JPH0538776A - Fire-resistant composite heat-insulating panel - Google Patents

Abstract

PURPOSE:To provide a composite heat insulation panel, for use in an architectural interior material or an exterior material, having an excellent fire-resistance and large mechanical strength and being composed of a metallic plate and foamable synthetic resin, besides, having no fear of separation between the metal and the foamable resin even by vibration during the cutting work. CONSTITUTION:As a surface material of both front and rear surfaces, metal plates 31,4 are used, and foamable phenol resin 23 is employed as a core material, and further serpentine sheets 9, 10 comprising a complex layer of being a corrugated board in its one surface are disposed on each interface between the metallic plates 3,4 and the foamable phenol resin 23, wherein the metallic plates 3,4 and serpentine sheets 9,10 are joined by an adhesive, and the serpentine surfaces 19,20 of the serpentine materials 9,10 and the foamable phenol resin 23 are joined by curing adhesion of resin raw liquid, thereby obtaining a fire-resistance composite heat insulation panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite heat insulating panel excellent in fireproofness, which is mainly used as an interior material or an exterior material for construction and is formed by laminating a metal plate and a synthetic foam resin.

[0002]

2. Description of the Related Art Foamed phenolic resin has excellent fireproofing and heat insulating properties. Especially, a product obtained by laminating a metal plate as a surface material on the surface of foamed phenolic resin has excellent fireproofing property and excellent heat insulating property. When a high degree of fireproof performance is required as an interior or exterior material for construction, it is preferably used as a fireproof heat insulating plate and widely used for various construction boards, metal siding, panels and the like.

On the other hand, Japanese Unexamined Patent Publication No. 60-46014 discloses a surface material made of a single-sided corrugated board produced by discharging a foamable phenolic resin stock solution onto the core surface of a single-sided corrugated board made of asbestos and a laminated board of the foamed phenolic resin. A fire resistant panel is disclosed.

In order to produce a foamed phenolic resin laminate, a foamable phenolic resin stock solution is injected between two surface materials and heat-foamed. However, the foamed molded product gradually shrinks in 1-2 months after molding. To do. In order to avoid this shrinkage, a single-faced corrugated board is used as the surface material of the laminated board, and a porous layer is provided between the corrugated core of the single-sided corrugated board and the foamed phenolic resin. A method of preventing shrinkage is known (JP-A-64)
-14026).

On the other hand, Japanese Utility Model Application Laid-Open No. 59-9817 discloses a heat-insulating composite panel obtained by laminating a single-faced corrugated board on both sides of a foamed phenolic resin with a liner on the outside, and further laminating metal foils on both sides. There is.

[0006]

Among the conventional fire-resistant heat-insulating laminates obtained by laminating the foamed phenolic resin and the surface material, the foamable phenolic resin stock solution is poured directly onto a metal flat plate to cause condensation while foaming. The laminated plate has a weak adhesive force between the metal plate and the foamed phenolic resin, and when an impact force or a bending force is applied from the outside, or when vibration is applied during cutting with an electric saw, etc., the metal plate and the foamed phenolic resin are separated. Easy to peel off and difficult to handle.

A laminated sheet formed by foaming a corrugated surface by pouring a foamable phenol resin stock solution on a corrugated surface using only one-sided corrugated board as a surface material improves the bonding strength between the corrugated surface and the foamed phenol resin, but foams after molding. Due to the shrinkage of the phenolic resin, considerable shrinkage occurs in the direction perpendicular to the crest line of the single-sided corrugated board, and the product dimensions are not stable.

[0008] The laminated sheet in which the foamed phenolic resin is laminated between the two single-sided corrugated board and the metal foil is attached to the liner surface of the outer single-sided corrugated board is improved in heat insulating property by the metal foil, but dimensional stability, And the fire resistance is insufficient.

Therefore, the present invention is a laminated board using a metal plate as a surface material and using a foamed phenol resin as a core material, which is excellent in fireproofing and heat insulation, and has an adhesive force between the metal surface material and the foamed phenol resin layer. It is an object of the present invention to provide a fireproof heat insulating laminated plate which is large and is free from the risk of peeling due to impact force during handling, bending and vibration during processing and the like.

