JPH08169975A - Fire-resistant panel - Google Patents

Abstract

PURPOSE: To obtain a fire-resistant panel being excellent in fireproofness, adhesion, heat-insulation properties, expansion ratio and mechanical properties, suffering less from coating film break and not impairing the appearance of a facing material for a long time by dispersing a resol phenolic resin powder in a plastic foam. CONSTITUTION: This panel 1 is prepared by dispersing a resol phenolic resin powder 3 in a plastic foam 2. In another embodiment, this panel 1 has a structure in which a facing material (4: surface material, 5: back material) is integrally and firmly fixed on at least either surface of a plastic foam 2 as a core material. Examples of the plastic foams include a polyurethane foam, a polyisocyanurate foam and a resol phenolic foam.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a heat insulating material for buildings and structures,
The present invention relates to a fireproof panel useful as a fireproof material, sound insulation material, interior material, exterior material, core material for various panels, and the like.

[0002]

2. Description of the Related Art Generally, flame-retardant polyurethane foam, polyisocyanurate foam, phenol foam (resole type, novolac type), polyethylene foam, etc. which are excellent as fireproof, heat insulating, adhesive and bulky materials. There is.

[0003]

However, in order to make the polyurethane foam and the polyisocyanurate foam more flame-retardant, the addition of inorganic aggregates such as pearlite particles, calcium carbonate and ammonium polyphosphate. . However, there are disadvantages that the cells of the foam become rough, the heat insulating property is deteriorated, the weight is increased, and the uniformity of fire prevention cannot be obtained, resulting in an increase in cost including yield.

Further, when a composite panel is produced by molding using this kind of plastic foam as a core material, the foam raw material component and the flame retardant component react with the foam component during the reaction to form a foaming mechanism and a reaction system. It has a drawback that it adversely affects the original physical properties (foaming ratio, homogeneous density), unbalance of reaction time, increase in amount of raw materials used, fire resistance, mechanical strength, etc.

Further, when the composite panel is formed as described above, extra gas generated during the reaction is stored between the face material and the core material to cause an unspecified bulge on the surface of the face material, There is a defect that peeling occurs between the face material and the core material.

Particularly, in a composite panel in which a phenol foam is formed by using a resol type phenol resin as a core material, a phenol resin, an acid curing agent and a foaming agent (alternative CFC 141b, methylene chloride) are mixed to form a foam. When formed, the condensation water during the reaction is 10 to 20% (weight ratio)
It is released, and this moisture is not released to the outside, and it adheres to the back surface of the surface material as water droplets or stays as water vapor in the space between the surface of this reaction material and the surface material, resulting in the adhesion between the foam and the surface material. There was a drawback in that the face material was significantly inhibited and the face material was separated from the core material.

The condensed water is indispensable in the reaction system and is an important component for foam formation. In addition, the reaction system of phenol foam has a rapid foaming and continuously reacts from cream time → gel time → tack free time → rise time while radially expanding the volume from the discharge part to the outside. In this reaction system, it is gel time that maximizes the adhesive strength that is favorable for the core material to come into contact with the face material, and there is no water on the back surface of the face material. In such a situation, it is impossible to evenly contact the face material and the core material, and there is a disadvantage that the adhesive force becomes uneven.

The gas, water, or gas remaining between the face material and the core material, or the gas, water, or the like generated until the reaction is completed and stabilized expands due to solar radiation (temperature change) and the surface of the face material is reduced to 0. Since it is pressurized with a vapor pressure of 5 kg / m ² or more, there are the above-mentioned large vulnerable points that impair the appearance of the decorative surface and peeling, which causes a wavy appearance. In addition, moisture has a disadvantage in that the acidic substance contained in the foam dissolves, the adhesive strength between the foam and the face material is reduced, and the coating film of the face material is destroyed.

[0009]

In order to eliminate such drawbacks, the present invention provides a method of adding a phenol resin powder (resole type) into a plastic foam and integrating the foam alone or as a core material of a composite panel. When forming the core material,
At the time of reaction, it basically reduces the generation of unnecessary gas, etc. that occurs until the property stabilizes, and it has the desired fire resistance, adhesiveness, and heat insulation properties.
The present invention proposes a fireproof panel that can obtain a foaming ratio and mechanical strength, has less damage to a coating film, has a low acidity, and does not spoil the appearance of a surface material for a long period of time.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the fireproof panel according to the present invention will be described in detail below with reference to the drawings. FIG. 1 is an explanatory view showing a typical example of a fireproof panel according to the present invention, 1 is a fireproof panel, 2 is a plastic foam, and 3 is a resol type phenol resin powder.

