JPH0687183A - Refractory composite sheet - Google Patents

Abstract

PURPOSE:To prevent a foamed constitution from being damaged by condensed water produced at the time of formation of a resol-type phenolic foam and also to improve the adhesion between a base and a core, fire resistance, strength, etc. CONSTITUTION:In a refractory composite sheet alpha of which a core 3 is formed between incombustible bases 1 and 2, the core 3 is constituted of a foamed body of resin of a resol-type phenolic foam 4 and of lightweight aggregate 5 and formed by mixing a fine powder grain material 6 of chaff in the resin of the resol-type phenolic foam 4 and the lightweight aggregate and by making the mixture foam and set, and the integration of the incombustible bases 1 and 2 with the core 3 is made firm by self-bonding properties at the time of formation of the resol-type phenolic foam 4. In this way, the refractory composite sheet alpha is prepared.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention is useful as a building, an interior wall material, an exterior wall material, a roof base material, a fire door, a partitioning material, etc., which requires fire resistance, and is lightweight and has heat insulating property, fire resistance,
The present invention relates to a fireproof composite plate having mechanical strength.

[0002]

2. Description of the Related Art In general, heat-resistant inner and outer wall composite plates are disclosed in Japanese Utility Model Publication Nos. 57-185535, 58-1538, 63-15444, and JP-B-2. 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 there is a disadvantage that the phenol foam leaks to the opposite surface, that is, the adhesive surface with the non-combustible base material, and the function of the adhesive cannot be exhibited. Further, in the above composite plate, a lightweight aggregate is laid finely, and this is integrated with a non-combustible base material with phenol foam to improve fire resistance, but the adhesive force of the phenol foam itself as the core material is not so much. It was not strong, and there was a defect that the phenol foam, which was the core material, peeled off from the noncombustible base material. Further, the composite board shown above is a building board in which 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 via an adhesive. However, impregnation of the raw material of phenol foam into the non-woven 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, there is concern about the adhesive strength. . Further, the above-mentioned composite plates (1) to (3) have a drawback that they lack adhesive strength for integrating the phenol foam and the face material. Further, the condensed water at the time of phenol foam formation hinders the reaction system of foam formation, making it difficult to form a homogeneous foam structure, and there are problems in heat insulation and adhesion to the non-combustible substrate.

[0004]

In order to eliminate such drawbacks, the present invention provides a fire-resistant composite plate in which a core material is formed between incombustible base materials, wherein the core material is a foam of a resol-type phenol foam resin. The core material is made of lightweight aggregate, and the resol type phenolic foam resin and the lightweight aggregate are mixed with the fine powder particles of rice husks and foamed and cured to form the core material. Integrating with the material proposes a fire-resistant composite plate that is fixed by the self-adhesiveness when forming phenol foam.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the fireproof composite plate according to the present invention will be described in detail below with reference to the drawings. That is, FIG.
FIG. 1 is a cross-sectional view showing a typical example of a fire-resistant composite plate according to the present invention, α is a fire-resistant composite plate, 1 and 2 are non-combustible base materials, 3 is a core material, 4 is a resole-type phenol foam, and 5 is lightweight. Aggregate 6 is a fine-grained material made of chaff.

More specifically, examples of the non-combustible base materials 1 and 2 include aluminum, iron, copper, stainless steel, titanium, aluminum / zinc alloy plated steel sheet, galvalume steel sheet, galfan, enamel steel sheet, fluororesin coated steel sheet, clad steel sheet, A sandwich steel plate (vibration control steel plate) or the like, or one or more of these color-coated metal plates or inorganic plates such as gypsum board, which are roll-formed, press-formed, extruded, etc. (A)-(f)
It may be molded into an arbitrary shape as shown in. In addition,
2A to 2F, the lightweight aggregate 5 is not shown.

The core material 3 is a resol type phenolic foam 4 in which fine particles 6 made of rice husks are mixed, and a lightweight aggregate 5 made of fine particles 6 made of rice husks is finely packed.
It is formed by being formed uniformly or ubiquitously.

