JPH08246641A - Composite panel - Google Patents

Abstract

PURPOSE: To prevent the generation of deformations by installing a fiber sheet and a breathable sheet member inside a core material of a composite material under sandwich structure or a bordering area between the core material and a front surface material or between the core material and a rear surface material. CONSTITUTION: A core material 3 made of a synthetic resin foam, such as phenol foam is filled up between a surface material 1 and a rear surface material 2, which are made of a metal sheet, thereby forming a composite panel A. A fiber sheet 7, such as polyester fiber or a weatherable sheet member 8 made of sheet-like fibers, such as cotton or fur, are installed inside the core material 3 of the composite panel A or at least in a bordering area between the core material 3 and the surface material 1 or between the core material 3 and a rear surface material 2. It is, therefore, possible to prevent the generation of deformations, such as swelling on a decorated surface or warping since the gas generated in the core material is discharged outside from the breathable sheet member 5.

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, in a composite panel having such a structure, under high heat, the front surface material and the back surface material are deformed in different directions by being pulled toward the heating side due to the difference in heat conduction. Due to this, a gap is created in the connecting part, and heat and flame leak from this part to the opposite side, and J
There was a defect that the test of IS-A-1304 for a fire resistant structure for 1 hour could not be passed. Further, this kind of composite panel, particularly the composite panel manufactured by discharging the core material in a liquid or granular form, has the following drawbacks. That is, phenolic foam, polyurethane foam, synthetic resin foam such as polyisocyanurate foam is an unreacted component of the components used when forming the core material, an excess gas component produced by the reaction (chlorine, carbon dioxide, methylene chloride, formaldehyde, steam, The surface of the composite panel may be swollen or warped with a gas such as hydrogen), and the image of the decorative surface may be significantly deteriorated.

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 sandwiched between a surface material and a back surface material. By using a composite panel forming a sheet-like fiber sheet and a thread-like breathable sheet member formed along at least one of the boundaries between the core material and the surface material or the core material and the back surface material, Since the gas generated in the core material is released from the breathable sheet member to the outside, 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, as shown in FIGS. 1 to 3, the composite panel A has a front material 1 and a back material 2 sandwiching a core material 3 made of a synthetic resin foam, and its overall shape is as shown in FIGS. As shown
From a surface material 1 made of a long 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, a decorative surface 6, a fiber sheet 7, and a breathable sheet member 8. It is an elongated one formed of a formed metal panel, metal shielding, and the like. 4 is a cross-sectional view showing a construction state of the composite panel A shown in FIG.

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.

In addition, in particular, the core material 3 is made to have fire resistance, and a fire resistant structure test (JIS-A-1304) of a building structure portion, a fire protection test of a building fire door (JIS-A-1311), a fireproof warehouse (JIS- S-1037) and the like, in order to obtain a core material 3 having a performance of passing a fire resistance test, as shown in FIGS. 3 and 4, a configuration including a plastic foam 3a and an inorganic board 3b interposed at both ends. To do.

As the plastic foam 3a, a resol type phenol foam is mixed with a foaming agent, aluminum hydroxide (Al (OH) ₃ ), ammonium polyphosphate, graphite, a curing agent, and an inorganic material such as calcium silicate or calcium carbonate. Then, it is foamed and cured to form a finished density of about 50 to 300 Kg / m ³ .

Resol type phenolic foam (hereinafter,
Phenolic foam) is mainly produced by a continuous foaming molding method, and has the properties of noncombustibility, low smoke generation, and low toxicity compared to other synthetic resin foams (plastic foams). Is. Further, a metal siding material formed by sandwiching this phenol foam on a metal plate is JIS-A-1301 as a single body.
(Fire protection test method for wooden parts of buildings), JIS-A-1
It has a fireproof performance that passes the fireproof structure test of 302 (fireproof test method of non-combustible structure part of building).

As the foaming agent, a stock solution of phenol foam is used.
When the amount is 0 part by weight, 2 to 50 parts by weight is mixed with the undiluted solution of the phenol foam, and examples thereof include methylene chloride and carbonate (powder).

Aluminum hydroxide is mixed in an amount of 50 to 300 parts by weight based on 100 parts by weight of the undiluted solution of phenol foam, and is useful as a flame-retardant material, a refractory material, and a heat-resistant material. Is. For example, the composition thereof has a moisture content of 0 to 30%, a particle size of 10 to 100 μm, and a purity of 90% or more.

Ammonium polyphosphate is used as a reaction control material and a flame retardant material, when 1 to 25 parts by weight of the phenol foam stock solution is mixed with the phenol foam stock solution. The particle size is 30-100 μ.

The graphite is mixed in an amount of 2 to 30 parts by weight based on 100 parts by weight of the phenol foam stock solution. The effect is that the phenol foam is carbonized at the time of fire to form voids, and the voids are closed by graphite expanded by heating to prevent deterioration of fire resistance performance due to thinning.

The curing agent is a phenol foam stock solution of 10 parts.
When the amount is 0 part by weight, 10 to 50 parts by weight is mixed with the stock solution of the phenol foam, which is an organic phosphoric acid type or a mixture of phosphoric acid type and PSA type.

