JPH0622971B2 - Fireproof building material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a building material having excellent fire resistance and sound insulation.

Conventional technology and problems to be solved by the invention Conventionally, as a base material for partition walls, ceilings, etc., a gypsum board using a hydraulic substance as a binder, a wood cement board, etc. The one in which a metal plate is attached and integrated on the surface of is used.

Since the former is composed of non-combustible material, it has tentative fire resistance, but when exposed to a flame, the moisture contained in the crystals is released, and the vapor explodes or the strength drops sharply. There was a drawback.

On the other hand, since the latter has a large heat transfer coefficient and thermal expansion coefficient of the metal plate, when exposed to a high temperature, thermal stress is generated at the interface between the base material and the metal plate, resulting in peeling or warpage.

Therefore, when the building material according to the above-mentioned conventional example is used for a partition wall or a ceiling, problems such as sudden collapse and fall of the fire and deformation of the evacuation opening and opening of the door have been pointed out.

On the other hand, a wood material with a large cross-sectional area is excellent in fire resistance because the surface is only carbonized, and even if there is a fire, the damage due to the flame does not progress to the inside and the thermal stress is small. There is a report.

In addition, partition walls, ceilings, etc. are required to have sound insulation properties, but the sound insulation effect does not improve unless the weight and thickness of the building materials described above are increased, and sound insulation performance is improved while maintaining machinability and workability. There was a problem that it could not be done.

In view of the above problems, the present invention is lightweight and retains excellent cutting processability, and also has excellent sound insulation and fire resistance,
In particular, it is an object of the present invention to provide a building material having fire resistance with a small decrease in strength under a high temperature environment.

Means for Solving the Problems The gist of the present invention is, in order to achieve the above object, have a fire resistance in which a protective layer mainly composed of powder particles mainly composed of a carbon component and a thermosetting synthetic resin is provided on the surface of a base material. It is found in construction materials.

Further, in order to achieve the same object, the present invention provides a protective layer mainly comprising carbon particles and thermosetting synthetic resin on the surface of the base material, and further providing a decorative layer on the surface thereof. It may be a building material having fire resistance.

As the base material, plywood, particle board, LV
In addition to wood materials such as L and thin wood plates, water-curable inorganic materials such as gypsum board, calcium silicate board, wood chip cement board, and slag gypsum board can be mentioned, but the base material is not necessarily limited to a plate-like material, It may be columnar or rod-shaped.

When the base material is a wood material, the wood material itself has a small thermal conductivity, and a carbonized layer is generated by thermal decomposition at the interface with a protective layer described later, and this carbonized layer serves as a heat insulating material. Effectively prevent thermal decomposition inside. Further, since the carbonized layer relieves the stress generated between the base material and the protective layer, there is an advantage that surface peeling and cracks are less likely to occur.

On the other hand, when the base material is an inorganic material, since the base material is not directly exposed to the flame by the protective layer described later, the decomposition of crystal water is less, explosion is less likely to occur, and the fire resistance of the base material is further improved. There is an advantage.

In addition to wood, the powder grains mainly composed of carbon components are seeds of grassy plants such as kollyan, wheat, sugar cane, rice and millet, hulls, trunks, branches, leaves, etc. It is obtained by thermally decomposing and baking, and the higher the treatment temperature is, the more preferable. For example, if the processing temperature is 300 ° C to 500 ° C,
Carbonization proceeds, but firing at a temperature of 1000 ° C. or higher is more preferable because the carbon shrinks, the specific surface area becomes small, and the carbon becomes rich, which makes combustion difficult.

In addition to the artificially produced charcoal and graphite, naturally occurring graphite and various charcoals can be used as carbon powder particles. If scale-like carbon powder particles are used among these, they overlap each other when forming the protective layer, so that there is an advantage that a dense protective layer can be formed. The particle size of this carbon powder is 30
~ 2000 microns is preferred.

Other than the above, mica can be used as the flaky powdery material. Further, silica, alumina, magnesia or the like may be mixed in the powder particles. In particular, rice husks such as grassy plants contain a large amount of silica, and when fired, a mixture with carbon powder particles appears at once, which is preferable.

Further, a fibrous material, a lightweight aggregate, or the like may be added as a reinforcing material or an extender.

On the other hand, as the thermosetting synthetic resin, for example, a novolac type or resol type phenol resin or an initial condensate of a melamine resin is suitable in order to improve the wettability with carbon powder particles. In particular, since the phenolic resin has a large amount of fixed carbon, carbonization by thermal decomposition has the advantage of further improving resistance to oxidation.

There are various methods for forming the protective layer, but the first method is to spray the self-curing carbon powder particles composed of carbon powder particles and thermosetting low molecular weight material on the surface of the base material. ,
There is a method of heating and pressing.

That is, as a method of obtaining a self-curing carbon powder, carbon powder and solid thermosetting synthetic resin, for example, the initial condensation product of a resole type phenol resin is charged into a kneader,
After kneading this with an alcohol solvent or the like, the kneaded product is taken out from the kneader, and in order to further improve the mixing, the molded product extruded and molded is dried, and then crushed to obtain a self-curing carbon powder. is there.

