JPH05229042A - Non-combustible honeycomb structural material and non-combustible board - Google Patents

Abstract

PURPOSE:To inexpensively produce a non-combustible honeycomb structural material and a non-combustible board having lightweight properties and non- combustibility and capable of holding a predetermined shape under a high temp. use condition. CONSTITUTION:Non-combustible sheets 2 formed from a slurry based on sepiolite by a papermaking method are laminated in a honeycomb shape using a vinyl acetate type adhesive 3 between the sheets and an inorg. impregnant 4 is infiltrated in and applied to the entire surface of the honeycomb structual material thus formed.

Description

Detailed Description of the Invention

[0001]

The present invention has heat resistance and nonflammability,
Lightweight and high-strength, partition wall material as building material,
The present invention relates to a non-combustible honeycomb structural material and a non-combustible board that can be used as a core material for panels such as shutters, doors, and floors, as well as structural materials for aircraft, interior panels for railway vehicles, and the like.

[0002]

2. Description of the Related Art Conventionally, a paper honeycomb in which a thick paper is formed into a honeycomb is widely used as a structural material which is lightweight, has a certain strength, is inexpensive and is easy to handle.

However, since this paper honeycomb is of paper quality, it easily burns and is unsuitable for a place requiring high rigidity.

For this reason, conventionally, when these characteristics are required, paper using asbestos has been used. However, asbestos has a harmful effect on health, so recently
It has been discontinued.

Therefore, a honeycomb core formed by laminating metal foils of aluminum, stainless steel or the like is usually used as a structural material in a place that is lightweight, non-combustible and requires high rigidity.

[0006] Honeycomb structural materials using these metal foils are used for various structural materials such as aircrafts, railway vehicles, and building materials because of their high rigidity and strength due to their shape characteristics despite their light weight.

However, the honeycomb structure material using these metal foils is very expensive as compared with the paper honeycomb.

From the above, Japanese Patent Laid-Open No. 60-250
In Japanese Patent Laid-Open No. 945 and Japanese Patent Laid-Open No. 63-178033,
A technique of a honeycomb structure material having improved flame retardancy using a paper containing aluminum hydroxide is disclosed.

[0009]

However, the above-mentioned JP-A-60-250945 and JP-A-63-178033 have been proposed.
Although the technique disclosed in the publication has flame retardancy, it is indispensable to mix about 30% of pulp in order to improve the bending strength, so that the technique is relatively easy to burn. Although it is possible to improve the flame retardancy to some extent by impregnating diatomaceous earth, urea melamine, etc., there is no shape retention property after thermal decomposition and it easily collapses. Therefore, even though it is flame-retardant, the place of use is considerably limited.

On the other hand, a gypsum board is sometimes used as a backing material for the partition wall material, but the gypsum board is heavy and easily broken.

Therefore, the object of the present invention is to provide a nonflammable honeycomb structure material and a nonflammable board which are lightweight, have nonflammability, can retain a predetermined shape even under high temperature use, and can be manufactured at low cost. To do.

[0012]

A non-combustible honeycomb structure according to the invention of claim 1 uses a vinyl acetate adhesive between layers of a non-combustible sheet formed by making a slurry containing sepiolite as a main component. It is a laminate of honeycombs.

In the non-combustible honeycomb structure according to the second aspect of the present invention, a non-combustible sheet formed by making a slurry containing sepiolite as a main component is laminated in a honeycomb shape by using a vinyl acetate adhesive between layers. The whole surface is coated with an inorganic impregnating agent.

The noncombustible board according to the invention of claim 3 is
A non-combustible honeycomb structure made by stacking non-combustible sheets made of a slurry containing sepiolite as a main component between layers using a vinyl acetate adhesive, and a slurry containing sepiolite as a main component The non-combustible plate material is adhered to both surfaces of the non-combustible honeycomb structure material through a vinyl acetate adhesive.

In the non-combustible honeycomb according to the invention of claim 4, a non-combustible sheet formed by making a slurry containing sepiolite as a main component is laminated in a honeycomb shape by using a vinyl acetate adhesive between layers, and the surface thereof is formed. Non-combustible honeycomb structure material formed by applying an inorganic impregnating agent to the whole, and made by making a slurry containing sepiolite as a main component, and adhered to both sides of the non-combustible honeycomb structure material via a vinyl acetate adhesive. And non-combustible plate material.

