JPH0574460B2 - - Google Patents

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a method of manufacturing a construction material used as a base material for partition walls and ceilings.

[Conventional technology]

Architectural materials such as partition walls and ceiling base materials are required to be fire resistant, and such fire resistant construction materials have traditionally been made of inorganic hydraulic materials such as gypsum boards and wood chip cement boards as a binder. There are also products available in which a metal plate is attached to the surface of a base material such as plywood or particle board.

[Problem to be solved by the invention]

The former has a certain degree of fire resistance because it is mainly composed of noncombustible materials, but when exposed to flame, the water contained in the crystals of the hydraulic substance is liberated, and this water vapor is released. There was a problem that this could lead to explosions or a sudden decrease in strength. In addition, the latter has a large thermal conductivity and coefficient of thermal expansion of the metal plate, and there is a large difference in thermal conductivity and coefficient of thermal expansion with the base material, so when exposed to high temperatures, peeling occurs between the base material and the metal plate. There was a problem that there was a risk of warping or deformation occurring. As you can see, these conventional construction materials do not have sufficient fire resistance, and if they are used as a base for partitions or ceilings, they may suddenly collapse or fall down when a flame breaks out, or form an evacuation exit. In some places, problems occur such as the evacuation exit becoming deformed and the door becoming unable to open. In addition, partition walls and ceilings are required to have sound insulating properties in addition to fire resistance, and the sound insulating properties of these building materials are mainly increased by increasing their thickness. There was a problem in that the weight increased and there was a risk that workability or cutting workability would deteriorate. The present invention has been made in view of the above points, and an object of the present invention is to provide a method for manufacturing construction materials that can improve fire resistance and sound insulation without increasing the thickness. It is something to do.

[Means to solve the problem]

