JPH06126876A - Flame retardant heat insulator - Google Patents

Abstract

PURPOSE:To provide a heat insulator which has a light weight, excellent flame retardance, processibility, does not affect influence to human body and has a relatively low cost. CONSTITUTION:When thermosetting resin such as resol type phenol resin, etc., is foamed and cured, it is heated together with flame retardant soft surface material papermaking from mica and inorganic fiber, thereby obtaining a flame retardant heat insulator in which paper and thermosetting resin foam are integrally molded.

Description

Detailed Description of the Invention

[0001]

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

[0002]

2. Description of the Related Art Thermosetting resin foams have excellent heat insulation performance and material properties such as low water absorption or low density, and a heat insulation panel for construction is known as a typical use thereof. However, since the thermosetting resin foam has a low resistance to fire, it is necessary to add a flame-retardant material or to surface an inorganic material such as gypsum board or calcium silicate board or a metal plate or metal foil such as iron or aluminum. It was necessary to compound it as a material.

[0003]

However, when an inorganic material such as gypsum board or calcium silicate board is compounded on the surface of the thermosetting resin foam, the weight of the board increases and the handling becomes poor. In addition, when processing the heat insulating material at the construction site, it becomes impossible to easily cut with a knife as in the case of the foam alone, which makes the processing inconvenient. Further, when a metal plate or metal foil of iron, aluminum or the like is compounded, not only the workability deteriorates, but also the thermosetting resin foam used as described below may be limited. For example, when phenolic foam is used as a thermosetting resin foam, phenolic foam is more corrosive to metals than other plastic foams. Since it is necessary to use expensive face materials, the heat insulating panel obtained is expensive, and its use is limited to special uses such as a decorative wall.

On the other hand, by using asbestos paper which is very excellent in heat resistance as the soft surface material, it is possible to obtain a heat insulating material which has excellent fireproofing properties and is lightweight, inexpensive and excellent in workability. However, asbestos is expected to adversely affect the human body, and asbestos-free building materials are being promoted worldwide, so it will be difficult to use asbestos materials for new construction in the future. Therefore, a soft surface material to replace asbestos paper is being developed, and as a typical one, there is calcium carbonate paper or calcium hydroxide paper prepared by mixing calcium carbonate or calcium hydroxide with a pulp raw material. Since pulp is flammable, sufficient fire protection cannot be obtained.

Although there is a glass fiber non-woven fabric as a soft surface material that does not contain pulp, when a thermosetting resin is foam-molded using this glass fiber non-woven fabric as a surface material, the resin is the surface of the surface material due to the large voids between the glass fibers. Bleeds into the product, resulting in a poor product appearance. Although there is a method to increase the basis weight to prevent the resin from seeping out, this method reduces the folding property, so the thermosetting using a continuous laminator etc., which is commonly used as a production method, is performed. It becomes impossible to integrally mold the heat insulating resin foam and glass fiber. Furthermore, when a face material in which a face material such as calcium carbonate paper or aluminum hydroxide paper and a glass fiber nonwoven fabric are adhered and laminated and a thermosetting resin foam are combined, leaching of resin onto the surface of the face material can be prevented. However, since different kinds of face materials are laminated, the face material must be relatively expensive. Further, when the flame retardancy test is carried out, it is difficult to pass the flame retardance test due to the heat generated by the combustion of the pulp in the face material.

Therefore, an object of the present invention is to provide a heat insulating material for construction which is light in weight, excellent in strength, workability and flame retardancy, safe for human body and good in appearance.

[0007]

That is, the present invention is characterized in that a flame-retardant soft face material made of mica and inorganic fibers is integrally molded on one or both sides of a thermosetting resin foam. It is a flammable heat insulating material. Examples of the thermosetting resin foam used in the present invention include phenol foam, polyisocyanurate foam, and polyurethane foam. The most preferable thermosetting resin is phenol foam from the viewpoint of heat resistance. The thermosetting resin foam is, for example, a thermosetting resin such as a resol-type phenolic resin in a cream form, and if necessary, a foam stabilizer, a foaming agent, a curing agent and other additives are mixed, and the flame retardance described later. The thermosetting resin is foamed and cured by being heated together with the soft surface material to be integrally molded.

The flame-retardant soft surface material made of mica and inorganic fibers used in the present invention means mica, that is, mica,
And a sheet-like material in which inorganic fibers are mixed. Mica that can be used here is K ₂ Al ₄ (S
iAl) ₂ O ₂₀ (OH) ₂ or KMg _2.5 (Si ₄ O ₁₀ ) F
A layered aluminum silicate-based mineral having a composition such as ₂ , which may be natural or synthetic. The content of mica in the soft surface material is preferably 20 to 99% by weight, more preferably 50 to 80% by weight. If the content is less than 20% by weight, the face material has a poor fold resistance, so that it becomes difficult to integrally form the thermosetting resin foam heat insulating material by the continuous laminator. On the other hand, if it exceeds 99% by weight, the proportion of the inorganic fibers as the base material of the face material decreases, so that the mechanical strength required for the face material cannot be obtained.