[0010]

[Means for Solving the Problems] In order to achieve the above object,
As a result of intensive studies by the present inventors, a corrugated sheet material having a corrugated shape on at least one side such as a single-faced corrugated board is interposed between the metal surface material and the foamed phenolic resin, and the corrugated sheet material is provided on the inner surface of the metal surface material. Is firmly adhered with an adhesive, and the expandable phenol resin stock solution is poured onto the corrugated surface of the corrugated sheet material to heat and foam it, so that the corrugated sheet material and the foamed phenol resin are firmly bonded, resulting in heat insulation and fire protection. The inventors have completed the present invention by finding that a fireproof heat-insulating laminate having excellent properties and dimensional stability and excellent bonding strength between laminated materials can be obtained.

That is, the present invention provides a fireproof composite heat insulating panel having a metal plate as a surface material on one or both sides and a foamed phenol resin as a core material, and a single-layer corrugated sheet at the interface between the metal plate and the foamed phenol resin. Material or a corrugated sheet material having a corrugated shape on at least one side, such as a corrugated sheet material formed of a single-sided corrugated board, and the metal plate and the corrugated sheet material are bonded together with an adhesive, and the corrugated sheet material The gist of the fireproof composite heat insulating panel is characterized in that the corrugated surface and the foamed phenolic resin are joined by curing and adhesion of a foamable phenolic resin stock solution.

The metal plate used in the composite heat insulation panel of the present invention has a thickness of 0.2 to 2 mm, preferably 0.2 to 1.
0 mm thick steel plate, color coated steel plate, resin coated steel plate, resin bonded steel plate, zinc, tin, etc. plated steel plate,
Any metal plate used as the surface material of the laminated plate such as an aluminum plate and a stainless steel plate can be used.

In addition to a flat plate, the metal plate is a metal plate having a corrugated shape, a square shape, or an uneven shape on the surface by embossing, bending, etching, etc. by a roll former or the like to enhance aesthetics or increase strength. Used.

The corrugated sheet material interposed between the metal plate and the foamed phenolic resin may be a single-layer corrugated sheet material, but like a single-sided corrugated cardboard, only one side of the corrugated core and the planar liner is corrugated. A corrugated sheet material having a plurality of layers is preferably used because when the liner surface and the metal plate are bonded together, the bonding surface is wide and strong bonding is possible. As a corrugated sheet material consisting of multiple layers, in addition to single-sided corrugated board, two single-sided corrugated boards are bonded to one corrugated side of one core paper and the other liner side to form a single-sided liner for double-sided corrugated board You may use the corrugated sheet material which has a corrugated shape only on one side of the shape except paper.

As the material of the corrugated sheet material, kraft paper, liner paper, roofing paper, glassine paper, aluminum hydroxide paper, calcium carbonate paper, calcium silicate paper, etc. are used, and these are impregnated with a flame retardant or flame retardant resin. It is possible to use a material that has been applied and flame-retarded.

As the material of the corrugated sheet material, non-woven fabric, metal foil, flame-retardant synthetic resin sheet, etc. can be used in addition to the above various papers.

The basis weight of the corrugated sheet material is 100 to 500 g / m ^2.
If it is less than 100 g / m ² , the strength is insufficient, and the bonding strength for interposing the metal surface material and the foamed phenolic resin to bond them is lowered. If it exceeds 500 g / m ² , the fire resistance of the non-combustible material is lowered. The wave height of the corrugated sheet material is 1 to 10 mm, preferably 2 to
It is 5 mm.

For the adhesion of the metal plate and the corrugated sheet material, any known adhesive that can bond the material of the metal and the corrugated sheet material is used. Epoxy-based, phenol-based, resorcin-based, vinyl acetate-based, ethylene vinyl acetate-based, urethane-based adhesives and the like are used, and particularly phenol-based and highly flame-retardant adhesives are preferably used. The amount of the adhesive used is preferably about 30 g / m ² as a solid content.