In order to achieve the above object, the present invention mainly uses a self-curing powder or granules of mica with a thermosetting synthetic resin attached as a binder to the surface of the powder or granules of mica, or a filler mainly of carbonates or carbonates. Self-curing powder with a thermosetting synthetic resin attached as a binder to the surface of hydrogen salt powder, or the surface of carbonate or bicarbonate powder with filler mainly containing hydrogen salt powder and granule. Using a self-curing powder to which a thermosetting synthetic resin is attached as a binder, the self-curing powder is placed on the surface layer of a base material, and then heated and pressed to form a protective layer on the surface of the base material. It is used to manufacture building materials by laminating layers. The present invention will be explained in detail below. Base materials include plywood, particle board,
Wooden boards such as LVL (laminated veneer lumber) and thin wood boards, and inorganic boards made of inorganic hydraulic substances as a binder such as gypsum boards, calcium silicate boards, wood chip cement boards, and slag gypsum boards can be used. . This base material is not limited to a plate-like material as described above, but may be formed into a columnar shape, a rod-like shape, or the like. In addition, as a filler to be filled in the protective layer,
In the present invention, mica powder and carbonate or hydrogen carbonate powder are used. Calcium carbonate, magnesium carbonate, or the like can be used as the carbonate powder, and sodium hydrogen carbonate or the like can be used as the hydrogen carbonate powder. These can be used alone or in combination as necessary. Mica has a scaly shape, and the flake diameter is 10~
1400μ and an aspect ratio of 20 to 100 are preferable. In addition, carbonates and hydrogen carbonates can be used in powder form adjusted to any desired form, and the particle size is 0.2 to 200μ.
is preferred. On the other hand, as the thermosetting resin serving as the binder of the protective layer, any resin such as a novolak type phenolic resin, a resol type phenolic resin, a furan resin, a melamine resin, etc. can be used. In forming the protective layer, first, a self-curing powder is prepared by adhering the thermosetting resin to the surface of the filler. That is, a filler and a solid thermosetting low-molecular material, such as an initial condensate of resol type phenolic resin, are put into a kneader, and after kneading these with a solvent such as alcohol, the kneaded product is taken out from the kneader and extruded. By putting it into a molding machine, extruding it while further kneading it, drying the extruded product, and crushing it, it is possible to obtain a self-curing powder with a thermosetting resin attached to the surface of the filler. can. Furthermore, in producing the self-curing powder, the thermosetting resin can be attached to the surface of the filler at the same time as the initial condensation product of the thermosetting resin is synthesized. That is, for example, when reacting an initial condensate of phenolic resin, a filler is put into a reaction vessel together with phenols and aldehydes, and the phenolic resin synthesis reaction is carried out in this state, thereby producing phenol on the surface of the filler. A self-hardening powder can be obtained by uniformly depositing the resin, filtering it off, and drying it. In addition to the above-mentioned mica, carbonate, and hydrogen carbonate alone or as a mixture, as the filler, carbon powder or other powder such as alumina or magnesia can be blended as necessary to further strengthen the filler. Fibrous materials, lightweight aggregates, etc. can also be added as lumber or bulking materials. There are various methods for forming a protective layer on the surface of a substrate using the self-curing powder produced as described above. The first method is to spread self-curing powder to a uniform thickness on the surface of the base material and then heat and pressure mold it to form a filler and a hardened thermosetting resin. This is a method in which a protective layer is integrally laminated on the surface of a base material. Also the second
In the method described above, the above-mentioned self-hardening powder is uniformly dispersed and then pressure is applied with a roll heated to about 50 to 100°C, thereby partially compressing the self-hardening powder. This is a method in which a protective layer is integrally laminated on the surface of a base material by creating a sheet material, overlapping the sheet material on the surface of the base material, and molding the sheet material under heat and pressure. The third method is to form a protective layer at the same time when manufacturing wood chip cement boards, particle boards, etc., and the above-mentioned self-hardening property is applied to the surface of forming mat made by kneading wood chips, adhesives, cement, etc. By disposing a sheet material of powder or self-hardening powder and forming it under heat and pressure, a protective layer can be created on the surface of wood cement board, particle board, etc. at the same time as the board is made. can be integrally layered. In general, fillers have poor wettability with thermosetting resins, and forming a protective layer by kneading the filler and thermosetting resin and applying it to the base material does not allow the filler to be uniformly wetted in the protective layer. However, as described above, a protective layer is formed using self-curing powder with thermosetting resin attached to the surface of the filler. By doing so, it is possible to form a protective layer in which the filler is uniformly dispersed and the density is uniform, and the fire resistance performance can be stabilized. In addition, even if the base material is porous, the self-hardening powder is embedded in the porous part of the surface and integrated.
A strong protective layer can be formed. When forming the protective layer as described above, the thickness of the protective layer is preferably set to about 0.5 mm to 5 mm. Further, it is preferable to set the filler content in the protective layer to be 50% by weight or more, and it is preferable to set the specific gravity of the protective layer to be 1.0 or more. Incidentally, a decorative material such as a veneer, a synthetic resin sheet, or a glass cloth may be attached to the surface of the protective layer, and in this case, the construction material can be used as it is as a decorative member. In addition, the protective layer may be provided on both the front and back sides of the base material, and in this case, the stress of expansion and contraction between each layer is balanced on the front and back, making it difficult for warping to occur.
Moreover, since the protective layer is thicker as a whole, it becomes difficult for fire to penetrate in the event of a fire, and the sound insulation properties are also improved.

[Effect]

