JPH06229035A - Core material - Google Patents

Abstract

PURPOSE:To manufacture a durable and lightweight core material by forming a grid out of a wooden skelton body, and realizing an efficient foaming process, while accelerating the adhesion and integration of the grid and resol type phenol foam through the absorption of condensed water generated due to the reaction of the foam. CONSTITUTION:A rod type horizontal muntin 3 and a plate type muntin 4 orthogonal therewith are combined to constitute a wooden skelton body 2. Also, foam 6 is resol type phenol foam having such a grade as equivalent to or more than a quasi-noncombustible material, and has fire proof, fire resistance and adhesion characteristics. Thereafter, a sheet material A is laid on the entire surface of an interior wall made of the predetermined form of a material, and the skelton body 2 is placed on a humidified lower mold. Then, space 5 is filled from level above the body 2 with the undiluted solution of original foam 6 blended and mixed with each component. A heated upper mold is immediately placed on the lower mold, and the skelton body 2 is released after the lapse of the predetermined time, thereby manufacturing a core material 1. According to this construction, the fire proof characteristics of the phenol foam 6 can be utilized to a maximum extent. Also, the hygroscopic characteristics as the attribute of the phenol foam 6 and condensed water generated upon the reaction thereof can be properly coped with the humidity conditioning and hygroscopic characteristics of the wooden skelton body 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a building material, and more particularly to a lightweight and lightweight core material which requires heat insulation, fire resistance and mechanical strength.

[0002]

2. Description of the Related Art In general, phenol foams, particularly resole type phenol foams, are disclosed in JP-A-62-
As described in JP-A-10359 and JP-A-63-185613, reinforcing fibers and short fibers are mixed in the foam to improve the strength.

[0003]

However, the above-mentioned is a structure in which the mat-like fiber is an aggregate and the is a short fiber is an aggregate. For this reason, the viscosity increases during foaming, so it becomes difficult to uniformly impregnate the unfoamed phenol foam stock solution to achieve uniform foaming, depending on the degree of impregnation. Therefore, there is a disadvantage that productivity, heat insulation, and weight reduction are lacking, and cost is increased.

[0004]

In order to eliminate such drawbacks, the present invention forms a lattice with a wooden skeleton material in a dry state having a moisture content of about 15% and has a constant thickness and outer dimensions. In addition, the strength is also covered with a lattice, and further, condensed water during the reaction of the resol-type phenol foam is absorbed to promote close contact and integration of the lattice and the foam without inhibiting the reaction, thereby achieving efficient foaming. Further, since the wooden skeleton is integrally provided as a reinforcing material for the foam, the humidity inside the foam is also controlled by the wooden skeleton, and changes due to shrinkage due to drying are reduced. In addition, the wooden skeleton material functions as a moisture-exhausting material (function of humidity-conditioning material) even in the unlikely event of water absorption, and it is lightweight and has significantly improved heat insulation, productivity, dimensional stability and strength
In addition, we propose a core material with improved sound insulation.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the core material according to the present invention will be described in detail below with reference to the drawings. FIG. 1 is a partially cutaway perspective view showing a representative example of a core material according to the present invention. The core material 1 includes a resole phenolic foam 6 (hereinafter simply referred to as foam) in a space 5 of a wooden skeletal material 2 shown in FIG. 6) is integrally filled.

To explain further, the wooden skeleton member 2 is, for example, a combination of a bar-shaped horizontal bar 3 and a plate-shaped vertical bar 4 orthogonal to the bar-shaped horizontal bar 3, and mainly comprises (1) a reinforcing function and (2) humidity control. It has a function, (3) a dimension stabilizing function, and (4) a reaction obstacle eliminating function. That is, the above (1) and (3) are performances of the wooden skeleton material 2, and (2) is the material having the humidity control property of the wooden skeleton material 2, which is effectively utilized to cause dimensional deformation and reaction. It is intended to absorb condensed water. Further, since the foam 6 itself is a foam having a little water absorption, it also has a drainage function (by evaporation) of its water absorption.