Resol type phenolic foam (hereinafter,
(Phenolic foam) 4 is mainly manufactured by a continuous foaming molding method, and has noncombustibility, low smoke generation, and low toxicity performance compared to other synthetic resin foams (plastic foams). It is a thing.

The lightweight aggregate 5 is made of pearlite grains, vermiculite, shirasu balloon, gypsum slag, talc stone, glass beads, etc., and improves the fire resistance of the core material 3 and also the mechanical strength of the fire resistant composite board α. It is what makes me.

The fine powder granules (hereinafter, simply referred to as rice husks) 6 made of rice husks are obtained by finely crushing the rice husks to form fine powder granules (about 10 to 200 mesh). Having a function as a material, a bulking material, a heat insulating material, etc. When the phenol foam 4 is formed by mixing it with a resin which is a raw material of the phenol foam 4, a reaction inhibition preventing material for the phenol foam 4 and a noncombustible base material are secondarily formed. Adhesion strengthening material with 1, 2, reinforcing material for core material 3, fireproof material (formation of carbonized layer)
And the like.

More specifically, the rice husk 6 is uniformly mixed in the phenol foam 4 in the figure as shown in an enlarged view in FIG. 3, and the water generated when the phenol foam 4 is formed is absorbed by the rice husk 6. Then, the water which inhibits the formation of the foamed structure of the phenol foam 4 is removed, and the foamed structure of the phenol foam 4 is homogenized to improve the mechanical strength of the core material 3 (reinforcement of compressive strength, decrease of brittleness), In addition to improving the heat insulating property, the cost of the expensive phenol foam 4 is reduced to reduce the cost, and the phenol foam 4 is mixed in the lightweight aggregate 5.

Further, since the rice husk 6 has a homogeneous foam structure, the adhesive force between the non-combustible base materials 1 and 2 and the core material 3 is improved,
The mechanical strength of the fireproof composite plate α is also improved.

Further, the rice husk 6 is carbonized in the event of a fire and the core material 3
A carbonized layer is formed inside, which also helps improve fire resistance.

Next, an example of the method for manufacturing the fireproof composite plate according to the present invention is shown in FIG. First, a non-combustible substrate 1, for example, a color steel plate (thickness: 0.35 mm) is fed from a feeding step A (uncoiler, lifter, etc.) to a raw material discharging step B,
40 to 60 parts by weight of fine particles of rice husk 6 relative to 100 parts by weight of unfoamed resol type phenol foam stock solution,
A lightweight aggregate 5 made of pearlite grains mixed with rice husks 6 is mixed and uniformly stirred, and a stock solution 3a of a core material 3 is discharged from a discharger C onto a back surface 1a of a non-combustible base material 1 and a non-combustible base material is added thereon. The material 2, for example, a color steel plate (thickness 0.27 mm) is stacked through a feeding process D (uncoiler, lifter, etc.) and fed to a predetermined type curing oven E, and continuous or multi-stage pressurization (pressing). ) About 7 to 15 minutes by foaming method, 30 to 100 ° C
It is then cured, foamed and cured, then cut to a predetermined size with a cutter F, and then fed to the packaging step G.

Further, A ₁ and D ₁ shown by dotted lines are molding machines for the non-combustible base materials 1 and 2, and the non-combustible base materials 1 and 2 are shown in FIGS.
It is for molding into a predetermined shape as shown in (f).

