JPH08177207A - Composite panel - Google Patents

Abstract

PURPOSE: To prevent deformation, such as a blister, by a method wherein a plurality of very small vent holes are formed in the core of a sandwich panel and one of boundaries between the core and a surface material and between the core and a back material. CONSTITUTION: A composite panel A is molded in such a manner that a core 3 formed of a synthetic resin foam is sandwiched between a surface material 1 and a back material 2 both made of a metallic sheet. During manufacture of the composite panel A, holes are formed in the back of the surface material 1 by means of a piano wire to form very small through-holes 7 (vent holes) in the back of the surface material 1. A chemical reaction occurs in the core 3 due to the remaining acid component of a curing agent and a foaming agent used in the core 3 to generate gas, and the gas is discharged through the header section part of the composite panel A by means of the very small through-holes 7. This constitution prevents the occurrence of deformation, such as a warp, due to internal gas and reduces the cost.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention
The present invention relates to a composite panel that can be used as an outer wall material, a roof material, a ceiling material, a floor material, a partition material, a fire door, and the like, is free from deformation such as swelling and warping after manufacturing, and has excellent strength.

[0002]

2. Description of the Related Art In general, a number of composite panels in which a thin plate-shaped front material and a back surface material sandwich a core material made of a synthetic resin foam have been invented and put on the market.

[0003]

However, the composite panel of this kind, particularly the composite panel manufactured by discharging the core material in a liquid or granular form, has the following drawbacks. That is, phenol foam, polyurethane foam,
Polyisocyanurate foam has deformations such as unreacted components used when forming the core material and surplus gas components generated by the reaction that the surface of the composite panel swells or warps over time, greatly improving the image of the decorative surface. Had been lowered to.

Particularly, for example, when a phenol foam raw material (resole type) formed by reaction foaming by mixing and discharging a phenol resin stock solution, an acid curing agent and a foaming agent is used as a core material, the reaction occurs in the phenol foam. Condensed water at the time of about 10% of the weight is retained, and due to changes in the outside temperature etc. during the curing period of the product or after the construction of the composite panel,
Since water vaporizes and there is also no escape route, it remains between the surface material or back surface material of the composite panel and the core material, causing gas swelling or warping between the surface material or the back surface material and the core material of the composite panel. However, there is a drawback that the appearance of the composite panel and the strength of the composite panel are adversely affected over time due to deterioration of mechanical strength or the like.

[0005]

In order to eliminate such drawbacks, the present invention provides a composite panel in which a core material made of a synthetic resin foam is integrally sandwiched between a surface material and a back surface material. By using a composite panel in which a plurality of very small ventilation holes are formed in at least one of the boundaries between the core material and the surface material or between the core material and the back surface material, the gas generated in the core material is discharged from the minimal ventilation holes to the outside. Therefore, the present invention proposes a composite panel in which the decorative surface of the composite panel does not swell or warp for many years.

[0006]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the composite panel according to the present invention will be described in detail below with reference to the drawings. That is, the composite panel A is, as shown in FIG.
A front material 1 and a back material 2 sandwich a core material 3 made of a synthetic resin foam, and the whole shape is shown in FIG.
As shown in the sectional view of (b), a surface material 1 made of an elongated thin plate, a male connecting portion 4 formed at one end in the width direction, a female connecting portion 5 formed at the other end, and a decorative surface 6 It is a long object made of a metal panel, metal siding, etc.

The surface material 1 and the back surface material 2 are thin metal plates such as iron, aluminum, copper, stainless steel, titanium and aluminum.
Roll forming of zinc alloy plated steel plate, enamel steel plate, clad steel plate, laminated steel plate (PVC steel plate, etc.), sandwich steel plate (damping steel plate, etc.) Molded into various shapes by press molding, extrusion molding, etc., or formed into various arbitrary shapes by extrusion molding, press molding, autoclave culturing, etc. of inorganic materials, and also aluminum vapor-deposited paper, asbestos paper, kraft paper , Asphalt felt, metal foil (Al, Fe, Pb, Cu), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper, aluminum hydroxide paper, glass fiber non-woven fabric, etc., or a laminate of two or more kinds Alternatively, it is a sheet-like material that is waterproofed or flame-retarded.

The core material 3 is made of synthetic resin foam, and is made of synthetic resin foam such as polyurethane foam, polyisocyanurate foam, phenol foam, vinyl chloride foam, polyethylene foam, polystyrene foam and urea foam. It is a thing.
In particular, when it is made of phenol foam, it is formed integrally by mixing an undiluted solution of resol-type phenol and an acid curing agent, discharging the mixture on the back surface side of the front surface material 1 or the back surface material 2, and heating to cause reactive foaming. .