In the method of bonding the metal plate and the corrugated sheet material, an adhesive is applied or sprayed on the metal plate by using a roll coater or a spraying device, the corrugated sheet materials are bonded together, and then heated if necessary. Instead of applying the adhesive to the surface of the metal plate, the adhesive may be applied to the corrugated sheet material. The adhesive may be applied uniformly on the entire adhesive surface, or may be applied in the form of strips or dots.

Although the thickness of the foamed phenolic resin of the fireproof composite heat insulating panel of the present invention varies depending on the use, it ranges from 20 to 50.
0 mm is suitable. As the undiluted solution of the foamed phenolic resin, a resol type, a benzylic ether type liquid phenolic resin is used, and a freon having an appropriate boiling point as a foaming agent, a volatile foaming agent such as dichloromethane, or carbon dioxide gas by thermal decomposition, A decomposed foaming agent that generates nitrogen gas or the like is added, and further a foam stabilizer such as silicone and a curing agent such as acid or isocyanate are mixed. If necessary, an acid neutralizer or a flame retardant may be added and a filler or a fibrous material may be mixed as a reinforcing agent. This foamable phenol resin stock solution is foamed and cured by heating to form a foam.

In order to manufacture the fireproof composite heat insulating panel of the present invention, two adhesive plates of a metal plate and a corrugated sheet material are placed with the corrugated surfaces of the corrugated sheet material facing each other with a space therebetween, and a foaming property is provided therebetween. Phenol resin stock solution is poured, and the space between both metal plates is kept constant and heated for a predetermined time. Heating temperature is 40-8
0 ° C is selected and the heating time depends on the thickness of the panel,
It is 1 minute or more, preferably 3 to 10 minutes.

In the fireproof composite heat insulating panel of the present invention, a metal plate may be used only as a surface material on one side, or a metal plate may be used as a surface material on both sides. When using a metal plate only for the one-sided surface material, as the other one-sided surface material, it is possible to use any hard flame-retardant surface material other than the metal plate used as the surface material of a normal fireproof panel, Further, soft side materials such as single-sided corrugated board, kraft paper, aluminum hydroxide paper, aluminum kraft paper, and metal foil may be used. Of the surface materials other than the metal plate, in the case of a surface material that can firmly bond the surface material and the expanded phenol resin by curing and bonding the foamable phenol resin stock solution, the surface material and the expanded phenol resin can be directly cured and bonded. Although it is possible to bond, if sufficient bonding force does not occur with curing adhesion of a foamable phenol resin stock solution such as a metal plate and a foamed phenolic resin, between the surface material and the foamed phenolic resin as in the case of a metal plate. It is possible to firmly bond the corrugated sheet material and the surface material with an adhesive via the corrugated sheet material, and to firmly bond the corrugated surface of the corrugated sheet material and the foamed phenolic resin by curing adhesion.

In order to continuously produce the fireproof composite heat insulating panel of the present invention in which both sides are metal plates, the composite surface material in which the metal plate and the corrugated sheet material are laminated is moved horizontally with the corrugated surface facing upward. , The foamable phenol resin stock solution was sprayed on the corrugated surface continuously and uniformly, and the composite surface material in which the metal plate-corrugated sheet material was laminated was placed on the corrugated surface downward, and the composite surface material was moved by the conveyor. Meanwhile, it is continuously heated through a heating chamber.
For continuous heating, a double conveyor in which two steel or rubber belt conveyors or slat-shaped conveyors are arranged in parallel at regular intervals is preferably used, whereby the interval between the metal plates is regulated to be constant. It can be foamed while. When only one surface is made of a metal plate, by replacing one of the above composite surface materials with another surface material, a fireproof composite heat insulating panel can be similarly produced continuously.

[0024]

The contents of the present invention will be described below with reference to the drawings. FIG. 1 is a sectional view of an example of a fireproof composite heat insulating panel of the present invention. Reference numerals 3 and 4 denote metal plates, and the liner surfaces 11 and 12 of the corrugated sheet materials 9 and 10 in a single-faced corrugated board are bonded to one surface thereof with an adhesive to form surface materials 17 and 18. The two surface materials 17, 18 are arranged in parallel with the corrugated surfaces 19, 20 facing each other, and the foamed phenolic resin 23 is placed in the gap.
Is filled.

