JPH05222784A - Heat-sound-fire preventing panel - Google Patents

Abstract

PURPOSE:To the functional improve by installing a core, laminated with mineral fiber boards, on one side or both sides of a honeycomb core filled up with phenol foam, and covering each outer covering material on the one side or both the sides. CONSTITUTION:Phenol foam made up of foaming resol type, novolak type phenol resins is charged to a honeycomb consisting of a paper honeycomb, a metallic honeycomb or the like. Next, a mineral fiber board, using rock wook, etc., for a principle ingredient is laminated on the one side or both the sides. In succession, an outer covering material composed of a decorative metal plate, a dressed veneer board, etc., is applied to the one side or both the sides. With this constitution, heat-sound-fire preventabilities are improvable and simultaneously lightweightiness is promotable and, mechanical strength can be enhanced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel excellent in heat insulation, sound insulation and fire protection used as a peripheral wall material such as a door panel, a partition wall panel, an inner / outer wall panel, a vehicle panel and the like.

[0002]

2. Description of the Related Art A panel having a honeycomb of paper, aluminum or plastic as a core material and covered with a plastic plate, an aluminum plate, a steel plate or a plywood on both sides thereof is lightweight and has excellent mechanical strength. It is widely used for partition walls, interior and exterior walls, and vehicle panels. However, a panel using honeycomb as a core material has a multiple structure in which an outer covering material is joined to both front and back surfaces of a rigid honeycomb core by means of an adhesive or the like, so that the honeycomb core is thermally or acoustically connected. There is a problem that heat insulation and sound insulation are inferior due to the formation of various bridges, causing heat transmission, resonance transmission in the low range, and acoustic transmission loss (sound insulation loss) due to the coincidence effect in the high range. Furthermore, the flame retardancy against heat and heat and the heat shielding property are insufficient, and the fireproof property is not satisfied at present.

In order to solve such a problem, attempts have been made to improve heat insulation, sound insulation and fire prevention by filling a honeycomb core with a heat insulating material such as rock wool or glass wool or a plastic foam. It has been found that such a filling method cannot prevent thermal or acoustical bridging, and a satisfactory improvement in the performance cannot be expected.

Further, in Japanese Utility Model Laid-Open No. 59-120212, a glass core material is formed in the order of a honeycomb core, a glass wool, and a honeycomb core to fill the facing hollow portions of the front and back double-sided jacket materials. Although a sound insulation panel in which wool is inserted as an intermediate layer of a core material is disclosed, this panel can prevent thermal or acoustic bridging and improves heat insulation and sound insulation, but a honeycomb core Since it is divided into two layers, the mechanical strength is reduced, the characteristics of the honeycomb are not only sacrificed, but also the improvement of fire resistance cannot be achieved, and the manufacturing method is complicated, and there is a problem such as lack of practicality. The current situation is that it has not been resolved.

[0005]

SUMMARY OF THE INVENTION Therefore, an object of the present invention is to provide a heat insulating property, a sound insulating property, and a fireproof property without sacrificing the above-mentioned characteristics of a panel having a honeycomb core which is lightweight and has excellent mechanical strength. It is to provide a panel that is capable of imparting a property.

[0006]

The present invention has been made to achieve the above-mentioned object, and a panel of the present invention has a honeycomb core in which phenol foam is filled with a phenolic foam, and one or both surfaces of the mineral phenolic foam are minerals. It is characterized by including a core material formed by laminating high-quality fiber boards, and covering one or both surfaces of the core material with such a structure. With such a structure, the same lightweight as a conventional panel using honeycomb as a core material is provided. And, it has become possible to provide a panel having excellent heat insulation, sound insulation, and fire protection while maintaining mechanical properties.

As the honeycomb core used in the panel of the present invention, a paper honeycomb made of a craft parf paper system;
Aramid honeycomb made of aromatic polyamide paper; aluminum hydroxide, glass fiber, calcium silicate fiber,
Non-combustible paper-based honeycomb consisting of inorganic materials such as rock wool and ceramic wool, or organic materials such as flame-retardant pulp;
An aluminum-based metal honeycomb or the like may be used, and these cell shapes include shapes such as squares, rectangles, triangles, and circles in addition to hexagons.

Examples of the phenol foam to be filled in the honeycomb core include a resole type phenol resin, a modified phenol resin, and a phenol foam obtained by foaming and curing a novolac type phenol resin having a softening point of 30 to 80 ° C. Here, the resol type phenolic resin is
It is a liquid phenol resin obtained by a conventional method using phenols and aldehydes with an alkaline catalyst such as potassium hydroxide, calcium hydroxide or amine.