To explain further, the fireproof panel 1 shown in FIG. 1 is useful when used alone as a heat insulating material, a fireproof material, a soundproofing material, and a core material without using a surface material 4 and a back surface material 5 described later. The plastic foam 2 is made of one kind of polyurethane foam, polyisocyanurate foam, phenol foam (resole type), polyethylene foam and the like, and the expansion ratio is about 5 to 100 times.

The resol type phenol resin powder 3 is a
It is a phenol resin having a spherical shape and a size of 0.
05-1.5 mmφ position, bulk density 0.06-0.8 g /
cm ³And (a) heat melting type, (b) partially heat
Melting type, (c) heat infusible type, or (d) firing
There are 4 types such as type, especially in the case of a true sphere liquidity
Is good. The amount added to the plastic foam 2 is
The maximum is plastic foam
Weight that 2 itself can function as a sufficient binder, for example,
For example, 10 to 5 for 100 parts by weight of plastic foam
It is a 00 weight part, and when surface-treated with a surfactant,
It is possible to increase the amount added by adding
Wear.

FIG. 2 shows another embodiment, which is a composite type fire-resistant panel in which face materials are integrally fixed to at least one side, in the figure, both sides of the fire-resistant panel 1 shown in FIG. It is composed of at least one kind of flexible material, hard base material and the like. More specifically, as the flexible material, kraft paper, aluminum foil, aluminum kraft paper, non-woven fabric (carbon, alumina, rock wool, graphite, inorganic fibers such as glass, polyester-based, nylon-based, aramid-based resin Manufactured), asphalt felt and the like. Further, as the hard substrate, a thin metal plate such as iron,
Aluminum, copper, stainless steel, titanium, 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.), etc. (Including a plate) formed into various shapes by roll molding, press molding, extrusion molding or the like, or composed of an inorganic material.

FIG. 3 shows another invention according to the present invention. In the fireproof panel 1, the surface material 4 and the plastic foam 2 are provided.
The exhaust port forming materials 6 are arranged at an arbitrary pitch in between, and are useful for discharging the gas generated during the reaction of the plastic foam 2 and the contact with and integration with the surface material 4 and the gas generated over time. is there. The exhaust port forming material 6 is formed by twisting fibers into a string or a plastic foam 2
A substance that dissolves or shrinks depending on the components present therein, for example, a filamentous material containing starch, ethylene glycol, paraffin, vegetable fiber, animal fiber, etc. as its main component, and configured to be embedded in a linear or net shape. is there.

FIG. 4 shows a refractory panel 1 of FIGS. 2 and 3, which has a blind hole 7 for surely discharging the above-mentioned unnecessary gas on the back surface, and has a diameter of about 1. 0.1 to 5 mmφ, pitch is 50 to 1
It is distributed at about 500 mm. The gas pressure of the refractory panel 1 was 0.01 kgf / cm ² .

Example 1 In the case of polyurethane foam (a) Polyol 60 parts by weight (b) Polyisocyanate (MDI) 100 parts by weight (c) Foaming agent (alternative CFC 141b) 40 parts by weight (d) Foam stabilizer ( Toray Silicon) 2 parts by weight (e) Catalyst 3 parts by weight (f) Phenolic resin powder (resole type) 50 parts by weight Thermal infusibility (type C)

(Example 2) In the case of polyisocyanurate foam (a) 60 parts by weight of polyol (b) 170 parts by weight of polyisocyanate (MDI) (c) 40 parts by weight of foaming agent (alternative CFC 141b) (d) foam stabilizer Agent (Toray Silicon 193H) 2 parts by weight (e) Catalyst (trade name: DABCO) 5 parts by weight (f) Phenolic resin powder (resole type) 30 parts by weight (average particle size: about 0.06 mm)

(Example 3) In the case of phenol foam (a) Resol type phenol resin 100 parts by weight (nonvolatile content 80%, viscosity 2000 cps / 20 ° C) (b) Hardener 20 parts by weight (65% paratoluene sulfonic acid aqueous solution) (C) Blowing agent 13 parts by weight (Alternative CFC 141b) (d) Additive 5 parts by weight (silicone, ammonium polyphosphate, etc.) (e) Catalyst 3 parts by weight (f) Phenolic resin powder (resol type) 10 parts by weight ( (Average particle size 0.02mm)

(Example 4) In the case of phenol foam (a) Resol type phenol resin (b) Curing agent 20 parts by weight (65% paratoluenesulfonic acid aqueous solution) (c) Blowing agent 13 parts by weight (Alternative CFC 141b) ( d) Additive 5 parts by weight (silicone, ammonium polyphosphate, etc.) (e) Catalyst 3 parts by weight (f) Phenolic resin powder (resole type) (average particle size 0.018 mm) (g) Aluminum hydroxide (H) string (Cotton thread twisted to a diameter of about 5 mmφ) 4 threads / 20 cm interval The pitch P in FIG. 3 was 20 cm, and the threads were arranged endlessly in the longitudinal direction. (H) Paraffin having a semicircular cross section and a height of 1 to 2 mm was continuously planted on the back surface of the surface material 4 at the same intervals as in (H).

