JPH0622972B2 - Manufacturing method of building materials - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing 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 a certain degree of fire resistance, but when exposed to a flame, the water contained in the crystals is liberated and explodes due to the vapor, or the strength drops sharply. There was a drawback.

On the other hand, in the latter case, the heat transfer coefficient and the thermal expansion coefficient of the metal plate are large, so when exposed to high temperature, stress concentrates at the interface between the base material and the metal plate, causing peeling and warping, and the plate deformation increases. There was a drawback.

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 having a large cross-sectional area is excellent in fire resistance because even if it is in a fire, its surface is only carbonized, damage due to flame does not progress inside, and thermal stress is small. There is a report. Therefore, it has been proposed to carbonize the surface of the building material in advance with, for example, a burner to form a carbonized layer.

However, in this method, since the carbonized layer is porous,
Oxygen easily passes through the carbonized layer to reach the substrate. Therefore, if the base material is thin, there is a problem in that the base material is easily ignited and burned to penetrate the flame.

Therefore, in order to provide a dense protective layer on the surface of the base material, it has been considered to fix the carbon powder particles to the surface of the base material using a thermosetting synthetic resin as a binder.

However, the carbon powder particles are difficult to wet with the thermosetting synthetic resin, and are difficult to be uniformly dispersed only by kneading and coating, so that the density of the protective layer becomes non-uniform and the fire resistance tends to vary.

In view of the above problems, the present invention has an object of improving fire resistance by forming a strong and uniform protective layer on the surface of a base material.

Means for Solving the Problems The present invention, in order to achieve the above-mentioned object, a self-curing carbon powder comprising a thermosetting resin adhered to the surface of powder consisting mainly of a carbon component is used as a base material. The method for producing a building material is characterized in that it is placed on the surface and then heated and pressed to form an integral protective layer on the surface of the base material.

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, the better.
For example, if the treatment temperature is 300 ° C. to 500 ° C., carbonization proceeds, but if calcined at a temperature of 1000 ° C. or higher, the carbon shrinks, the specific surface area becomes small, and the carbon becomes rich. It is more preferable because it becomes difficult to burn.

In addition to artificially produced velocities and graphite, naturally occurring graphite and various kinds of charcoal 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 the carbon powder is 30 to 2
000 microns is preferred.

On the other hand, as the thermosetting 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 wettability with carbon powder particles. Especially, since phenolic resin has a large amount of fixed carbon,
Carbonization by pyrolysis has the advantage that the heat insulating property is enhanced and the fire resistance is further improved.

As a method for producing a self-curing carbon powder, carbon powder and a solid thermosetting low molecular weight material, for example, an initial condensate of a resol type phenol resin is charged into a kneader, and these are kneaded with an alcohol solvent or the like. After that, there is a method in which the kneaded product is taken out from the kneader, the molded product extruded and molded is dried, and then pulverized to obtain a self-curing carbon powder.

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 the carbon powder particles by a reaction, and the resin is allowed to pass and then dried to obtain a self-curing carbon powder material.

In addition, if necessary, silica, alumina, may be added powdered particles such as magnesia, and in plants such as rice plants, if a material containing a large amount of silica such as rice husk is fired, a mixture with carbon powder particles is formed, It is suitable.

Further, a fibrous material or a lightweight aggregate may be mixed as a reinforcing material.

As the base material, wood materials such as plywood, particle board, LVL, wood veneer, plaster material, calcium silicate board,
Water-curable inorganic materials such as wood chip cement board and slag gypsum board can be mentioned, but the base material is not necessarily limited to a plate shape, and may be a columnar shape or a rod shape.

When the base material is a wood material, the wood material itself has low thermal conductivity, and a carbonized layer is generated by thermal decomposition at the interface with the protective layer described below, 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 delamination and cracks are unlikely to occur.

On the other hand, when the base material is an inorganic material, the base material is not directly exposed to the flame due to the presence of the protective layer, so the water contained in the crystals is less liberated, the explosion is less likely to occur, and the fire resistance of the base material is reduced. There is an advantage of improving.

As a method of forming a protective layer on the surface of the base material, for example, there is a method of forming a protective layer by spraying a self-curing carbon powder on the surface of the base material and then heating and pressing. .

According to this method, a protective layer having a desired density and thickness can be easily formed on the surface of the base material by simply spraying the self-curing carbon powder on the surface of the base material and heating and pressing. Compared with the conventional method of forming a protective layer by applying a kneaded material in a wet state, there is an advantage that a pretreatment and a drying step are unnecessary.

As another method, a self-curing carbon powder is sprinkled on the upper surface of a forming mat formed by kneading a small piece of wood and a binder such as an adhesive or cement, and heat-pressing the powder. There is a method of forming a protective layer at the same time as the plate.

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.

