JPH06198790A - Composite board - Google Patents

Abstract

PURPOSE:To provide a composite board, which is useful for building, interior and exterior wall material, partitioning material or the like of structure and lightweight, has fire resistance, heat resistance and smoke resistant properties, is excellent in mechanical strength and can stand one-hour heat-resistance test. CONSTITUTION:In composite board (alpha) in continuous form having core material 2, which is made of synthetic resin foam pinched between incombustible base materials 1, and male-female joining structures at the right and left ends of the core material, non-woven fabric 6 is formed between at least one incombustible base material 1 and the core material 2, the core materials 2 in the male joining part 3 portion and in the female joining part 4 portion at the right and left ends of the core material are made of high density phenolic foam mixed with lightweight aggregate 5, while the core material 2 in the remaining portion is made of low density phenolic foam and, at the same time, inorganic boards 7 are formed in the male joining part 3 portion and in the female joining part 4 portion at the right and left ends of the core material.

Description

Detailed Description of the Invention

[0001]

INDUSTRIAL APPLICABILITY The present invention is useful as an interior / exterior wall material and a partition material in buildings and structures, and is lightweight, has fire resistance, heat resistance, smoke resistance, has excellent mechanical strength, and has a fire resistance of 1 hour. It also relates to a composite board that can also pass.

[0002]

2. Description of the Related Art In general, heat-resistant inner and outer wall composite plates are disclosed in Japanese Utility Model Publication No. 57-185535, Japanese Utility Model Publication No. 58-1538, Japanese Utility Model Publication No. 63-15444, and Japanese Patent Publication No. No. 18230, etc. are known.

[0003]

However, these composite plates have major drawbacks in the following points. That is, in the above composite plate, the non-woven fabric is a thin non-woven fabric such as glass fiber, and the phenol foam leaks to the opposite surface, the so-called, non-combustible base material-bonding surface, and there is a disadvantage that the function of the adhesive agent cannot be sufficiently exhibited. there were.

In the above composite plate, a lightweight aggregate is finely laid between the noncombustible base material and the core material, and this is integrated with the noncombustible base material with phenol foam to improve the fire resistance. The adhesive strength of the phenol foam itself, which is the material, is not very strong, and there is a drawback that the phenol foam, which is the core material, peels off from the noncombustible base material.

In the above-mentioned composite plate, a non-combustible sheet impregnated with sodium borate and a phenol foam are integrally fixed, and a non-combustible impermeable layer is integrally fixed on the non-combustible sheet with an adhesive. It is a building board. But,
Impregnation of the raw material of phenolic foam into the nonwoven fabric is likely to occur only on the surface, and the reaction system of alkali and acid hinders foam formation, leading to a decrease in adhesive strength.

Further, since the composite plate has a structure in which the face material and the phenol foam containing aggregate are integrated and the fusion is used to integrate the face material and the core material, the adhesive strength is uncertain. was there. In addition, the above-mentioned composite plates (1) to (5) are required to have higher adhesiveness and heat resistance in order to integrate the phenol foam and the surface material.
Fire resistance 1 of A-1304 (fire resistance test method for building structures)
There was a weakness that could not pass the time fireproof structure test. In addition, the conventional composite plate using a pearlite-mixed phenol foam as a core material has a low bending mechanical strength, which results in a small wind pressure resistance, which makes it difficult to cope with high-rise buildings.

[0007]

In order to eliminate such drawbacks, the present invention has an elongated shape having a core material made of a synthetic resin foam between nonflammable substrates and having male and female connecting structures at the left and right ends. In the composite board, a non-woven fabric is formed between at least one of the non-combustible base material and the core material, and the core material at the left and right male and female connection parts is made of high-density phenol foam mixed with lightweight aggregate. By forming the core material of other parts with low density phenol foam and forming inorganic boards on the male and female connecting parts on the left and right ends, there is fire resistance, heat resistance and smoke resistance. , A composite plate excellent in mechanical strength is proposed.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the composite plate according to the present invention will be described in detail below with reference to the drawings. That is, FIG. 1 and FIG. 2 are a partially cutaway perspective view and a sectional view of a construction state showing a typical example of a composite plate according to the present invention, and 1 is an incombustible base material composed of a surface material 1a and a back surface material 1b. 2 is a core material, 3 is a male connecting portion, 4 is a female connecting portion, 5 is a lightweight aggregate, 6 is a non-woven fabric, 7
Is an inorganic board.