[0016]

In the first aspect of the invention, since the noncombustible honeycomb structure material is composed of flexible sepiolite, the bending strength is high and the honeycomb core can be manufactured. In addition, the noncombustible honeycomb structure has noncombustibility due to the noncombustible property of sepiolite, which is a mineral fiber, and it is possible to maintain a predetermined shape even after contact with a flame. Furthermore, since sepiolite is inexpensive in terms of material, a non-combustible honeycomb structure material can be manufactured at low cost.

In the invention of claim 2, the same action as in claim 1 is achieved, and since the inorganic impregnating agent is applied to the entire surface of the honeycomb core after it is manufactured, the tensile strength,
The compressive strength can be improved, and the film formation can increase the surface strength to prevent the fibers from fuzzing or peeling off. Further, ignition of the vinyl acetate adhesive can be suppressed.

In the invention of claim 3, since the non-combustible board is entirely composed of sepiolite,
In addition to the same effect as above, since the non-combustible plate material is adhered to both surfaces, it has high strength against a compressive load from the lateral direction. Furthermore, when a surface material such as a steel plate is attached to the side surface of the board, the entire surface of the noncombustible plate material becomes a bonding surface, so the bonding strength is greater than when the surface material is directly bonded to the noncombustible honeycomb structure material. ..

In the invention of claim 4, the same operation as in claim 3 is performed, and since the inorganic impregnating agent is applied to the entire surface of the honeycomb core after it is manufactured, the tensile strength,
The compressive strength can be improved, and the film formation can increase the surface strength to prevent the fibers from fuzzing or peeling off. Further, ignition of the vinyl acetate adhesive can be suppressed.

[0020]

【Example】

<First Embodiment> A first embodiment of the present invention will be described below with reference to FIGS.

FIG. 1 is a perspective view showing a noncombustible honeycomb structure material according to the first embodiment of the present invention. In the figure, reference numeral 1 is a honeycomb core having a constant width formed by laminating a plurality of noncombustible sheets 2 containing sepiolite as a main component using a vinyl acetate adhesive 3 and expanding them. The solid content of the vinyl acetate adhesive 3 is usually 30 to 50%. Reference numeral 4 denotes an inorganic impregnating agent which is formed on the entire surface of the noncombustible sheet 2 by a known means such as dipping or spraying after being formed into a honeycomb shape. As the inorganic impregnating agent 4, various water-soluble or water-dispersible agents are used. Inorganic agents of the type can be used, and water glass, aluminum phosphate solution, colloidal silica, colloidal alumina, etc. mixed with a curing agent, a catalyst, etc. are used in consideration of heat resistant temperature, coating workability, drying speed, etc. The optimum material may be selected by using water glass in this embodiment. The vinyl acetate adhesive 3 has a solid organic component content of 5% excluding the solvent to ensure nonflammability.
Below.

Here, sepiolite, which is the main component of the noncombustible honeycomb structure material, will be described.

Sepiolite is a clay mineral commonly referred to as mountain leather, mountain cork, and mountain wood, and sepiolite in Japan is one of these. The appearance may be cork-like, leather-like, or a pure white soft lump, but it is generally a magnesium silicate lump having fibrous properties. For the time being, although it is classified as a one-dimensional structure clay, it can be considered as a crystalline three-dimensional structure of bricks that can be easily shaved in a certain direction depending on the viewpoint, and a crystal form group consisting of silicon, magnesium, oxygen, hydroxyl group, and crystal water is formed. Is forming. Physical properties have basic properties such as adsorption, thixotropy, and solidification. And it is known as an inexpensive material.

Next, the non-combustible sheet 2 to the honeycomb core 1
A process of manufacturing the will be described.

FIG. 2 is an explanatory view showing a manufacturing process of the noncombustible honeycomb structure material according to the first embodiment of the present invention.