[Examples 1 to 4 and Comparative Examples 1 and 2] A mold having an internal volume of 350 mm in length and width and 50 mm in height was formed with a thickness of 5 mm.
Of 0.5 mm thick metal plate shown in Table 1 as a composite surface material and the liner surface of the single-sided corrugated corrugated sheet material with a basis weight of 25 g / m ² polyethylene-vinyl acetate (EVA) adhesive What was adhere | attached with the agent was used. Examples 1 to 4 in Table 1 show examples of the fireproof composite heat insulating panel of the present invention produced by using the composite surface material produced by changing the metal plate and the corrugated sheet material. In this example, the corrugated sheet material has a wave height of 3 mm and a basis weight of 240 g / m ² .

First, the composite surface material is loaded into the mold with the corrugated surface facing up. This was placed in a constant temperature bath at 70 ° C. and taken out when the temperature of the mold became constant, and the resol type phenol resin stock solution (viscosity 2900 cps / 25 ° C.) was treated with Freon 113 and silicone foam stabilizer SH-193 (manufactured by Toray Silicone Co., Ltd.). ) And 64% phenolsulfonic acid are mixed and stirred, and the mixture is poured onto the corrugated surface of the composite surface material in the mold, and the same composite surface material that has been heated to 70 ° C. in a constant temperature bath is directed downward. And put it on the phenol resin stock solution, and close the upper lid of the mold.
The mixture was placed in a constant temperature bath at 0 ° C., taken out 10 minutes later, and released to obtain a fireproof composite heat insulating panel. The obtained composite heat insulating panel has a thickness of 50 mm and the density of the foamed phenolic resin of the core material is 40 kg / m ³
The amount of Freon 113 as a foaming agent was adjusted so that Table 1 shows the results of tests on the composite heat insulating panel, which were conducted on bending strength, tensile strength, presence or absence of peeling when the panel was cut, flammability, and the like.

[Table 1]

In Table 1, the bending strength is ASTM D-
According to 790, the measurement was performed under the condition that the span was 200 mm. Tensile strength was measured according to ASTM D-1623. A hand saw was used for the panel cutting test. Flammability test is JI
It was conducted according to the surface test of S A1321. The quasi-non-combustible acceptance standard of the JIS standard is temperature time area ≤100 ° C minutes, smoke coefficient CA value ≤60, and afterflame ≤30 seconds. In addition, as a comparative example, the same test was performed in the case of using a single-layer surface material in which the corrugated sheet material was not laminated instead of the composite surface material 17 and in the case of using only the corrugated sheet material as the surface material without laminating the metal plates. The results obtained are shown as Comparative Examples 1 and 2 in Table 1.

[Embodiment 5] FIG. 2 shows a process chart of an example of a continuous manufacturing method of a fireproof composite heat insulating panel of the present invention. One, two
Is a bundle of metal plates, and EVA is rolled by the roll coaters 5 and 6 on one surface of the metal plates 3 and 4 made of steel.
The system adhesive is applied continuously. On the other hand, from the corrugated sheet material bundles 7 and 8, the corrugated sheet material 9 in the shape of a single-sided corrugated board,
10 is pulled out, and its liner surfaces 11 and 12 are metal plates 3 and
The adhesive coating surface of No. 4 is continuously stuck by the sticking rollers 13 and 14, and then heated by the infrared heaters 15 and 16 to be completely adhered, and the metal plates 3 and 4 and the corrugated sheet materials 9 and 10 are laminated. The composite surface materials 17, 18 are obtained.