An inorganic material such as calcium silicate or calcium carbonate is mixed to improve the shape retention and fire resistance of the plastic foam 3a.

The inorganic board 3b is used to enhance the fire resistance of the connecting portion, which will be described later. For example, calcium silicate board, calcium carbonate board, gypsum board, perlite cement board, rock wool board, slate board, ALC. Board,
PC board, other inorganic lightweight body, inorganic lightweight foam, or one or more of these composite boards, or super high density resin (high density phenol foam, etc.), male connection part 4 of composite panel A, female type It is interposed integrally with the connecting portion 5.

The fiber sheet 7 formed on the back surface of the surface material 1, the back surface material 2 or in the core material 3 is a fiber formed into a sheet, and the material thereof is polyester fiber, nylon fiber, vinylon fiber, boron. It is a continuous or hydrophilic sheet-like material made of one kind of fiber, carbon fiber, alumina fiber, silicon carbide fiber, aramid fiber, glass fiber and the like.

When the core material 3 is a synthetic resin foam, it is bonded by its self-adhesiveness. However, when the core material 3 is a molded body, an adhesive agent is used. The surface material 1 and the back surface material 2 are integrated with each other.

The breathable sheet member 8 formed on the back surface of the surface material 1 is made of a breathable member, and is used for the residual acid component of the curing agent and foaming agent used for the plastic foam 3a after the plastic foam 3a is manufactured. Excess gas components (chlorine, carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen) that have caused a chemical reaction in the plastic foam 3a due to the influence, or a gas such as condensed water at the time of reaction are combined by the breathable sheet member 8. It can be released to the outside from the cross section of the mouth of panel A. For this reason, the front and back surfaces of the manufactured composite panel A are free from deformation such as swelling and warpage due to internal gas, and are excellent in strength and fire resistance. Of course, a plurality of layers may be formed on both sides of the plastic foam 3a, the surface material 1 side, the intermediate portion, the back surface material 2 side, or a layer shape.

The breathable sheet member 8 is shown in FIG.
(B), FIG. 6, and FIG. 7, which forms a minimal gap in the plastic foam 3a, and includes, for example, cocoon, cotton, hemp, hair (vegetable fiber, animal fiber, Synthetic resin fibers, etc.) are thin and long stretched fibers and twisted. More specifically, the extremely small gaps formed in the breathable sheet member 8 are filled with surplus gas components (chlorine, carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen) in the plastic foam 3a, or gas such as condensed water at the time of reaction. In order to allow ventilation, the composite panel A is continuously formed up to the end of the mouth to form a communication structure.

More specifically, the breathable sheet member 8 is formed by inserting it together when the plastic foam 3a is formed, and is embedded by the plastic foam 3a. The resin of the plastic foam 3a does not penetrate into the breathable sheet member 8 and is formed only on the outer surface portion of the breathable sheet member 8. Therefore, the central portion of the breathable sheet member 8 has minimal communication. A gap is formed. Further, in the figure, the protrusion 8a is formed to exert the anchor effect of improving the adhesiveness with the core material 3.

With the structure of the core material 3 as described above, the front surface and the back surface of the manufactured composite panel A are swollen by the internal gas,
The composite panel A has no deformation such as warpage and is excellent in adhesive strength and fire resistance.

Reference numeral 9 denotes an inorganic packing material, which is made of, for example, rock wool felt, ceramic wool, or the like, which prevents a gap from being formed between the connecting portions during a fire resistance structural test and shuts out the intrusion of flame, and mainly fire resistance. It is useful as a function of materials, airtight materials, etc.

Numeral 10 is a waterproof packing material, which is generally commercially available such as polyvinyl chloride type, chloroprene type, chlorosulfonated polyethylene type, ethylene propylene type, asphalt impregnated polyurethane type, EPM, EPDM and the like. It is mainly useful as a function of a waterproof material, an airtight material, and the like.

[0028]

[Other Embodiments] The embodiment described above is one embodiment of the composite panel according to the present invention, and is shown in FIGS. 9 to 29 (a), (b).
Can be formed as shown in FIG. That is, FIG.
FIGS. 10A to 10D and FIGS. 10A to 10D show examples of forming the breathable sheet member 8, and particularly FIGS.
(C) is a breathable sheet member 8 formed by corrugating the breathable sheet member 8. In the figure, an example is shown in which the fiber sheet 7 and the breathable sheet member 8 are formed on both the surface material 1 and the back surface material 2.

11 to 18 (a) to 18 (h) show an embodiment in which the minimum ventilation hole 11 is formed in the composite panel A from the back material 2 side. More specifically, FIG. 11 to FIG.
As shown in FIG. 15, holes are formed in the core material 3 from the back surface material 2. In the figure, as shown in FIG.
Perforated up to. The extremely small ventilation holes 11 are formed by the excess gas component (chlorine, which passes through the breathable sheet member 8).
It is for releasing gas such as carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen) to the outside. Further, even if the minimum ventilation hole 11 is not formed up to the breathable sheet member 8, the surplus gas component in the vicinity of the formation of the minimum ventilation hole 11 is discharged to the outside. The size is about 0.1 to 5 mmφ.