The foam 6 is a resol type phenolic foam having a density of about 30 to 500 kg / m ^{3 and} a fire resistance, a fire resistance and an adhesive property equal to or higher than that of a semi-combustible material, and a thickness of about 10 to 100 mm. Is. Further, the foam 6 has a function of passing a fire resistance of 1 hour by adding a proper amount of foam alone or aluminum hydroxide, ammonium polyphosphate, carbon black and the like.

The manufacturing method will be briefly described below. The sheet material A is provided on the entire inner wall of a predetermined mold material (not shown),
Place the wooden skeleton 2 on the lower mold humidified to about 90 ° C,
Unfoamed foam 6 in which each component is blended and mixed from above
Immediately after filling the space 5 with the undiluted solution, the heated upper mold is immediately placed on the lower mold, and the mold is removed after a lapse of a predetermined time (about 1 to 10 minutes) to produce the core material 1 as shown in FIG. To be done. Of course, deaeration holes are provided in the upper and lower mold members as needed.

The above description is only one example of the core material according to the present invention, and the wooden skeleton material 2 can be constructed as shown in FIG. That is, FIG.
Is made of substantially the same material and is made into a lattice shape. In the figure, (b) shows a wooden skeleton material 2 in which a fitting notch is provided, for example, at one end of a vertical crosspiece 4, and a horizontal crosspiece 3 is fitted therein. , (C) shows a wooden skeleton member 2 in which vertical bars 4 are fixed in parallel on a surface member B,
FIG. 1D shows a wooden skeleton material 2 which is a paper honeycomb (including a non-combustible paper which is made non-combustible by a condensed phosphoric acid treatment and other treatments).

Further, the core material 1 itself can be constructed as shown in FIG. That is, (a) is a core material 1 in which face materials B are integrally interposed on the upper and lower surfaces, (b) is a core material 1 in which one surface is a face material B and the other surface is a sheet A, and (c) is a rectangle The core material 1 whose outer peripheral surface is covered with the sheet A and is integrated, (d) is the core material 1 whose both sides are the surface material B and the upper and lower surfaces are the sheet A, and the upper surface is the cushion material (e). The core material 1 in which C and the back surface are integrated with the surface material B is the core material 1.

The sheet A is made of one or more of paper, synthetic resin, metal, non-woven fabric and the like, and the face material B is plywood, wood board, metal board, It is made of at least one kind of synthetic resin plate and noncombustible plate material (gypsum board, calcium silicate board, calcium carbonate board, ALC board, cement board, wood wool cement board, wood chip cement board, etc.).

The cushion material C is made of synthetic resin, glass fiber, or inorganic fiber having a bulk specific gravity of about 2 to 5 times, or rubber.

[0013]

As described above, according to the core material of the present invention, the fire resistance of phenol foam can be maximized. Water absorption, which is an attribute of phenol foam, and condensed water at the time of reaction can be reliably covered by the humidity control and water absorption of the wooden frame material. The mechanical strength and dimensional stability, which are weak points of phenol foam alone, can be greatly improved. The core material itself can pass the fireproof test for 1 hour (the backside temperature is about 140 ° C and all other items are cleared). It can also reduce the weight of the core material and enhance the heat insulation. Very easy to manufacture. There are characteristics and effects.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing an embodiment of a core material according to the present invention.

FIG. 2 is a partially cutaway perspective view showing an example of a wooden skeleton material used as a core material according to the present invention.

3 is a partially cutaway perspective view showing another embodiment of the wooden frame member used in FIG. 1. FIG.

FIG. 4 is an explanatory view showing another embodiment of the core material according to the present invention.

[Explanation of symbols]

 A sheet B face material C cushion material 1 core material 2 wooden skeleton material 3 horizontal rail 4 vertical rail 5 space 6 resol type phenolic foam

Claims (1)

[Claims] 1. A core material in which a wooden skeleton material is integrally interposed in a resol-type phenol foam.