Next, the foamable phenol resin stock solution 21 is uniformly sprayed on the lower composite surface material 17. A double conveyor 22 composed of two belt conveyors in which the corrugated surfaces 19 and 20 of the two composite surface materials 17 and 18 are opposed to each other and the distance between them is kept constant, and the belt conveyors are horizontally arranged in parallel with each other.
It is sandwiched between and moved horizontally at a constant speed. This double conveyor 22 is passed through the heating chamber to heat and keep it at a constant temperature. The foamable phenol resin stock solution 21 is heated during being conveyed by the double conveyor 22, foamed and cured to become a foamed phenol resin 23. After passing through the double conveyor 22, it is cut into a predetermined length by a cutting machine 24.

[0030]

According to the fireproof composite heat insulation panel of the present invention, the surface
The metal plate 3 maintains the strength and fire resistance, the foamed phenolic resin 23 of the core material has a large heat insulating property and maintains the heat insulating property of the composite heat insulating panel, and the foamed phenolic resin 23 has a large flame retardant property. The fire resistance of the phenol resin 23 is enhanced. Corrugated sheet material 9 between the metal plate 3 and the foamed phenolic resin 23
The corrugated sheet material 9 and the metal plate 3 are firmly bonded together by an adhesive, and the foamable phenol resin stock solution 21 foams and cures on the corrugated surface 19 of the corrugated sheet material 9. The surface 19 is firmly adhered by curing adhesion, and the anchoring effect of the foamed phenolic resin 23 penetrating into the corrugated surface 19 enhances the bonding force, so that vibration due to processing when using the fireproof composite heat insulation panel, etc. Then, the foamed phenolic resin 23 and the composite surface material 1
The corrugated surface 19 of No. 7 is not likely to peel off, and the mechanical strength is also improved.

Further, in the fireproof composite heat insulation panel of the present invention, there is a possibility that the product shrinks in the direction perpendicular to the wave crest line of the corrugated sheet material during storage, as in the case where only the corrugated sheet material is used as the surface material. And has excellent dimensional stability.

[0032]

EFFECTS OF THE INVENTION The fireproof composite heat insulating panel of the present invention has excellent heat insulating properties and fireproof properties, excellent mechanical strength, and the corrugated surface of the composite surface material and the foamed phenolic resin of the core material due to vibration during cutting. There is no risk of peeling.

[Brief description of drawings]

FIG. 1 is a sectional view of an example of a fireproof composite heat insulating panel of the present invention.

FIG. 2 is a process drawing of an example of a method for manufacturing a fireproof composite heat insulating panel of the present invention.

[Explanation of symbols]

 1, 2 Metal plate winding bundle 3, 4 Metal plate 5, 6 Roll coater 7, 8 Corrugated sheet material winding bundle 9, 10 Corrugated sheet material 11, 12 Liner surface 13, 14 Laminating roller 15, 16 Infrared heater 17, 18 Composite Surface Material 19, 20 Corrugated Surface 21 Foamable Phenolic Resin Stock Solution 22 Double Conveyor 23 Foamed Phenolic Resin 24 Cutting Machine

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification number Office reference number FI technical display location B32B 27/42 101 7016-4F E04F 13/12 A 7806-2E (72) Inventor Hiroshi Yamazaki Hyogo 1176, Uchigaike, Inami-cho, Inami-cho, Kako Toyo Rubber Industries, Ltd., Hyogo Plant, Hyogo Factory (72) Inventor Shingo Baba 1176, Uchigaike, Inami-cho, Kako-gun, Hyogo Toyo Rubber Hyogo Works, Hyogo Factory

Claims (1)

[Claims] 1. A fireproof composite heat insulation panel comprising a metal plate as a surface material on one or both sides and a foamed phenol resin as a core material, wherein a single layer corrugated sheet material or one surface is provided at an interface between the metal plate and the foamed phenol resin. A corrugated sheet material having a corrugated shape on at least one side, such as a corrugated corrugated sheet material composed of a plurality of corrugated sheets, is interposed, the metal plate and the corrugated sheet material are bonded with an adhesive, and the corrugated sheet material has a corrugated surface. A fireproof composite heat insulation panel, characterized in that the foamed phenolic resin and the foamed phenolic resin are bonded together by curing adhesion of a foamable phenolic resin stock solution.