JPH09144276A - Building panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To prevent a surface material from being detached from a core material and protect a building panel from warping to swelling by providing a continuous length-like breathable sheet which has formed an uneven rib by way of a bonding agent on the rear surface of at least the surface material. SOLUTION: A breathable sheet 5 is placed on the rear surface of at least a surface material 1 by way of a bonding agent 4, thereby providing a building panel A. The breathable sheet 5 serves to enhance the strength of the building panel A itself and enhances the bonding strength of a core material 3 and the surface material 1. An uneven rib 6, which comprises a recessed area 6a and a projected area 6b, is continuously formed on the breathable sheet 5. The uneven rib 6 forms a void α, which is substantially triangular in a cross section, between the breathable sheet 5 and the surface material 1, thereby emitting a reactive gas or aqueous vapor generated from the core material 3 by way of the breathable sheet 5 after the manufacture of the core material 3. The released gas is further discharged from a large-sized area to the outside of the building panel A by way of the void α.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to construction,
It can be used as an outer wall material, roof material, ceiling material, floor material, partition material, fire door, etc., and it is free from deformation such as swelling and warping after manufacturing, and has excellent fire resistance, fire resistance, and mechanical strength. It is related to the panel for use.

[0002]

2. Description of the Related Art In general, a large number of building panels in which a core material made of a phenol resin foam (phenol foam) is sandwiched between a thin plate-shaped surface material and a back surface material have been invented, devised and put on the market.

[0003]

However, in the building panel using phenol foam as the core material as described above, the self-adhesiveness of the phenol foam is generally weak and the surface material, the back surface material and the core material are not easily bonded to each other. It was inferior in adhesiveness and easily peeled off. In general, when the synthetic resin foam is used as the core material, the mechanical strength of the building panel itself is inferior, and due to the aging of the synthetic resin foam, unevenness or warpage occurs on the building panel surface. In some cases, such problems may occur. Furthermore, when the core material is formed, a reaction gas is generated and remains in the core material,
Condensed water at the time of reaction is kept at about several tens percent of the weight in phenol foam, and there is no escape route due to moisture vaporization due to changes in the outside temperature, etc. during the curing period of the product or after construction of construction panels. For this reason, the residual between the surface material or the back surface material of the building panel and the core material causes gas swelling or warpage on the back surface material or the back surface material of the building panel. In some cases, there was a problem that adversely affected.

[0004]

In order to eliminate such drawbacks, the present invention provides a construction panel in which a core material made of synthetic resin foam is sandwiched between a surface material and a back material, and at least the surface material is Since a long breathable sheet with concave and convex ribs formed on the back via an adhesive is provided,
The mechanical strength of the building panel itself is improved, and the adhesive strength with the core material is also improved, and the reaction gas and water vapor in the core material are released to the outside of the building panel from the voids formed by the uneven ribs of the breathable sheet. However, the present invention proposes a building panel that does not adversely affect the manufactured building panel such as warpage or blistering.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a building panel A according to the present invention will be described in detail below with reference to the drawings. That is,
The building panel A is a cross-sectional view of FIG. 1A and FIG.
As shown in FIG. 1 (b), which is an enlarged view of a portion (a), a core material 3 made of a synthetic resin foam whose main material is, for example, a phenol resin is sandwiched between a front surface material 1 and a rear surface material 2. The building panel A, at least the surface material 1
The corrugated breathable sheet 5 is arranged on the back surface side (the surface on the side of the core material 3) of which the adhesive 4 is interposed.

The surface material 1 and the back surface material 2 are thin metal plates such as iron, aluminum, copper, stainless steel, titanium and aluminum.
Zinc alloy plated steel plate, Galvalume steel plate, Enameled steel plate, Clad steel plate, Laminated steel plate (PVC steel plate, etc.), Sandwich steel plate (Vibration suppression steel plate, etc.), Vinyl chloride resin, Polycarbonate resin, etc. (Of course, color plates coated with these in various colors. Roll molding, press molding,
Various shapes such as extrusion molding, inorganic materials such as extrusion molding, press molding, autoclave aging, etc., and 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., laminated with one or more kinds, or composed of waterproof and flame-retardant sheet-like material Is.

The core material 3 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 formed by mixing an undiluted solution, a curing agent, and a foaming agent, discharging the mixture on the back surface side of the surface material 1 or the back surface material 2, and heating to react, foam, and cure. Further, in the core material 3, as various flame-retardant materials, lightweight aggregates (perlite particles, glass beads, gypsum slag, talc stones, silas balloons, aluminum hydroxide, etc.), fibrous materials (glass wool, rock wool, carbon fiber, Graphite, etc.) can be mixed to improve fire resistance and fire resistance.

Further, examples of the adhesive 4 include elastomer type epoxy resin, emulsion type such as isocyanate such as methylene diisocyanate (abbreviation MDI), hot melt type, and its modified isocyanate such as urethane modified or buret modified isocyanate. One type of isocyanurate-modified isocyanate or the like is used. For example, as shown in FIG.
Is to be applied.