The modified phenol resin is a type obtained by modifying the resol type phenol resin or the benzylic type phenol resin obtained with an acetate catalyst with an isocyanate compound, a polyester prepolymer, an epoxy resin prepolymer or the like.

The novolak type phenol resin is a solid type resin obtained by using an oxalic acid catalyst for phenols and aldehydes, and has a softening point of 30-80.
The reason why the temperature is set to 0 ° C is that the resin is mixed with a foaming agent, a foam stabilizer and a curing agent in the softening point range to foam and cure at a temperature of 130 to 170 ° C.

The mineral fiber board used in the panel of the present invention contains rock wool as a main component and organic fibers such as kraft pulp, recycled pulp and vinylon; attapulgite, sepiolite, potassium titanate fiber, glass fiber, Inorganic fibers such as ceramic wool;
Clay, mica, gypsum, talc, aluminum hydroxide,
Calcium carbonate, vermiculite, shirasu balloon,
An inorganic slurry such as boric acid; a binder such as phenol resin, melamine resin, poval, starch and acrylic resin; and an aqueous slurry comprising a binding aid such as polyacrylamide and a sulfuric acid band are used in a cylinder or fourdrinier machine. The sound absorbing, heat insulating and non-flammable mineral fiber board having a rock wool content of 70 wt% or more and a density of 300 kg / cm ³ or more, which is obtained by drying and hardening the wet board produced in (1), can be mentioned.

The panel of the present invention comprises a core material obtained by laminating the above-mentioned mineral fiber board on one side or both sides of the honeycomb phenol foam in which the above-mentioned honeycomb core is filled with the above-mentioned phenol foam. The core material having such a configuration is manufactured, for example, as follows.

That is, the above-mentioned phenol resin is added with a freon gas, a carbonate, methylene chloride, dinitrosopentamethylenetetramine, a blowing agent comprising a hydrocarbon-based freon substitute gas, a silicone-based foam stabilizer, phenolsulfonic acid, and paratoluenesulfonic acid. Acid or hardener such as hexamethylenetetramine, hardener such as diphenylmethane diisocyanate, etc. Liquid or solid foaming property obtained by adding inorganic or organic substances such as clay, glass fiber, mica, gypsum, wood powder, etc. The phenolic resin is first produced.

Next, when the above-mentioned foamable phenol resin is liquid, it is directly coated on a non-combustible paper surface material (for example, non-combustible paper consisting of calcium silicate, pulp, glass fiber, aluminum hydroxide, a binder and a fixing agent). By doing so, a face material coated with a foamable phenol resin is obtained.

On the other hand, when the above-mentioned foamable phenol resin is in a solid state, it is sprayed and melted on a face material, or it is melted or dissolved by a solvent to be in a liquid state so that it can be coated. A surface material coated with a foamable phenol resin is obtained by coating an inorganic surface material and volatilizing a solvent as needed.

Next, the above-mentioned foamable phenol resin-coated face material is pressed against the upper surface of the above-mentioned honeycomb core having a predetermined cell structure, while the lower surface is pressed against the above-mentioned mineral fiber board to foam. By heat-foaming and curing the soluble phenolic resin in the honeycomb cell, a core material in which the mineral fiber board is laminated on one surface of the honeycomb phenolic foam in which the honeycomb core is filled with the phenolic foam is obtained. Also, spread the mineral fiber board on the surface (inorganic surface material coated surface) opposite to the surface of the core material on which the mineral fiber board is laminated, using an epoxy resin, synthetic rubber resin or vinyl acetate resin adhesive. By post-bonding using, the core material in which the mineral fiber boards are laminated on both surfaces of the honeycomb phenol foam is obtained.

When a mineral fiber board is used as the upper and lower surfaces when the phenol resin is foamed, a core material in which the mineral fiber boards are laminated on both surfaces of the phenol foam can be directly obtained. Further, when an inorganic surface material other than the mineral fiber board is used as the upper and lower surface materials when the phenol resin is foamed, it is necessary to post-process the mineral fiber board on one or both sides of the molded product after foaming. is there.

In the production of the core material for the panel of the present invention, JP-A-3-7312 and JP-A-59-8933 are used.
The method described in Japanese Patent No. 5 or the like can be appropriately adopted.

The panel of the present invention can be obtained by coating one or both surfaces of the core material obtained as described above with an outer coating material. As the jacket material, decorative steel plate, decorative copper plate, decorative aluminum plate, flame-retardant decorative plywood, decorative carbon fiber or glass fiber reinforced phenolic resin plate (CFRP, GFR)
P) and the like are preferably used, but not limited thereto.