Further, as another method of obtaining a self-curing carbon powder material in which a resin is uniformly attached to the surface of carbon powder particles, when synthesizing a phenol resin, these carbon powder particles are put in a reaction vessel in advance. There is a method in which a resin is uniformly attached to the surface of carbon powder particles by reaction, the resin is separated, and then dried to obtain a self-curing carbon powder material.

After spraying this self-curing carbon powder on the surface of the base material, the protective layer is formed by pressing the material.

According to the above method, even if it is hard to get wet such as carbon powder particles,
A self-curing carbon powder granule having a thermosetting synthetic resin attached can be obtained. As a result, if the self-curing carbon powder is sprayed on the surface of the base material in a predetermined amount and heated and pressed, a protective layer can be easily obtained, and there is an advantage that the fire resistance of the base material does not vary. .

At the time of heating and pressing, a decorative layer may be integrated by disposing a paper, cloth, non-woven fabric or resin sheet on the self-curing carbon powder particles.

As a second method, the self-curing carbon powder particles are uniformly dispersed, and the self-curing sheet material having a predetermined thickness is partially pressed by roll pressing at a temperature of 50 ° C to 100 ° C. Got
There is a method of forming a protective layer on the surface of a base material by coating the surface of the base material with this self-curing sheet material and then heating and pressing.

According to this method, a uniform self-curing sheet material is heated and pressed onto the surface of the base material, so that there is an advantage that even in a large-sized building material, the protective layer becomes uniform and the fire resistance does not vary.

In this method, when the self-curing sheet material is manufactured, paper, cloth, non-woven fabric or a resin sheet may be arranged on one side thereof to be integrated. The attaching step can be omitted.

Alternatively, the self-curing sheet material may be superposed on the surface of the base material coated with the adhesive and heated and pressed.

A third method is to dispose the self-curing powder or the self-curing sheet material on the upper surface or the lower surface of a forming mat formed by kneading a small piece of wood and a binder such as an adhesive or cement, and heat it. There is a method of forming a protective layer at the same time as a plate by pressing.

According to this method, since a mixed and integrated layer is formed at the interface between the base material and the protective material, there is an advantage that it strongly adheres and peeling or cracking hardly occurs.

A fourth method is to knead the carbon powder and the thermosetting low molecular weight material into paste form through various solvents,
It is a method of pressing it with a roll as it is and extruding it into a sheet shape, placing it on the surface of the base material, then heating and pressing to form a protective layer. Even if a paper, cloth, nonwoven fabric or resin sheet is placed at the same time Good.

As a fifth method, a strong acid is added to graphite to form an intercalation compound, which is heated and expanded about 10 to 100 times, and then thermosetting into a sheet-like product by pressing with a roll at room temperature. There is a method in which a protective low molecular weight material is impregnated, and this is placed on the surface of a base material and heated and pressed to form a protective layer.

The fixed content of carbon powder particles in the protective layer is 50% by weight or more, preferably 60 to 95% by weight, and the specific gravity of the protective layer is 0.8 or more, preferably 1.0 to 1.4. .
The thickness of the protective layer is 0.5 to 5 mm, preferably 1 to 3
mm is good.

Furthermore, if protective layers are provided on the front and back surfaces of the base material, the material becomes a so-called sandwich construction,
Since the mechanical properties are stable, warpage is less likely to occur, and since the protective layer is thicker, the flame is less likely to penetrate during a fire and the sound insulation is improved.

Furthermore, a wood thin plate, a
It is preferable to provide a decorative layer such as a synthetic resin sheet or a decorative sheet such as glass cloth.

Example 1 Scale-like carbon powder particles and a resole-type phenol resin were added to a double-arm kneader at a weight ratio of 65:35,
After stirring and kneading for a minute, this kneaded product was extruded and molded by a continuous kneading extruder, the molded product was air-dried to volatilize the solvent, and then this was crushed by a crusher to obtain a self-curing carbon powder granule. It was

Next, this self-curing carbon powder was used to make the thickness 17 mm and the specific gravity 0.
70 particle boards (commercially available) are sprinkled on the front and back surfaces, and heated and compressed at 160 ° C for 5 minutes to give a thickness of 1.5 on the front and back surfaces.
A building material having a protective layer of mm and a specific gravity of 1.2 was obtained and used as a sample.

Example 2 Scale-like carbon powder particles and a resole-type phenol resin having a viscosity of 200 poise were added to a double-arm kneader at a weight ratio of 100: 6.
The mixture was charged at a ratio of 5, stirred for 30 minutes, kneaded, and discharged, and then the paste-like kneaded material was pressed by a roll to obtain a sheet-like self-curing protective material, which was placed on the front and back surfaces of the gypsum board. By depressurizing through a wire mesh, punching medal and heating and pressing at 160 ° C for 10 minutes,
A building material having a thickness of 1.5 mm and a protective layer having a specific gravity of 1.0 and a total thickness of 15 mm was obtained on each of the front and back surfaces and used as a sample.