In the construction material according to the present invention, which is produced by laminating a protective layer on the surface of the base material as described above, even if a fire occurs, mica powder and carbonate will not be present.
It is shielded by a protective layer containing bicarbonate powder as a filler, and can prevent the base material from being exposed to flame. In particular, when mica powder is used as a filler, since the mica powder is scaly, it can be overlapped to form a dense protective layer, which is highly effective in blocking flames. In addition, when carbonate or hydrogen carbonate powder is used as a filler, it decomposes at a temperature of about 1000°C and generates carbon dioxide gas, and the extinguishing action of this carbon dioxide gas causes the base material to burn with flame. It is possible to prevent this from happening. When the thermosetting resin contained in the protective layer is burned by the action of flame, it is carbonized to form a carbonized layer, and this carbonized layer acts as a heat insulating material to prevent high temperatures from acting on the base material. It is something that can be done. Among thermosetting resins, phenolic resins and furan resins have a large amount of residual carbon and are burned to form carbon bonds, which can significantly improve the thermal shock resistance of the protective layer. It is particularly preferable to use it as In addition, the protective layer contains mica powder, carbonate, or bicarbonate powder as a filler, so it suppresses thermal expansion and contraction behavior even when heated during flames, and protects the base material. There is no risk of peeling or warping due to differences in thermal expansion and contraction between the layers. If the base material is a wood material, even if heat acts on the surface of the wood material through the protective layer, the surface of the wood material will be carbonized and a carbonized layer will be formed, and this carbonized layer will act as a heat insulator. Since the thermal conductivity of the wood material itself is low, the interior thereof is prevented from being thermally decomposed. In addition, the carbonized layer formed on the surface of this wood material relieves the stress generated between the backing material and the protective layer, making it difficult for peeling or cracking to occur between the base material and the protective layer. . On the other hand, when the base material is an inorganic material, the flame does not directly act on the base material because it is blocked by a protective layer, so there is less decomposition of the crystallized water of the hydraulic substance in the inorganic material, and explosions are prevented from occurring. Ru. In addition, in the present invention, as a filler, a self-curing powder or granule in which a thermosetting synthetic resin is attached as a binder to the surface of mica powder or granule, or a filler mainly in carbonate or hydrogen carbonate powder is used. Self-curing powder with a thermosetting synthetic resin attached as a binder to the surface of the body, or heat as a binder to the surface of powder and carbonate or hydrogen carbonate as a filler. By using self-curing powder particles to which a curable synthetic resin is attached, the filler can be uniformly dispersed to form a protective layer with a uniform density, making it possible to stabilize fire resistance. Further, even if the base material is porous, the self-hardening powder can be embedded in the porous portion of the surface and integrated to form a strong protective layer. In addition, when mica powder is used as a filler, since mica is scaly, it is oriented in a layered manner within the protective layer, and the sound passing through the construction board is affected by each mica powder. This will attenuate the sound and provide a high level of sound insulation. Moreover, since the mica powder is thin and many pieces are densely stacked in parallel with the protective layer, sound insulation can be ensured without the need to form a thick protective layer.

【Example】

The invention will now be illustrated by examples. Example 1 Mica powder having a weight average flake diameter of 20μ and a weight average aspect ratio of 25 and a solid resol type phenolic resin were charged into a double-arm kneader at a weight ratio of 65:35, and methyl alcohol was used as a solvent. Add 50 parts by weight to these 100 parts by weight,
After stirring and kneading for 30 minutes, the kneaded product was extruded using a kneading extruder and further air-dried to volatilize the solvent. By pulverizing this with a pulverizer, a self-hardening powder having an average particle size of 50 μm was obtained. Next, this self-hardening powder material is 17 mm thick and has a specific gravity of 0.50.
By spraying 1800 g/m ² on the front and back surfaces of the particle board and heating and pressurizing it for 5 minutes at 160℃ and 25 kg/cm ² , the thickness of each particle board is increased on both the front and back surfaces. is 1.5mm and has a specific gravity
Construction material laminated with 1.2 protective layer (total thickness 20mm)
I got it. Example 2 A reaction vessel was charged with 770 parts by weight of phenol, 1328 parts by weight of 37% formalin, and 80 parts by weight of hexamethylenetetramine.
1650 parts by weight of mica powder having a size of 20μ and a weight average aspect ratio of 25 was charged. This takes about 60 minutes and 90
The temperature was raised to ℃ and the reaction was continued for 3 hours.
After cooling, the mixture was filtered and air-dried to obtain 2,380 parts by weight of self-hardening powder having an average particle size of 100 μm. The content of phenolic resin in this self-curing powder was 30% by weight. Using this self-hardening powder, a building material (total thickness: 2 mm) was obtained in the same manner as in Example 1. Example 3 In Example 2, calcium carbonate powder with an average particle size of 10 μm was used in place of the mica powder to obtain 2350 parts by weight of self-hardening powder with an average particle size of 50 μm. The content of phenolic resin in this self-curing powder was 30% by weight. Using this self-hardening powder, a building material (total thickness: 20 mm) was obtained in the same manner as in Example 1. Example 4 The self-hardening powder of mica obtained in Example 2 and the self-hardening powder of calcium carbonate obtained in Example 4 were mixed at a weight ratio of 50:50, and this was used. A building material (total thickness: 20 mm) was obtained in the same manner as in Example 1. The building materials obtained in Examples 1 to 4 above were subjected to a bending creep test under flame. Creep tests under flame are used to understand the fireproof bending performance in high-temperature environments and to examine the burnout of floors and load-bearing walls in the event of a fire. In the device, the tip of the flame of a Bunsen burner supplied with city gas via a ballast to maintain a constant flow rate is brought into contact with the back side of the central concentrated load point of the sample, and the temperature of the tip of the flame is set to approximately 700°C. At the same time, the time until failure (fire resistance time) was measured while applying a load set to 1/5 of the sample's bending failure strength to the edge of the sample. Moreover, the above-mentioned Example 1,
The sound insulation performance (transmission loss) at 500Hz was measured for the building materials obtained in 3 and 4. For comparison, a wooden cement board with a thickness of 12 mm and a specific gravity of 1.15 was used as Comparative Example 1, a gypsum board with a thickness of 12 mm and a specific gravity of 0.76 was used as a Comparative Example 2, and a particle board with a thickness of 20 mm and a specific gravity of 0.53 was used as a Comparative Example 3. , a bending creep test under flame was conducted for each, and for Comparative Example 3, the sound insulation performance was also measured. The results are shown in the table below.