The panel of the present invention has the advantage of being lightweight. Further, one or both sides of the phenol foam core are laminated with the mineral fiber board, and the fiber arrangement of the mineral fiber board is in the direction perpendicular to the honeycomb core, so that thermal and acoustic bridging of the rigid honeycomb core can be prevented. Therefore, it is possible to impart further excellent heat insulating properties, sound insulating properties, and fireproof properties without impairing the mechanical properties and heat insulating properties of the honeycomb phenol foam. In particular, since the mineral fiber board protects against fire and heat, the fire resistance is significantly improved. Since the panel of the present invention is a panel in which an outer covering material such as a steel plate, an aluminum plate, a copper plate, a flame-retardant plywood, CFRP, GFRP is covered with an adhesive as an outer covering material, heat insulation,
It has excellent sound insulation and fireproof properties, and is suitable for use as door panels, partition wall panels, interior and exterior wall panels, and the like.

[0021]

The present invention will be further described with reference to the following examples.

Example 1 (1) Production of Phenolic Resin 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 subjected to an isothermal reaction at 90 ° C. for 60 minutes, followed by bromination. After adding 85 parts by weight of cresol monoglycidyl ether and reacting for another 20 minutes, the pH of the reaction liquid was 7.0.
Oxalic acid was added to 7.3 to neutralize the reaction solution and dehydrated under reduced pressure at 80 ° C to give a solid content of 89% by weight and 30 ° C.
A liquid resol type phenol resin solution having a viscosity of 5700 cps, a free phenol of 3.0 wt% and a free formaldehyde of 1.9 wt% was obtained.

(2) Manufacture of mineral fiber board Solid components are 76 parts by weight of rock wool, 10 parts by weight of aluminum hydroxide, 3 parts by weight of pulp, 5 parts by weight of sepiolite, 4 parts by weight of poval, 1 part by weight of polyacrylamide,
A 4% by weight aqueous dispersion containing 1 part by weight of a sulfuric acid band was made into an aqueous slurry with a pulper and a despar, and the obtained slurry was made into paper by a Fourdrinier paper making machine and was dehydrated and press-molded to form a wet board. Subsequently, it was dried at 250 ° C. for 1 hour and at 170 ° C. for 1 hour, surface-machined by a planer, density 380 kg / m ³ , bending strength 28 kg / cm.
² , non-combustible grade white mineral fiber board was obtained.

(3) Manufacture of core material composed of honeycomb phenol foam and mineral fiber board Resol type phenol resin solution 10 obtained in the above (1)
In 0 parts by weight, a foam stabilizer (L534 manufactured by Union Carbite Co., Ltd.
0) 1 part by weight and 10 parts by weight of a flame retardant (antimony trioxide) were added to obtain a liquid resol type phenol resin composition. Next, 20 parts by weight of a foaming agent (trichlorotrifluoroethane) and 15 parts by weight of a curing agent (phenol sulfonic acid) were added to this resin composition. Furthermore, a foaming stock solution is obtained by adding a pH adjuster so that the pH of the foamed cured product becomes approximately neutral, and the foaming stock solution is discharged from the discharge port of the mixing and discharging machine to a top surface material (calcium silicate 33% by weight, pulp 30 %, Glass fiber 3% by weight, aluminum hydroxide 30% by weight, binder 3% by weight and fixing agent 1% by weight), and the foam density after foaming and curing is 35 kg / m.
^The effervescent stock solution was uniformly coated with a doctor knife so as to be ³ . Then, the foamable stock solution coating surface of the upper surface material was brought into contact with the upper surface of the honeycomb core material (thickness: 26 mm: paper honeycomb manufactured by Nagoya Core Material Co., Ltd., product number 30KR) with a pressure roll.

On the other hand, a thickness of 9 m obtained in (2) above.
A mineral fiber board of m and a density of 380 kg / m ³ was supplied and brought into contact with the lower surface of the same core material. The upper and lower surfaces are brought into contact with the upper and lower surfaces, and the core material having a honeycomb-shaped cell structure is sent to the curing furnace while being pressed against the upper and lower endless belts.
By heating and foaming and curing, a mineral fiber board was laminated as a lower surface material, and a noncombustible paper was laminated as an upper surface material on a honeycomb phenol foam to prepare a core material (C ₁ ).

(4) Manufacture of a panel by covering with a jacket material Commercially available natural veneer-attached flame-retardant decorative plywood (thickness: 5 mm) is applied to both surfaces of the core material (C ₁ ) obtained in (3) above with vinyl acetate. A resin emulsion adhesive (applied amount: about 200 g / m ² ) was pressure-bonded to produce a panel (P ₁ ).

