m
^It is preferably ² or more, on the other hand, the basis weight is preferably 200 g / m ² or less in order to obtain good face-folding property.

The phenol foam referred to in the present invention is a resol type phenol foam. The flame-retardant heat-insulating board of the present invention is a foaming agent such as a silicone-based surfactant in a resol type phenol resin, a hydrocarbon-based foaming agent containing chlorine such as 1,1,3 freon, phenolsulfonic acid, and toluene. The reaction mixture which is made into a cream by adding a sulfonic acid-based curing agent such as sulfonic acid and other additives as necessary to form a creamy reaction mixture may be supplied to the continuous laminator together with the above face material, or may be molded together with the above face material. By heating and foam-curing in the frame, it is possible to obtain a flame-retardant heat insulating board in which a soft surface material is integrally molded on the surface by the self-adhesive force of phenol foam.

[0013]

EXAMPLES The present invention will be described in more detail with reference to examples.

[0014]

Example 1 Glass fiber (average diameter 9 μm, average length 10)
mm) 65% by weight, acrylic latex (solid content conversion)
A slurry composed of 15% by weight and 20% by weight of aluminum hydroxide is supplied to a wet paper machine to make a paper, and the basis weight is 75 g / m.
^Two non-woven fabrics were obtained. This non-woven fabric is 35 cm in length and width
Cut into stainless steel molds (inner method, vertical and horizontal 35c
m) on the bottom, preheat the mold to 70 ° C. in advance, and add 100 parts by weight of the resol-type phenol resin,
A creamy product obtained by adding 1 part by weight of a silicon-based surfactant as a foaming agent, 15 parts by weight of 1,1,3 freon as a foaming agent, and 15 parts by weight of phenolsulfonic acid as a curing agent, and stirring at high speed for 30 seconds. The mixed solution is poured onto it, and fixed with a stainless steel upper lid on which the above-mentioned non-woven fabric to be the other face material is laid, through a spacer so as to have a predetermined thickness, and hot press set at 80 ° C (high temperature and high pressure). It was heated for 10 minutes in a molding device) to foam and harden it, and after hardening, it was released from the mold to obtain a flame-retardant heat insulating board in which soft surface materials were integrated on both surfaces.

Table 2 shows the results of an evaluation test conducted on the obtained heat-insulating board concerning fire resistance performance of Class 2 flame-retardant specified in Japanese Industrial Standard, JIS A 1321. When judged by the pass standard value shown in Table 1, it is pass,
It can be seen that the flame-retardant heat board obtained according to the present invention has a flame-retardant class 2 flame-retardant performance.

[0016]

[Comparative Example 1] A heat insulating board having a soft surface material integrated on both surfaces was obtained in the same manner as in Example except that a commercially available glass fiber nonwoven fabric having a basis weight of 100 g / m ² was used. , This board had no phenolic resin leaching from the surface of the face material and was not valuable as an industrial product.

[0017]

[Table 1]

[0018]

[Table 2]

[0019]

The flame-retardant heat insulating board of the present invention exhibits the following effects. Since it does not use inorganic hard surface materials such as gypsum board or calcium silicate board, it is lightweight and easy to handle during transportation and construction of the heat insulating board. Since a soft surface material that does not contain asbestos is used, it does not adversely affect the human body during and after the installation of the heat insulating board. Since the leaching of the phenol resin to the surface of the surface material can be prevented without laminating different kinds of surface materials, the obtained heat insulating board is relatively inexpensive. Since it has a flame-retardant class 2 level flame-retardant performance, it is not necessary to further subject the surface of the heat insulating board to fire treatment.

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Claims (1)

[Claims] 1. A flame-retardant heat insulating board, characterized in that a soft foam material made of glass fiber, polymer latex and aluminum hydroxide is integrally molded on one or both sides with phenol foam as a core material.