The inorganic fiber used here may be an inorganic non-combustible base material as long as it has the shape retention property of the face material and the required mechanical strength. Preferred examples include silica-alumina fibers and glass fibers. The content ratio of the inorganic fiber in the soft surface material is preferably 1 to 80% by weight, more preferably 20 to 50%.
% By weight. If the content is less than 1% by weight, the mechanical strength required for the face material cannot be obtained. Also, the content ratio is 80
If the amount exceeds 5% by weight, the face material has poor foldability, and it is difficult to integrally form the thermosetting resin foam heat insulating material by a continuous laminator.

The flame-retardant soft surface material of the present invention is prepared by feeding the slurry containing the above mica and inorganic fibers to a wet paper machine and making the paper by a conventional method, or press-molding the slurry with a pot press or the like. To get The flame-retardant soft surface material preferably has a basis weight of about 50 to 500 g / m ² . If the basis weight of the face material is less than 50 g / m ² , the mechanical strength required for the face material cannot be obtained, and it is difficult to integrally mold the thermosetting resin foam insulation with a continuous laminator, and the face material is broken. In addition, it is impossible to impart sufficient flame retardancy to the heat insulating material. On the other hand, if it exceeds 500 g / m ² , the foldability of the face material decreases. Thickness is 0.05-1mm
Is preferred.

The method for producing the flame-retardant heat-insulating material of the present invention includes a thermosetting resin, a foam stabilizer, a foaming agent, a curing agent and, if necessary, other additives added and mixed to form a creamy mixture. Is supplied to a continuous laminator together with the above-mentioned face material, or the creamy mixture is flowed into a mold lined with the face material and then heated to foam and cure. The thickness of the flame-retardant heat insulating material thus obtained is 10 to 10
The volume density of the thermosetting resin foam in the flame-retardant heat insulating material is preferably about 20 to 70 kg / m ³ .

[0012]

With the above-mentioned structure, it is possible to obtain a lightweight heat insulating material having excellent strength, workability and flame retardancy. This is due to the following action. 1. Since mica has a film-forming property, it can be made into a sheet without using an organic binder such as pulp or polymer latex that is flammable like general non-combustible paper, so it is flame-retardant, processable, and lightweight. Excellent in performance. 2. Since mica has heat resistance up to around 1000 ° C, the face material is less likely to be damaged even when exposed to a fire, and heat transfer to the back side can be prevented, so the thermosetting resin foam is damaged. You don't have to receive it. 3. The inorganic fiber is a nonflammable base material for the face material, and can exhibit the shape retention property of the face material and the mechanical strength required for the face material.

[0013]

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

[0014]

Example 1 Wet 150 g of a slurry consisting of 49% by weight of synthetic mica having a composition of NaMg _{2.5 (} Si ₄ O ₁₀ ) F ₂ (average particle size 3 μm), 1% by weight of silica-alumina glass fiber, and 50% by weight of water. It was supplied to a paper machine and paper was made by a conventional method to obtain a sheet having a thickness of 0.2 mm and a basis weight of 400 g / m ² . The obtained sheet was cut into lengths and widths of 35 cm, laid on the bottom of a stainless mold (internal length and width of 35 cm, height 3 cm), and preheated to 70 ° C. On the other hand, 100 parts by weight of the resol type resin, 2 parts by weight of a silicon-based surfactant as a foam stabilizer and HC as a foaming agent.
Add 12 parts by weight of FC-123 and 15 parts by weight of phenolsulfonic acid as a curing agent, and mix with a mixer.
The creamy mixture obtained by high-speed stirring for 0 seconds was poured into the former mold, and the stainless steel lid covered with the sheet was fixed via a spacer so that the thickness became 12 mm. By placing the mold in a hot press (high temperature and high pressure molding machine) set at 80 ° C., heating for 10 minutes to foam-cure, and then removing the contents from the mold,
A flame-retardant phenol foam insulation panel having mica sheets integrated on both surfaces was obtained. The bulk density of the foam is 40 kg
/ M ³ .

Regarding the obtained heat insulating panel, JIS A
An evaluation test was conducted on the fire resistance performance of Class 2 flame retardant specified in 1321. The acceptance criteria defined above are shown in Table 1. As shown in the results of the test in Table 2, the heat insulating panel of the example satisfied the criteria of Table 1.

[0016]

[Table 1]

[0017]

[Table 2]

[0018]

The flame-retardant heat insulating material of the present invention is light in weight because it does not use an inorganic hard surface material such as gypsum board or calcium silicate board, so that it is easy to handle during transportation, construction, etc.
Processing such as cutting can be easily performed by using a knife or the like. Further, since the flame-retardant soft surface material does not contain asbestos, there is no adverse effect on the human body, and since no glass fiber is used, it is possible to obtain a heat insulating material which is also preferable in appearance.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location E04B 1/94 R 7521-2E F16L 59/02 // B29K 105: 04 105: 08 B29L 31:10 4F

Claims (1)

[Claims] 1. A flame-retardant heat insulating material, characterized in that a flame-retardant soft face material made of mica and inorganic fibers is integrally molded on one or both sides of a thermosetting resin foam.