First, in the cutting step shown in (a), the non-combustible sheet 2 formed by making a slurry containing sepiolite as a main component is cut into a certain width, and then the coating step in (b) is carried out. The vinyl acetate adhesive 3 is linearly applied to the surface of the cut non-combustible sheet 2 at a constant interval and a constant width by screen transfer or roller coating. At this time, if the coating amount of the vinyl acetate adhesive 3 is large, it flows laterally and the lines are disturbed. On the contrary, if the coating amount is small, adhesion failure occurs. .. In this example, the coating amount of the vinyl acetate adhesive 3 was set to about 10 g / m ² . Subsequently, the vinyl acetate adhesive 3 is applied to the other noncombustible sheets 2 in the same manner. Here, the position where the vinyl acetate adhesive 3 is linearly applied is a position where the adjacent noncombustible sheets 2 are alternately shifted by a half pitch when a plurality of noncombustible sheets 2 are laminated. The width dimension of the vinyl acetate adhesive 3 applied linearly is the length dimension of the cell overlapping surface of the honeycomb core 1 after completion, and the width dimension of the vinyl acetate adhesive 3 is changed to change the honeycomb dimension. The cell size of core 1 will change.

After the vinyl acetate adhesive 3 is applied at regular intervals, a plurality of the non-combustible sheets 2 that have been applied are laminated in the laminating and crimping step (c), and they are crimped from above and below to be joined to form a linear shape. The sheet block 5 is formed by applying the vinyl acetate-based adhesive 3 of No. 1 by shifting by half pitch alternately.

Thereafter, in the cutting step (d), the sheet block 5 is cut into the width dimension of the finished product to form the cut sheet block 6.

Then, in the spreading step (e), the cutting sheet block 6 is stored in the liquid tank 7 in which the inorganic impregnating agent 4 is stored.
By expanding from both sides in a state of being immersed in the liquid, taking out from the liquid tank 7, and drying and solidifying the inorganic impregnating agent 4,
The honeycomb core 1 is completed. Although the inorganic impregnating agent 4 is used during the spreading operation, it may be formed into a honeycomb shape by spreading and then dipped in the liquid tank 7 to be applied. However, the workability is better when the liquid is expanded while being immersed in the liquid tank 7.

Next, an example of manufacturing the non-combustible sheet 2 constituting the honeycomb core 1 will be described with reference to FIG.

The non-combustible sheet 2 in this example was produced by using sepiolite as a main material, adding a polymer binder, glass fiber and the like to form a slurry, and paper-making.

FIG. 3 is an explanatory view showing the outline of the manufacturing process of the non-combustible sheet of the first embodiment of the present invention.

In the drawing, in the defibration step A, sepiolite as a main raw material, glass fiber as a reinforcing material, a small amount of wood pulp and synthetic fiber are put into a defibrating machine and defibrated by stirring to disperse the fibers. Improve Note that here,
The amount of wood pulp is 5% by weight or less. If it is mixed more than this, nonflammability will be impaired.

Next, in the raw material mixing step B, the disintegrated paper material, polymer binder, softening agent, stabilizer and the like are put into a mixing tank and mixed to prepare a slurry. As the polymer binder used here, a thermosetting resin was used in order to satisfy the requirements of structural strength and water resistance, and further a thermoplastic resin was used.

The slurry mixed in the raw material mixing step B is
In order to carry out a coagulation treatment suitable for papermaking, in the process step C, a focusing reaction device is used for focusing. Then, process step C
The slurry prepared in (1) is sent to a stock tank, and enters a storage step D in which the mixed state is always maintained to be uniform so that sedimentation separation or collapse of the prepared sheet does not occur.

Then, the slurry uniformly maintained in the accumulating step D is pumped up to the metering hopper by a metering pump,
Lead to the papermaking process E.

In the papermaking process E of this example, papermaking was carried out using a round net paper machine. The slurry concentration at this time is 0.05
.About.0.5%, and the paper machine used a 60-80 mesh net.

The wet sheet obtained by dehydrating the slurry in the papermaking step E is transported to the drying furnace in the drying step F and dried at a required temperature for a predetermined time to evaporate the moisture in the inside and cause the reaction of the binder. Accelerate to dry and solidify.

By the above, the incombustible sheet 2 having a plate thickness of 0.1 to 1.0 mm is completed. The non-combustible sheet 2 has high heat resistance, and can maintain a predetermined shape by producing a small amount of smoke and blackening even when a fire is approached.

As described above, in the honeycomb core 1 which is the non-combustible honeycomb structure material of the above-mentioned embodiment, the vinyl acetate adhesive 3 is used between the non-combustible sheet 2 made of the slurry containing sepiolite as a main component. And stack them in a honeycomb
The inorganic impregnating agent 4 is dip-coated on the entire surface.