Comparative Example In the case of phenol foam (a) Resol type phenol resin 100 parts by weight (b) Polyisocyanate (MDI) 100 parts by weight (c) Foaming agent (alternative CFC 141b) 40 parts by weight (d) Foam control Agent (Toray Silicone) 2 parts by weight (e) Catalyst 3 parts by weight

Therefore, the fireproof panel 1 having the structure shown in FIG. 2 is used in Examples 1 to 3, the surface material 4 is a surface-treated steel sheet having a thickness of 0.5 mm, and the back surface material 5 is a surface-treated steel sheet having a thickness of 0.35 mm. The total thickness was 50 mm. In addition, referring to FIGS. 5A to 5C, is a test according to JIS-A-1321, is a test according to JIS-A-1301, is a test according to JIS-A-1304, is strength at 10% strain, and is with a projector. Heating, surface temperature 85-95 ℃
And maintain for 3 days. The pressure sensor is AB type 50PSI manufactured by Kronell Co., Ltd., and the conduit diameter is 1.5 mmφ. The gas pressure in the comparative example was 0.3 kg / cm ² for several hours after production at room temperature, and after heating, it became as shown in Table 1 of FIG. Is JIS-A-1
613 (test piece size is 50 × 5)
0 mm).

In FIG. 5, the back surface temperature of 260 ° C. or higher is a failure in the comparative example B. This is because the increase in the internal decomposition pressure caused a large amount of deformation, resulting in a gap in the connecting portion. In B, since the amount of the resol-type phenol resin is the same as that of the resol-type phenol resin powder 3 of Examples 3 and 4, there are more components remaining in the foam and decomposed than those of Examples 3 and 4.

[0023]

As described above, according to the fireproof panel of the present invention, unnecessary components, especially gas, generated by reaction and foaming can be reduced from the beginning. Since the absolute amount of unnecessary gas can be reduced, the adhesive strength can be strengthened, and the badness against the coating film, especially the acidity (about PH2) in phenol foam can be suppressed to about PH5, so that the deterioration of the coating film can be prevented. About 4 times better than that. Since the adhesive strength between the surface material and the plastic foam is high and the amount of unnecessary gas (decomposition gas, etc.) is small, the surface material does not swell or warp. When the exhaust port forming material is planted between the surface material and the plastic foam, the gas pressure is further reduced, and various inconveniences can be prevented. Fire resistance and fire resistance can be more surely improved by adding the resol type phenol resin powder. In the production of various foams, the resol-type phenol resin powder is fine particles, so that it can be mixed very easily and desired foams can be formed. There are characteristics and effects.

[Brief description of drawings]

FIG. 1 is an explanatory view showing an embodiment of a fireproof panel according to the present invention.

FIG. 2 is an explanatory view showing an embodiment of a fireproof panel according to the present invention.

FIG. 3 is an explanatory view showing an embodiment of a fireproof panel according to the present invention.

FIG. 4 is an explanatory view showing an embodiment of a fireproof panel according to the present invention.

FIG. 5 is an explanatory view showing a table for comparing the performance of the fireproof panels according to the present invention.

[Explanation of symbols]

 1 Fireproof panel 2 Plastic foam 3 Resol type phenolic resin powder 4 Surface material 5 Back material 6 Exhaust port forming material 7 Gas vent hole

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Claims (4)

[Claims] 1. A fire-resistant panel characterized by mixing resol-type phenol resin powder in plastic foam. 2. The fire-resistant panel according to claim 1, wherein the plastic foam is any of polyurethane foam, polyisocyanurate foam, and resol-type phenol foam. 3. The fire resistant panel according to claim 1, wherein a plastic foam is used as a core material, and a face material is integrally fixed to at least one surface of the core material. 4. A fire-resistant panel, characterized in that a face material is integrally fixed to both sides of a plastic foam, and an exhaust port forming material is integrally interposed in the foam or between the foam and the face material.