[Table] As shown in the table, it is confirmed that each example is superior to each comparative example in terms of fire resistance performance, etc.

【Effect of the invention】

As described above, the method for producing a building material according to the present invention uses a self-curing powder or granules in which a thermosetting synthetic resin is attached as a binder to the surface of a mica powder or a filler mainly made of carbonic acid. Self-curing powder with a thermosetting synthetic resin attached as a binder to the surface of salt or bicarbonate powder, or mica powder and carbonate or bicarbonate powder as a filler. Using a self-curing powder with a thermosetting synthetic resin adhered to the surface of the body as a binder, the self-curing powder is placed on the surface layer of a base material, and then heated and pressed onto the surface of the base material. Since the protective layer is laminated, even if the manufactured building material is exposed to flame in the event of a fire, the protective layer containing mica powder, carbonate, or bicarbonate powder as a filler protects the base material. In addition, when the thermosetting resin contained in the protective layer is burned by the action of the flame, it is carbonized and a carbonized layer is formed, and this carbonized layer acts as a heat insulating material. In addition, the protective layer contains mica, carbonate, and hydrogen carbonate powder as a filler, which suppresses thermal expansion and contraction behavior and protects the base material. This prevents the protective layer from peeling off from the material or causing warping, thereby significantly improving fire resistance and eliminating the risk of the material collapsing in the event of a fire. In addition, as a filler, a self-curing powder or granule with a thermosetting synthetic resin attached as a binder to the surface of mica powder or granule, or a filler with a binder attached to the surface of a carbonate or bicarbonate powder or granule. A thermosetting synthetic resin is attached as a binder to the surface of a self-curing powder or granular material with a thermosetting synthetic resin attached as a filler, or a granular material mainly of mica and carbonate or bicarbonate as a filler. By using self-hardening powder and granules, the filler can be uniformly dispersed to form a protective layer with a uniform density, making it possible to stabilize the fire resistance performance. Even if the material is of high quality, the self-hardening powder can be embedded in the porous portion of the surface and integrated to form a strong protective layer. In addition, when mica powder is used as a filler, mica has a scale-like shape, so it can overlap to form a dense protective layer, increasing the effect of blocking flame penetration and oxygen flow. This makes it possible to further improve fire resistance.
Moreover, the sound passing through the architectural board is attenuated by the scale-like mica powder particles arranged in layers, so that the sound insulation properties can be improved without increasing the thickness. Furthermore, when carbonate or bicarbonate powder is used as a filler, it decomposes at high temperatures and generates carbon dioxide gas, so the fire resistance can be further improved by the digestive action of this carbon dioxide gas. be.

Claims (1)

[Scope of Claims] 1. A self-curing granular material, in which a thermosetting synthetic resin is attached as a binder to the surface of a mica granular material as a filler, is placed on the surface layer of a base material, and then heated and pressed. A method for producing a building material, comprising laminating a protective layer on the surface of the base material. 2. After disposing a self-curing granular filler consisting of a thermosetting synthetic resin as a binder on the surface of a granular material mainly consisting of carbonate or hydrogen carbonate on the surface layer of the base material, heat and pressurize it to form the filler. A method for producing a construction material, which comprises laminating a protective layer on the surface of a base material. 3 After disposing a self-curing powder, which is a filler consisting mainly of mica powder and carbonate or hydrogen carbonate powder and a thermosetting synthetic resin as a binder, on the surface layer of the base material. . A method for producing a construction material, which comprises laminating a protective layer on the surface of the base material by applying heat and pressure.