Therefore, according to the above embodiment, since the honeycomb core 1 is made of flexible sepiolite, the bending strength is high, the honeycomb core 1 can be manufactured by expansion, and sepiolite which is a mineral fiber. Non-combustible properties and coating amount of vinyl acetate adhesive is 5% with solid organic component
By the following, even if the non-combustible honeycomb structure is brought into contact with a flame, it hardly burns, and a predetermined shape can be maintained. Furthermore, since sepiolite is inexpensive in material, the honeycomb core 1 can be manufactured at low cost. Since the layers are joined using the vinyl acetate adhesive 3 dissolved in an organic solvent, the coating workability is good and the drying property is excellent.

After the honeycomb core 1 is manufactured, the inorganic impregnating agent 4 is applied to the entire surface of the honeycomb core 1, so that the tensile strength and the compressive strength can be improved, and the surface strength can be increased by forming the film to increase the fiber fluff. It can prevent standing or peeling. Furthermore, since the adhesive layer is covered with the inorganic impregnating agent 4, the ignition of the vinyl acetate adhesive 3 can be significantly suppressed.

In addition, since the surface of the noncombustible sheet 2 is microscopically uneven, the anchoring effect of the nonflammable sheet 2 makes it more permeable to vinyl acetate adhesives than conventional aluminum hydroxide paper. It is possible to obtain a product having a high adhesive strength.

The first embodiment corresponds to the aspect of claim 2 and can also be said to correspond to the aspect of claim 1.

<Second Embodiment> Next, a non-combustible board according to a second embodiment of the present invention will be described with reference to FIG.

FIG. 4 is a sectional view showing a non-combustible board according to the second embodiment of the present invention. In the figure, the same reference numerals as those in FIGS. 1 and 2 are the same as or correspond to the components of the first embodiment.

In the figure, 1 is a honeycomb having a constant width formed by spreading a plurality of the same non-combustible sheets 2 as in the first embodiment by using a vinyl acetate adhesive 3 as in the first embodiment. It is the core. As with the first embodiment, it is desirable to apply the inorganic impregnating agent 4 to the entire surface of the honeycomb core 1 by means such as dipping.

Reference numeral 11 denotes a non-combustible board obtained by adhering non-combustible plate materials 12 to both side surfaces of the honeycomb core 1. The non-combustible plate material 12 is made of a slurry containing sepiolite as a main component, is made of the same material as the non-combustible sheet 2, and is considerably thicker than the non-combustible sheet 2. Reference numeral 13 is a vinyl acetate adhesive which is applied to both end faces of the honeycomb core 1 by means such as roller coating to bond the honeycomb core 1 and the noncombustible plate material 12.

The non-combustible board 11 of the second embodiment constructed as described above is made of sepiolite as a whole material. Since 12 is attached, it has high strength against a compressive load from the lateral direction. Furthermore, when a surface material such as a steel plate is attached to the side surface of the non-combustible board 11, the entire one surface of the non-combustible plate material 12 serves as a bonding surface, so that the bonding strength is higher than that when the surface material is directly bonded to the honeycomb core 1. Can be increased.

The second embodiment corresponds to the third or fourth aspect.

The above honeycomb core 1 or noncombustible board 1
1 is lightweight, has high strength, and has excellent heat resistance and incombustibility. Therefore, these are used alone or as a partitioning material for building materials by attaching a surface material such as steel plate as a backing material. It can be widely used for wall materials, shutters, doors, core materials for panels such as floors, structural materials for aircraft, interior panels for railway vehicles, and the like.

Particularly, in partition panels as building materials, since steel sheets as surface materials attached to both surfaces of the partition panels tend to be thin in recent years, it is strongly required to improve the strength of the core material as the backing material. The non-combustible board 11 is useful as a core material useful for this.

By the way, the nonflammable sheet 2 of each of the above-mentioned embodiments
Uses a thermosetting resin and a thermoplastic resin as a binder and a flocculant of a slurry containing sepiolite as a main component, but is not limited to this when the present invention is carried out. It may be an aggregating agent or a binder, and in short, it may be any as long as it can industrially make a slurry and can impart a required bonding strength.