To explain further, examples of the nonflammable substrate 1 include iron, aluminum, copper, stainless steel, titanium,
A type of aluminum / zinc alloy plated steel plate, enamel steel plate, clad steel plate, laminated steel plate (PVC steel plate, etc.), sandwich steel plate (vibration suppression steel plate, etc.) (including, of course, colored metal plates coated with these metal plates in various colors) Is molded into various shapes by roll molding, press molding, extrusion molding or the like, or is made of an inorganic material.

As shown in FIG. 1, the core member 2 has a male connecting portion 3
Side left end 3a, female connecting part side 4 right end 4a, and central part 2a are divided into three parts as a result. The left end 3a and the right end 4a have a refractory density. 10
The high density phenol foam of 0 to 500 Kg / m ³ is used, and the low density phenol foam having a density of 50 to 200 Kg / m ³ is used in the center 2a. Of course, the boundary between the left end portion 3a, the center 2a, and the right end portion 4a is not strictly divided, and high density and low density phenol foam are mixed.

The lightweight aggregate 5 is composed of pearlite grains, glass beads, gypsum slag, talc stone, shirasu balloon, etc., and is a general-purpose product that is generally popular. Also,
The mixed amount is determined by the desired performance.

The nonwoven fabric 6 is made of polyester, nylon,
Vinylon fiber, boron fiber, carbon fiber, alumina fiber,
It is composed of a continuous or hydrophilic sheet-like material made of one kind of silicon carbide fiber, aramid fiber, glass fiber or the like, and is adhesively fixed to at least one core material 2 side of the surface material 1a and the back surface material 1b via an adhesive agent. It was done. Further, the non-woven fabric 6 improves the adhesive strength between the core material 2 and the surface material 1a and the back surface material 1b, and also contributes to the improvement of the mechanical strength of the composite plate A. As the adhesive, an elastomer type epoxy resin, an isocyanate, for example, an emulsion type such as methylene diisocyanate (abbreviated as MDI), a hot melt type, and a modified isocyanate thereof such as urethane modified, buret modified isocyanate, isocyanurate modified isocyanate, etc. It consists of

Further, the non-woven fabric 6 is mainly composed of condensed water at the time of phenol foam formation, a function to dissipate and isolate water vapor to the outside, a water absorption function, a holding function, a face material function, a phenol foam reaction system control function, a reinforcing function, It serves as a fireproof and incombustible layer forming function and an anchoring function, and in particular, the voids and thickness of the nonwoven fabric 6 and the hydrophilic function of the non-woven fabric prevent escape of condensed water to the outside during the phenol foam reaction and decrease in adhesion due to condensed water. By controlling (adjusting) the prevention and reaction conditions, it is possible to control the curing in the optimum condition during the permeation of the nonwoven fabric 6 and to help strengthen the integration of the nonwoven fabric 6 and the phenol foam.

Although not shown, since the non-woven fabric 6 is continuous or hydrophilic, the adhesive and the phenol foam (core material 2) appropriately permeate into the non-woven fabric 6 during the production, and the non-combustible substrate. The adhesiveness between the core material 1 and the core material 2 is significantly enhanced, and deformation of the non-combustible base material 1 and the core material 2 due to aging after manufacturing is suppressed, and a beautiful appearance is formed over a long period of time. .

The inorganic board 7 is a calcium silicate board, a perlite cement board, a slate board, a gypsum board, a calcium carbonate board, etc., and is formed continuously on the male connecting part 3 and the female connecting part 4 of the composite plate α. It is effective for improving the fire resistance and mechanical strength (prevention of deformation) of the fire resistant panel α.

Numeral 8 is an inorganic packing material such as rock wool felt or ceramic wool for further improving the fire resistance.

The composite plate α thus formed uses JIS-A-JIS-A- because the high-density phenol foam having fire resistance is used in the connecting portion which is the weakest point of fire resistance.
Fireproof structure 1 of 1304 (fireproof test method for building structures)
It can be a composite board α that passes the time test, and
The central portion 2a, which is the main portion, has a low density to reduce the amount of expensive phenol foam resin used, and the non-woven fabric 6 is formed to improve the adhesiveness between the non-combustible base material 1 and the core material 2.