Example 2 (1) Manufacture of core material 16 mm thick instead of 26 mm thick paper honeycomb
Paper honeycomb (manufactured by Nagoya core material industry: product number 30K
(1), (2) of Example 1 except that R) was used.
In the same manner as (3), after obtaining a honeycomb phenol foam in which a mineral fiber board was laminated as a lower surface material and a non-combustible paper was laminated as an upper surface material, it was obtained in (2) of Example 1 on the upper surface side. The same mineral fiber board (thickness 9 mm, density 380 kg / m ³ ) as the lower surface material was pressure-bonded with a commercial vinyl acetate resin emulsion adhesive (applied amount: about 200 g / m ² ), and the mineral was formed on the upper and lower surfaces of honeycomb phenol foam A core material (C ₂ ) having a high quality fiber board and sandwiched with honeycomb phenol foam was produced.

(2) Manufacture of panel Example 1 was formed on both sides of the core material (C ₂ ) obtained in the above (1).
The same outer covering material as (4) of item (4) was applied in the same manner as (4) of Example 1 to obtain a panel (P ₂ ).

Example 3 (1) Manufacture of core material Commercially available novolac type phenol resin (manufactured by Gunei Chemical Industry Co., Ltd .: softening temperature 70 ° C.) was used as phenol resin, and 5 parts by weight of hexa were added to 100 parts by weight thereof. Methylenetetramine, 6 parts by weight of dinitrosopentamethylenemethylenetetramine,
1 part by weight of polydimethylsiloxane / EO / PO copolymer-based silicon foam stabilizer was mixed to obtain a foamable stock solution, which was heated and kneaded with a blender to prepare a glass woven cloth (basis weight: 100 g
/ M ² ), 500 g / m ^{2 was} applied to obtain a heat-foamable phenol resin sheet. The obtained heat-foamable phenolic resin sheet and the mineral fiber board (thickness 9 mm, density 380 kg / m ³ ) obtained in (2) of Example 1 were paper honeycomb (thickness 15 mm, manufactured by Nagoya Core Material Industry: Part no. 30KR) is brought into contact with the upper and lower surfaces respectively, and the thickness is set to 35 mm by a heat press, and by heat foaming and curing at 160 ° C for 10 minutes, a mineral fiber board is used as the lower surface material and a glass woven cloth is used as the upper surface material. A core material (C ₃ ) laminated on each of the honeycomb phenol foams was manufactured.

(2) Manufacture of panel The same outer covering material as in (4) of Example 1 was applied to both surfaces of the core material (C ₃ ) obtained in (1) above in the same manner as in (4) of Example 1. And a panel (P _3a ) was manufactured.

Commercially available colored zinc steel sheets (thickness 0.8 mm) were applied on both sides of the core material (C ₃ ) obtained in the above (1) with a flame-retardant epoxy resin adhesive (application amount: about 150 g / m ² ).
Then, the panel (P _3b ) was manufactured by crimping.

Comparative Example 1 A paper honeycomb (thickness: 35 mm, manufactured by Nagoya Core Material Co., Ltd .: product number 30KR) was coated on both sides with the same outer covering material as in (4) of Example 1 as in (4) of Example 1. Then, a comparative panel (P ₄ ) was manufactured.

Comparative Example 2 Commercially available colored zinc steel sheets (0.8 mm in thickness) were pressure-bonded to both sides of the same paper honeycomb as in Comparative Example 1 with a flame-retardant type epoxy resin adhesive (applied amount: about 150 g / m ² ). , A comparative panel (P ₅ ) was produced.

Physical Properties Test Table 1 shows the results of measuring the physical properties of the core materials and panels obtained in Examples 1 to 3 and the panels obtained in Comparative Examples 1 and 2. From Table 1, the panels of Examples 1 to 3 were significantly superior to the panels of Comparative Examples 1 and 2 in heat insulation, soundproofing, and fireproofing.

[0035]

[Table 1]

[0036]

As is apparent from the above-mentioned embodiments, the panel of the present invention is lightweight, has mechanical strength, and is excellent in heat insulating property, sound insulating property, and fireproof property. It can be effectively used as a wall panel, an inner / outer wall panel, and a vehicle panel.

Claims (1)

[Claims] 1. A core material comprising a honeycomb fiber foam in which a honeycomb core is filled with phenol foam, and a mineral fiber board is laminated on one or both surfaces of the honeycomb phenol foam, and one or both surfaces of the core material are covered with a jacket material. Characteristic heat insulation and sound insulation and fire protection panel.