Further, the honeycomb core 1 of each of the above-mentioned embodiments is
The non-combustible sheet 2 is formed by a manufacturing method in which the vinyl acetate adhesive 3 is staggered by a half pitch and linearly applied, and a plurality of layers are laminated and then spread. However, the present invention is not limited to this. Alternatively, for example, it may be formed by a roll core manufacturing method or a corrugated core manufacturing method.

Further, the honeycomb core 1 of each of the above-mentioned embodiments is
You may fill the cell space with heat insulating material such as foam material,
In this case, in addition to the above effects, it is possible to enhance the heat insulating effect, and it is also possible to impart sound absorbing characteristics.

[0056]

As described above, the non-combustible honeycomb structure material of the present invention is formed into a honeycomb shape by using a vinyl acetate-based adhesive between layers of a non-combustible sheet prepared by making a slurry containing sepiolite as a main component. It is laminated. Therefore,
Since the non-combustible honeycomb structure material is composed of flexible sepiolite, it has high bending strength, making it possible to manufacture a honeycomb core, and at the same time, the characteristics of mineral fiber sepiolite and the coating amount of vinyl acetate adhesive are By limiting the amount to a predetermined amount or less, it has noncombustibility and can maintain a predetermined shape even after contact with flame. Furthermore, since sepiolite is inexpensive in terms of material, a non-combustible honeycomb structure material can be manufactured at low cost. Further, since the layers are joined with the vinyl acetate adhesive, the coating workability and the drying property are good.

Further, the non-combustible board of the present invention is a non-combustible honeycomb formed by stacking non-combustible sheets made of a slurry containing sepiolite as a main component in a honeycomb shape between layers using a vinyl acetate adhesive. It is composed of a structural material and a non-combustible plate material formed by making a slurry containing sepiolite as a main component and pasted on both sides of the non-combustible honeycomb structural material via a vinyl acetate adhesive. Therefore, since the material is composed of sepiolite as a whole, the same effect as that of the non-combustible honeycomb structure material can be obtained, and since the non-combustible plate material is attached to both surfaces, it is possible to apply a compressive load from the lateral direction. It also has high strength. Then, when a surface material such as a steel plate is attached to the side surface of the noncombustible board, the entire surface of the noncombustible plate material becomes a bonding surface, so that the bonding strength is higher than when the surface material is directly bonded to the noncombustible honeycomb structure material. Can be increased.

[Brief description of drawings]

FIG. 1 is a perspective view showing a noncombustible honeycomb structure material according to a first embodiment of the present invention.

FIG. 2 is an explanatory view showing a manufacturing process of the non-combustible honeycomb structure material according to the first embodiment of the present invention.

FIG. 3 is an explanatory view showing the outline of the manufacturing process of the non-combustible sheet of the first embodiment of the present invention.

FIG. 4 is a sectional view showing a non-combustible board according to a second embodiment of the present invention.

[Explanation of symbols]

 1 Honeycomb core 2 Non-combustible sheet 3,13 Vinyl acetate adhesive 4 Inorganic impregnating agent 11 Non-combustible board 12 Non-combustible plate material

Claims (4)

[Claims] 1. A non-combustible honeycomb structure material comprising a non-combustible sheet formed by making a slurry containing sepiolite as a main component in a honeycomb shape by using a vinyl acetate adhesive between layers. .. 2. A non-combustible sheet obtained by making a slurry containing sepiolite as a main component is laminated between layers using a vinyl acetate adhesive to form a honeycomb structure, and an inorganic impregnating agent is applied to the entire surface thereof. A non-combustible honeycomb structure material characterized by the above. 3. A non-combustible honeycomb structure material formed by stacking non-combustible sheets made of a slurry containing sepiolite as a main component in a honeycomb shape by using a vinyl acetate adhesive between layers, and sepiolite as a main component. Made by making a slurry as an ingredient,
A non-combustible board, comprising: a non-combustible plate material adhered to both surfaces of the non-combustible honeycomb structure material via a vinyl acetate adhesive. 4. A non-combustible sheet formed by making a slurry containing sepiolite as a main component is laminated in a honeycomb shape by using a vinyl acetate adhesive between layers, and an inorganic impregnating agent is applied to the entire surface thereof. Made of non-combustible honeycomb structure material and slurry with sepiolite as the main component,
A non-combustible board, comprising: a non-combustible plate material adhered to both surfaces of the non-combustible honeycomb structure material via a vinyl acetate adhesive.