Further, in the core material 3, lightweight aggregates (perlite particles, glass beads, gypsum slag, talc stones, zeolite also having an adsorbing ability, shirasu balloons, etc.) and fibrous materials (glass wool) are used as various flame retardant materials depending on the purpose. , Rockwool, carbon fiber, graphite, etc.), and aluminum hydroxide as an endothermic material may be mixed in at least 5 to 300 parts by weight to improve fire resistance and fire resistance.

The minimum through-holes 7 formed on the back surface of the surface material 1 in FIGS. 1A and 1B are holes formed on the back surface of the surface material 1 by a piano wire or the like when the composite panel A is manufactured. The pore size is about 0.01 to 5 mm. After the core material 3 is manufactured, the extremely small through-holes 7 undergo a chemical reaction in the core material 3 due to the residual acid component of the curing agent and the foaming agent used for the core material to generate gas such as chlorine and carbon dioxide. Also, this gas can be discharged to the outside from the cross section of the mouth of the composite panel A through the extremely small through holes 7.

Therefore, the surface of the composite panel A after manufacturing,
There is no deformation such as swelling or warping due to the internal gas on the back surface, and the composite panel A has excellent strength.

[0012]

[Other Embodiments] What has been described above is one embodiment of the composite panel according to the present invention, and the minimum ventilation hole 7 can be formed as shown in FIGS. That is, FIG.
In (a) to (e), (a) is a composite panel A in which the minimum ventilation holes 7 are formed on the surface material 1 side, and (b) is a back surface material 2.
The composite panel A having the minimum ventilation holes 7 formed on the side, (c) shows the composite panel A having the minimum ventilation holes 7 formed on the surface material 1 and the back surface material 2 side, (d), (e) shows the surface material 1 And the composite panel A in which the minimum ventilation holes 7 are formed in the back surface material 2 side and in the core material 3.

Further, FIG. 3 shows a composite panel A in which the minimum ventilation holes 7 are formed in a lattice shape, and FIGS. 4A to 4J and 5A to 5E show the minimum ventilation holes 7. It shows another embodiment of the shape.

Further, FIGS. 6A to 6E to FIG.
(A)-(e) shows other Examples of the composite panel A. That is, FIGS. 6 (a) to 6 (e) and FIGS. 7 (a) to 7 (e) show a composite panel A in which the minimal ventilation holes 7 are respectively deformed. In addition, FIGS. 8A to 8D and FIG.
(A)-(d) is a composite panel A in which the minimum ventilation holes 7 are formed as shown in the figure, and a plurality of minimum ventilation holes 7a are formed from the back material 2 side at an appropriate pitch. It should be noted that the very small ventilation holes 7
Since a is formed from the backing material 2 side, it is perforated after the composite panel A is formed.

Further, FIGS. 10A to 10C to FIG.
(A) to (e) show other examples of the composite panel A, and the minimal ventilation holes 7, 7a are omitted. In the figure, 8 is an inorganic packing material, 9 is an inorganic plate material, and 10 is a packing material. In particular, FIG.
14E and 14A to 14E show a composite panel A formed by extrusion molding the surface material 1 with a synthetic resin material (plastic) or a metal material (aluminum alloy or the like).

[0016]

As described above, according to the composite panel of the present invention, since the minimum ventilation holes are formed in the core material, even if gas is generated in the core material, the minimum ventilation holes can efficiently perform this. Since it is released to the outside from the cross section of the wood mouth, deformation such as swelling or warpage of the decorative surface of the composite panel does not occur for many years. Since there is no deformation on the decorative surface, deformation does not appear even if the surface material has a small thickness, so that cost can be reduced.
Improved aesthetics. Improved strength. Improving productivity (yield). Decrease in the number of complaints. There are characteristics and effects.

[Brief description of drawings]

FIG. 1 is an explanatory diagram showing a typical example of a composite panel according to the present invention.

FIG. 2 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 3 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 4 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 5 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 6 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 7 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 8 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 9 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 10 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 11 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 12 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 13 is an explanatory diagram showing another example of the composite panel according to the present invention.

FIG. 14 is an explanatory diagram showing another example of the composite panel according to the present invention.

[Explanation of symbols]

 A composite panel 1 front surface material 2 back surface material 3 core material 4 male connection portion 5 female connection portion 6 decorative surface 7 extremely small ventilation hole 7a extremely small ventilation hole 8 inorganic packing material 9 inorganic board material 10 packing material

Claims (1)

[Claims] 1. A composite panel in which a core material made of a synthetic resin foam is integrally sandwiched between a surface material and a back material, and at least a boundary between the core material or the core material and the surface material or between the core material and the back material. One is a composite panel having a plurality of extremely small ventilation holes formed along the longitudinal direction.