The breathable sheet 5 is made of a sheet material as shown in FIG. 2, for example, and has breathability. Further, the breathable sheet 5 improves the mechanical strength of the building panel A itself and also improves the adhesive strength between the core material 3 and the surface material 1.

Further, at least the breathable sheet 5 is formed with a concavo-convex rib 6 having a concave portion 6a and a convex portion 6b continuously. The concavo-convex ribs 6 are portions that improve the mechanical strength of the surface material 1 and are attached to the air-permeable sheet 5 described later with the adhesive 4.

Further, in the breathable sheet 5, a gap α having a substantially triangular cross section is formed between the breathable sheet 5 and the surface material 1 by the uneven ribs 6.

As shown in an enlarged view in FIG. 1 (b), the void α is a portion where the reaction gas or water vapor generated from the core material 3 after the core material 3 is manufactured is released through the breathable sheet 5. In addition, the released gas is released to the outside from the ostium of the building panel A through the void α so that the manufactured building panel A is not warped or swelled. Is.

Any material can be used as the material for the breathable sheet 5 as long as it is a breathable member, and the core material 3 is affected by the residual acid component of the curing agent and the foaming agent used for the core material 3 after the manufacture of the core material 3.
Excess gas components (chlorine, carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen) that have undergone a chemical reaction in the interior, or gas such as condensed water at the time of the reaction, through the air permeable sheet 5 It can be released from the part to the outside. Therefore, the front and back surfaces of the manufactured building panel A are free from deformation such as swelling and warping due to internal gas, and are excellent in strength and fire resistance.

As the material of the breathable sheet 5, for example, cotton, hemp, wool, silk and the like (vegetable fiber, animal fiber, synthetic resin fiber, etc.) are woven.

As an example of the overall shape of the building panel A, as shown in FIG. 3, a front surface member 1 and a back surface member 2 made of a long thin metal plate and a male type connection formed at one end in the width direction. It is formed from the portion 7, the female connecting portion 8 formed at the other end, and the decorative surface 9, and the uneven ribs 6 are provided along the longitudinal direction of the building panel A. In addition, in the figure, in particular, the building board A is further improved in fire resistance and fire resistance by interposing the inorganic board 10 and the inorganic packing material 11 in the joint portion generated by the connection of the building panels A to each other. is there.

[0016]

[Other Embodiments] The embodiment described above is one embodiment of the building panel A according to the present invention, and a building panel A as shown in FIGS. That is, in FIGS. 4 (a) to 4 (c), FIG. 4 (a) shows building panels A, (b), and (c) in which uneven ribs 6 are formed on the breathable sheet 5 formed on the backing material 2. Back of surface material 1, back surface material 2
3 is a building panel A in which an adhesive 4 is formed on the entire back surface of the above to form a breathable sheet 5.

5 (a) to 5 (e) are partially enlarged cross-sectional views showing another embodiment of the uneven ribs 6 of the breathable sheet 5, such as arcuate shape, triangular shape, and square shape. Is.

6 to 9 are sectional views showing examples of the overall shape of the building panel A, and FIGS. 6 (a) to 6 (c).
FIGS. 8A to 8C show examples of metal-based siding using a thin metal plate as the surface material 1 and aluminum vapor-deposited paper as the back surface material 2. Also, FIG.
(E) is a large-sized metal panel using a thin metal plate as the front surface material 1 and the back surface material 2, and is an example of the building panel A that passes the fireproof 1-hour structural test.

Further, FIG. 10 shows the surface material 1 having irregularities 9a to improve the design. Further, in FIGS. 9 and 10, reference numeral 12 is a flexible packing material. Note that FIG. 1A, FIG. 3, FIG. 4A, and FIG.
0, the adhesive 4 is omitted, and in FIGS. 6 to 10, the adhesive 4 and the breathable sheet 5 are omitted.

[0020]

As described above, according to the building panel of the present invention, the adhesive strength between the surface material and the core material is significantly improved, and the surface material and the core material are not separated after manufacturing.
The reaction gas and water vapor in the core material can be released to the outside of the building panel from the voids formed by the surface material and the rugged ribs of the breathable sheet, and the warp and swelling of the manufactured building panel can be prevented. There are features and effects such as.

[Brief description of the drawings]

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

FIG. 2 is an explanatory view showing an example of a breathable sheet used in the building panel according to the present invention.

FIG. 3 is an explanatory diagram showing an example of the overall shape of a building panel according to the present invention.

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

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

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

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

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

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

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

[Explanation of symbols]

 α Void A Construction panel 1 Surface material 2 Backside material 3 Core material 4 Adhesive 5 Breathable sheet 6 Uneven rib 6a Recessed portion 6b Convex portion 7 Male connecting portion 8 Female connecting portion 9 Decorative surface 9a Unevenness 10 Inorganic board 11 Inorganic packing material 12 Packing material

Claims (1)

[Claims] 1. A construction panel in which a core material made of a synthetic resin foam is sandwiched between a surface material and a back surface material, and a long ventilation with at least a concave and convex rib formed on the back surface of the surface material via an adhesive. A construction panel characterized by having a heat-resistant sheet.