As shown in FIG. 16, the locking piece 11a formed when forming the minimum ventilation hole 11 bites into the plastic foam 3a and exerts an anchoring effect, so that the adhesive strength between the plastic foam 3a and the backing material 2 is increased. Is greatly improved. It should be noted that the shape of the minimum ventilation hole 11 is shown in FIG.
As shown in (a) to (c), the locking piece 11a is provided.
The shape of is formed as shown in FIGS. 17 (b) and 17 (c).

Further, FIGS. 18a) to (h) and FIG.
9 (a) to 9 (h) show other examples of the perforation shape of the minimum ventilation hole 11. In the figure, an example is shown in which the fiber sheet 7 and the breathable sheet member 8 are formed on both the surface material 1 and the back surface material 2.

Further, FIGS. 20 (a) to 20 (f) to FIG.
(A) to (c) show other examples of the composite panel A, and the breathable sheet member 8 is omitted.

Further, FIG. 26 and FIG. 27 show the minimum ventilation holes 11
The back side of the above is covered with a breathable waterproof sheet 12, and is laminated so as to cover at least the surface of the minimum ventilation hole 11 formed in the back material 2. Further, the breathable waterproof sheet 12 does not prevent the gas discharged from the core material 3 through the minimal ventilation holes 11 from flowing out, and rainwater or the like from the surface of the complex panel A passes through the minimal ventilation holes 11 inside the complex panel A (that is, It is intended to prevent the core material 3) from entering.

An adhesive is generally used for laminating the backing material 2 and the breathable waterproof sheet 12, but
An adhesive is not provided at least between the minimum ventilation hole 11 and the breathable waterproof sheet 12, so that the breathability of the breathable waterproof sheet 12 is not hindered.

Further, FIGS. 28 (a), 28 (b) (a sectional view taken along the line aa in FIG. 28 (a)), and FIGS. 29 (a), 29 (b).
(A cross-sectional view taken along the line aa in (a)) is a composite panel A in which end walls 1a are formed at both ends (tree openings) in the longitudinal direction,
It is useful for improving the workability of vertical joints, strengthening waterproofness, and improving the aesthetics of the fit.

[0036]

As described above, according to the composite panel of the present invention, since the breathable sheet member is formed on the core material, the breathable sheet member can efficiently generate excess gas even if excess gas is generated in the core material. Since it is well discharged to the outside through the cross section of the composite panel and the minimum ventilation hole, 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, the engagement is reliable and the engagement force is strengthened, and it is strong against shaking such as an earthquake. When the locking piece is formed in the extremely small vent hole, the adhesive strength between the back surface material and the core material is improved. When the breathable waterproof sheet is laminated on the surface of the back surface material, it is possible to prevent rainwater from entering the core material from the surface of the composite panel without hindering the discharge of the surplus gas from the extremely small ventilation holes. The fiber sheet improves the adhesion between the surface material, the back surface material and the core material.
When the protrusions are formed on the breathable sheet member, the adhesion between the core material and the core material is improved due to the anchor effect and the strength is improved. There is no peeling. Productivity (yield) is improved. The number of complaints decreases. If a core material having a phenolic resin as the main component having the above-mentioned configuration is used, a fireproof structure test of a building structure part (JIS-A-1304), a fireproof test of a building fire door (JIS-A-1311), It has the performance to pass the fire resistance test of the fireproof warehouse (JIS-S-1037). There are characteristics and effects.

[Brief description of drawings]

FIG. 1 is a perspective view showing a typical example of a composite panel according to the present invention.

FIG. 2 is a perspective view showing a typical example of a composite panel according to the present invention.

FIG. 3 is a perspective view showing a typical example of a composite panel according to the present invention.

FIG. 4 is an enlarged cross-sectional view showing a construction state of the composite panel according to the present invention.

FIG. 5 is a partially enlarged cross-sectional view showing a typical example of the composite panel according to the present invention.

FIG. 6 is an explanatory view showing a fiber sheet of the composite panel according to the present invention.

FIG. 7 is an explanatory view showing a breathable sheet member of the composite panel according to the present invention.

FIG. 8 is an enlarged sectional view showing a breathable sheet member of the composite panel according to the present invention.

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

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

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

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

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

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

FIG. 15 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 16 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 17 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 18 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 19 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 20 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 21 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 22 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 23 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 24 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 25 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 26 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 27 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 28 is an explanatory view showing another embodiment of the composite panel according to the present invention.

FIG. 29 is an explanatory view showing another embodiment of the composite panel according to the present invention.

[Explanation of symbols]

 A composite panel 1 surface material 1a end face wall 2 back surface material 3 core material 3a plastic foam 3b inorganic board 4 male connection part 5 female connection part 6 decorative surface 7 fiber sheet 8 breathable sheet member 8a protrusion 9 inorganic packing material 10 waterproof Packing material 11 Extremely small ventilation hole 11a Locking piece 12 Breathable waterproof sheet

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. A composite panel comprising a sheet-like fiber sheet and a sheet-like air-permeable sheet member formed along one longitudinal direction.