The thickness of the protective layer to be formed is 0.5 to 5 mm, preferably 1 to
3 mm is preferable, and the fixed content of carbon powder particles is 50% or more by weight, preferably 60 to 95%. Also, the specific gravity is 0.
8 or more, preferably 1.0 to 1.4.

Furthermore, if protective layers are provided not only on one side but also on both sides of the plate-shaped substrate, a so-called sandwich construction is formed and the physical and mechanical properties of the material are stabilized, so that warpage is unlikely to occur. Moreover, since the protective layer becomes thicker, the flame is less likely to penetrate during a fire, and the sound insulation is improved.

A decorative layer made of a decorative sheet such as a thin wooden plate, a synthetic resin sheet, or a glass cloth may be provided on the surface of the protective layer. If the decorative sheet is integrated at the time of heating and pressing, the productivity is improved.

Example 1 10 kg of graphite was put into a double-arm kneader and the softening point was set to 8
After adding 11 kg of 60% methanol varnish of solid resol type phenol resin at 0 ° C. and stirring and kneading for 30 minutes, this kneaded product was extruded by a continuous kneading extruder to make a round bar having a diameter of 3 mm, and the round bar was air-dried. Evaporate the solvent methanol,
Then, this was crushed by a crusher to obtain a self-curing carbon powder having a particle diameter of 0.5 mm or less.

Then, this self-curing carbon powder is sprayed on the front and back surfaces of a particle board (commercially available) having a thickness of 17 mm and a specific gravity of 0.70 to deposit a thickness of about 3 mm, and then heated at 160 ° C. for 5 minutes. By tightening the protective layers to a thickness of about 1.5 mm, a building material having a total thickness of 20 mm was obtained and used as a sample.

Example 2 A building solvent obtained by the same procedure as in Example 1 was used as a sample, except that a 12 mm-thick gypsum board was used in place of the substrate in Example 1.

Example 35 In a four necked flask of 5, 770 g phenol, 37%
Formalin 1328g, Hexamethylenetetramine 80g
And flake graphite 110 having an average particle size of 5 μm.
I charged 0g.

The temperature was raised to 90 ° C., which required about 60 minutes, and 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 size 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 In place of the self-curing carbon powder used in Example 1, 10 kg of graphite and 6.5 kg of a resole type phenolic resin having a viscosity of 200 poise were added and kneaded for 30 minutes to form a paste. A construction material obtained by the same operation as in Example 1 except that the composition was directly applied was used as a sample.

Comparative Example 2 A commercially available wood chip cement board having a specific gravity of 1.15 was used as a sample.

Comparative Example 3 A commercially available gypsum board (general-purpose product) 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 Bunsen burner, which is supplied with city gas through a ballast, is applied so that the flow rate is constant.

The flame tip temperature 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 displacement amount 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 3 to 9 times that of Comparative Examples 1, 2, and 3.

EFFECTS OF THE INVENTION As is clear from the above description, by disposing the self-curing carbon powder on the surface of the base material and heating and pressing to form the protective layer,
A uniform and dense protective layer can be formed on the surface of the base material, and a building material having no variation in fire resistance can be obtained.

Moreover, since the carbon powder particles forming the protective layer have a function as a powder adhesive themselves through the thermosetting resin,
Even if the base material is porous, it penetrates into the pores of the base material and strongly integrates with the base material. Further, since the protective layer made of carbon powder particles has a small thermal expansion, the stress concentration generated between the base material and the protective layer in a high temperature environment is extremely small. As a result, warpage, peeling, cracks, etc. are unlikely to occur, and sufficient strength can be maintained for a long time even in the event of a fire.

In addition, the building material of the present application, which is covered with a uniform and dense protective layer made of carbon powder and synthetic resin, has a large oxygen index of the carbon powder, which makes it difficult to ignite or spread in the air and block oxygen. To be done. For this reason, even if the base material is a wood material, the inside does not burn, so the flame does not penetrate, and there is a useful effect in terms of fire resistance that it does not suddenly fall off during a fire.

Front Page Continuation (72) Inventor ▲ Yoshi ▼ Yasutoro Tada 1 Inaba, Inami-cho, Higashibura-gun, Toyama Prefecture Within Daiken Kogyo Co., Ltd. Previous 4-21 (72) Inventor Atsushi Takamatsu 2-14-5 Uchishiro-cho, Miyakojima-ku, Osaka-shi, Osaka (72) Inventor Isamu Ide 1648-15 Kanaoka-cho, Sakai-shi, Osaka

Claims (1)

[Claims] 1. A base material is prepared by arranging a self-curing carbon powder material obtained by adhering a thermosetting resin on the surface of powder particles mainly composed of carbon component, on the surface of the base material, followed by heating and pressing. A method for manufacturing a building material, comprising forming an integral protective layer on the surface of the building.