[0016]

[Other Embodiments] The embodiment described above is one embodiment of the fireproof composite plate according to the present invention, and the lightweight aggregate 5 can be formed as shown in FIGS. 5 (a) to 5 (f). That is,
FIG. 5 (a) is a lightweight aggregate 5, which is a refractory composite plate α in which pearlite grains 5a having a large grain size and pearlite grains 5b having a small grain size are densely packed to increase the density, and FIG. 5 (b) is a lightweight aggregate. 5
As the fireproof composite plate α, the pearlite grains 5a and the expansive graphite 5c that expands and foams at a high temperature are mixed to improve the fireproof performance. Further, FIG. 5 (c) shows a case where pearlite particles 5d coated with a superabsorbent polymer are used as the lightweight aggregate 5, and FIG. 5 (d) shows pearlite particles 5a and a hydrophilic surfactant 5e as the lightweight aggregate 5. Is a refractory composite plate α capable of adsorbing and retaining condensed water generated during the curing of the raw material of the phenol foam 4, improving the fire resistance by the water content, and shortening the curing time during manufacturing. Further, FIG. 5 (e) is a lightweight aggregate 5, a refractory composite plate α in which pearlite grains 5a and glass fibers 5f such as chopped strands are interposed to improve fire resistance and strength, and FIG. 5 (f) shows Perlite particles 5a having a large particle size and pearlite particles 5 having a small particle size on the non-combustible base materials 1 and 2 side of the core material 3.
refractory composite plate α formed by ubiquitously and closely packing b, FIG.
(G) is a fire-resistant composite plate α in which a non-woven fabric 8 such as hydrophilic polyester fiber is formed between the non-combustible base materials 1 and 2 and the core material 3 with an adhesive 7 interposed therebetween. Of course, although the non-woven fabric 8 is formed on both surfaces of the non-combustible base materials 1 and 2 in FIG. 5 (g), the non-woven fabric 8 may be formed on only one surface on the non-combustible base material 1 side.

[0017]

As described above, according to the fire-resistant composite plate of the present invention, the resol type phenol foam is used.
It is a fire-resistant composite board that has non-combustibility, low smoke emission, and low toxicity compared to other synthetic resin foams (plastic foams). Fine powder granules made of rice husk have the functions of water absorbing material, water retaining material, raising material, heat insulating material, etc., and are mixed with the resin that is the raw material of resol-type phenolic foam and the lightweight aggregate to foam phenolic foam. When the body is formed, it absorbs the condensed water generated during the reaction, serves as a material for preventing the foaming reaction of the phenol foam, and makes the foaming structure uniform. Reducing the amount of raw materials used by homogenizing the foam structure,
The fire-resistant composite plate has the functions of improving the heat insulating property, strengthening the adhesion between the non-combustible base material and the core material, and improving the strength of the core material (improving the compressive strength and reducing brittleness). Fine powder granules made of rice husk serve as a bulking material, reducing the amount of expensive resol-type phenol foam raw material used and contributing to cost reduction. Fine powder and grain made of rice husks form a carbonized layer in case of fire, and the fire resistance is improved. By closely packing the lightweight aggregate, it becomes a fire-resistant composite board that is resistant to fire and passes a fire-resistant structural test such as fire-resistant for 1 hour. It is much lighter than other inorganic fire-resistant panels and improves workability. There are characteristics and effects.

[Brief description of drawings]

FIG. 1 is a sectional view showing an example of a fire-resistant composite plate according to the present invention.

FIG. 2 is a cross-sectional view showing an example of a fireproof composite plate.

FIG. 3 is an explanatory view showing a part of the fire-resistant composite plate used in FIG. 1 in an enlarged manner.

FIG. 4 is an explanatory view showing an example of a process for producing a fire resistant composite plate according to the present invention.

FIG. 5 is a cross-sectional view showing another example of the fire resistant composite plate according to the present invention.

[Explanation of symbols]

 α Fire-resistant composite plate 1 Non-combustible base material 2 Non-combustible base material 3 Core material 4 Resol type phenolic foam 5 Light weight aggregate 6 Fine powder granules made of rice husks

Claims (1)

[Claims] 1. A refractory composite board in which a core material is formed between non-combustible base materials, wherein the core material comprises a foam of a resol-type phenol foam resin and a lightweight aggregate, and a resol-type phenol foam resin and a lightweight aggregate. Fine particles of rice husks are mixed in the aggregate and foamed and hardened to form the core material. The uncombustible base material and the core material are integrated by the self-adhesive property during phenol foam formation. A fire-resistant composite board characterized in that