Example 35 In a four necked flask of 5, 770 g of phenol, 37%
Formalin 1328g, Hexamethylenetetramine 80
g, and flake graphite 1 having an average particle size of 5 μm
100g was charged.

The temperature was raised to 90 ° C. in about 60 minutes, the reaction was continued for 3 hours, cooled, and then separated. This was air dried to obtain 1830 g of self-curing carbon powder particles having an average particle diameter of 50 μm. The content of the phenol resin in the obtained powder and granular material was 40%.

The building material obtained by operating this self-curing carbon powder in the same manner as in Example 1 was used as a sample.

Comparative Example 1 A commercially available wood chip cement board with a specific gravity of 1.15 was used as a sample.

Comparative Example 2 A commercially available gypsum board (general-purpose product) was used as a sample.

Comparative Example 3 A particle board having a specific gravity of 0.70 was used as a sample.

A bending creep test under a flame was conducted on the above-mentioned Examples 1, 2 and 3 and Comparative Examples 1, 2 and 3.

The bending creep test under flame is for knowing the fire resistance bending performance in a high temperature environment, and uses the board bending performance test method and device according to JIS A5908. The device corresponds to the back side of the central concentrated load point. Where you want to
It is arranged so that the tip of the flame of the Bunsen burner, which is supplied with city gas via a stabilizer so that the flow rate is constant, is applied.

The tip temperature of this flame was about 700 ° C., a load set to ⅕ of the bending fracture strength of the sample was applied, and the time required until the fracture and the amount of displacement at the load point were measured.

The measurement results are shown in Table 1.

As is clear from the above measurement results, it was found that each of Examples 1, 2, and 3 had a fire resistance performance 6 to 10 times that of Comparative Examples 1, 2, and 3.

Also, when the sound insulation performance at 500 Hz was measured,
Example 1 was 20 dB and Example 2 was 22 dB, whereas Comparative Example 2 was 16 dB.
It has been found that has a specific gravity almost equal to that of Comparative Example 2, but has better sound insulation than Comparative Example 2.

EFFECTS OF THE INVENTION As is clear from the above description, according to the present invention, the surface of the base material is covered with the protective layer made of carbon powder particles and thermosetting synthetic resin. In particular, if the carbon powder particles are flaky, the carbon powder particles overlap with each other to form a protective layer, so that the carbon powder particles are covered with a dense protective layer.

Since the carbon powder particles forming the protective layer have a function as an extender pigment through the thermosetting synthetic resin, even if the base material is porous, it penetrates into the pores of the base material. Then, while being strongly integrated with the base material, the thermal expansion of the protective layer made of carbon powder particles is small. In particular, if the carbon powder particles are scaly, they are oriented in a fixed direction, so that there is a stress relaxation action in the orientation direction. Therefore, the shear stress generated between the base material and the protective layer in a high temperature environment is small, warpage, peeling, cracking, etc. are unlikely to occur, and sufficient strength can be maintained for a long time even in a fire.

Further, the building material of the present application coated with the protective layer made of carbon powder particles and synthetic resin has a large oxygen index of the carbon powder particles, and thus is unlikely to ignite or spread in the air.

In particular, if the carbon powder particles are scale-like, the scale-like carbon powder particles are overlapped with each other to form a dense protective layer, so that oxygen is blocked. Therefore, the fire resistance is further improved, for example, even if the base material is a wood material, the inside does not burn, the flame does not penetrate, and it does not suddenly fall off during a fire, which is useful for fire resistance. It has a great effect.

Further, the protective layer is excellent in sound insulation, and particularly, when the carbon powder particles are scale-like, they form a protective layer having an orientation by being overlapped with each other, so that the protective layer has a high rigidity and is located below it. Since the protective layer effectively absorbs sound propagation energy due to the difference in rigidity with the base material, there is an effect of good sound insulation.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor ▲ Yashiro Yoshida, Inami No. 1 Inami, Inami-cho, Higashibura-gun, Toyama Prefecture Within Daiken Kogyo Co., Ltd. (72) Inventor ▲ Yoshida Tada Tada, Kawanishi-shi, Hyogo Prefecture Koujimae 4-21 (72) Inventor Atsuhisa Takamatsu 2-14-5 Uchishiro-cho, Miyakojima-ku, Osaka-shi, Osaka (72) Inventor Isamu Ide 1648-15 Kanaoka-cho, Sakai-shi, Osaka

Claims (2)

[Claims] 1. A building material having fire resistance, characterized in that a protective layer mainly composed of powder particles of a carbon component and a thermosetting synthetic resin is provided on the surface of a base material. 2. A fire-resistant material, characterized in that a protective layer mainly comprising carbon particles and thermosetting synthetic resin is provided on the surface of a base material, and a decorative layer is further provided on the surface thereof. Building materials that have.