Next, an example of the method for producing the composite plate α according to the present invention is shown in FIG. First, a non-combustible base material 1 serving as the surface material 1a, for example, a color steel plate (thickness 0.5 mm) is fed from the feeding step A (for example, uncoiler, lifter) or the like to the molding step B, and the shape as shown in FIG. Then, from the inorganic board insertion step C, calcium silicate plates are inserted at the left and right ends. After that, it is fed to the non-woven fabric forming step D, the surface material 1a is heated to about 20 to 50 ° C., and an adhesive (urethane resin or the like) is thinly applied to the necessary back surface with a roll coater, a spray gun E, etc. Non-woven fabric on top, for example 100 g / m ²
Sheet of polyester fiber (thickness: about 0.2 mm) is continuously supplied through the feeding process F and is temporarily adhered to the back surface of the surface material 1a, and then unfoamed resol mixed with pearlite particles. -Type phenol foam undiluted solution is ejected from the ejector G at a high density to the left and right ends of the non-combustible base material 1 so that the final density is about 100 to 500 kg / m ³ and the non-combustible base material 1 In the central part of the, the phenol foam raw material has a density of 50 to 200 Kg / m
Discharge so that the density is the ^third lowest, and then the backing material 1b
Non-combustible substrate 1, which will be, for example, color steel plate (thickness 0.5 m
m) is fed from the feeding process I to the forming process J, laminated and fed to a curing oven K of a predetermined type, and is cured continuously or in a badge system at 30 to 100 ° C. for 7 to 15 minutes, and then with a cutter L. It is fed to the packaging process M after being cut into a predetermined size.

The above description is merely one example of the composite plate α according to the present invention. The shape of the composite plate α is shown in FIG.
It is also possible to use the cross section shown in to (f). The lightweight aggregate 5, the non-woven fabric 6 and the like are not shown.

Further, various flame-retardant materials may be mixed in the core material 2 to form a composite plate α having further improved fire resistance. Of course, the densities of the left end portion 3a, the right end portion 4a, the center 2a, etc. can be variously set according to various performances.

[0021]

As described above, according to the composite plate of the present invention, the core materials at the left and right ends, which are the connecting portions of the composite plate, are formed of the high-density phenol foam mixed with the refractory lightweight aggregate. Since the inorganic boards are formed on the left and right ends, the fire resistance of the connection part, which is the weakest point in the fire resistance structure test, is improved, and the fire resistance structure 1-hour test of JIS-A-1304 (fire resistance test method for building structure parts) is performed. It becomes a composite board that uses a resin that passes as a core material. The core materials at the left and right ends that are the connecting parts of the composite plate are made of high-density phenol foam, and the other main parts are made of low-density phenol foam, so the fire resistance is comparable to that of conventional fire-resistant structural products The cost can be reduced without lowering the cost. By the non-woven fabric formed by interposing an adhesive on the back surface of the front and back materials, the adhesive strength between the front and back materials and the core material is improved,
In addition, the surface material can be kept flat and dimensional stability can be improved. A composite plate that is lightweight, has good workability, and has excellent fire resistance, heat resistance, and smoke resistance. The cost is lower and the composite plate is lighter in weight than the conventional fire-resistant structure having the same performance. There are characteristics and effects.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing an example of a composite plate according to the present invention.

FIG. 2 is a cross-sectional view showing a construction state of a composite plate according to the present invention.

FIG. 3 is an explanatory diagram showing an example of a process for producing a composite plate according to the present invention.

FIG. 4 is a cross-sectional view showing another embodiment of the composite plate according to the present invention.

[Explanation of symbols]

 α Composite plate 1 Non-combustible base material 1a Surface material 1b Back material 2 Core material 2a Central 3 Male type connection part 3a Left end part 4 Female type connection part 4a Right end part 5 Light weight aggregate 6 Nonwoven fabric 7 Inorganic board 8 Inorganic packing material

Claims (1)

[Claims] 1. A long composite plate having a core material made of a synthetic resin foam formed between nonflammable base materials and having male and female connecting structures on the left and right ends, wherein at least one of the nonflammable base material and the core material is A non-woven fabric is formed on the left and right sides, and the male and female connecting parts on the left and right ends are made of high-density phenol foam mixed with lightweight aggregate, and the other parts are made of low-density phenol foam. In addition, the composite board is characterized in that inorganic boards are formed on the male and female connecting portions on the left and right ends.