JPH0939130A - Honeycomb composite panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To be lightweight and to have high strength, fire resistance, and heat resistance by forming an inorganic layer at least on one side of a honeycomb structure in which a foamed phenol resin is packed and cured. SOLUTION: This honeycomb composite panel is composed of a molded article made from a foamed phenol resin 1 and a honeycomb structure 2 and an inorganic layer 3 containing a fiber reinforcing material formed on one side of the molded structure. The foamed phenol resin is made from an expandable novolac or resol type phenol resin. The inorganic layer 3 is made from a hydraulic setting material such as gypsum and cement. The honeycomb composite panel is obtained by a process in which slurry prepared by a method in which water is added to the inorganic material, and the mixture is adjusted of the viscosity appropriately, is applied at least on one surface of the honeycomb structure reinforced in advance by packing the foamed phenol resin, and dried.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel material useful as a building material such as a wall material or a floor material.

[0002]

Many of the interior materials to date have low fire resistance and heat resistance because the heat insulating layer is formed of a combustible resin foam. An object of the present invention is to provide a panel that is lightweight, has high strength, and has high fire resistance and heat resistance.

[0003]

Means for Solving the Problems As a result of intensive studies to achieve the above-mentioned object, the present inventors have found that at least one surface of a molded body obtained by filling and curing a honeycomb structure with a phenol resin foam. By forming an inorganic layer on
It was found that a panel material that is lightweight, has high strength, and is excellent in fire resistance and heat resistance can be obtained, and has reached the present invention.

That is, the honeycomb composite panel of the present invention has an inorganic layer such as gypsum on at least one surface of a molded body composed of a honeycomb structure filled with a phenol resin foam.

An example of the present invention is shown in FIG. The honeycomb composite panel shown in FIG. 1 is composed of a molded body composed of a phenol resin foam 1 and a honeycomb structure 2, and an inorganic layer 3 containing a fiber reinforcing material formed on one surface thereof.

The material of the honeycomb structure constituting the heat insulating material is kraft paper, phenol resin impregnated paper, non-combustible paper, F
RP, aluminum, aramid paper, etc. can be used. Further, the cells of the honeycomb structure may have a honeycomb shape, a cylindrical shape, or a corrugated plate shape.

The thickness of the molded body can be changed by using a honeycomb structure having a different thickness depending on the application.
It is usually 5 to 100 mm, and it is often used at 10 to 50 mm. The density of the phenol resin-filled honeycomb structure is 0.05 to 1.0 g / cm ³ , preferably 0.1 to
It is 0.5 g / cm ³ .

The inorganic layer is made of an inorganic curable substance, and examples of the inorganic curable substance include lime such as slaked lime and dolomite plaster, and hydraulic substance. Examples of hydraulic substances include gypsum and cement (self-hardening cement such as Portland cement and alumina cement, lime slag cement, hydraulic cement such as blast furnace cement).

In the present honeycomb composite panel, water is added to an inorganic composition to prepare a slurry-like substance prepared to have an appropriate viscosity,
It can be obtained by coating and drying on at least one surface of a honeycomb structure that has been filled and cured with a phenol foam in advance.

For example, as shown in FIG. 2, the surface of a molded body is processed into a concave shape having a diameter of 5 to 10 mm, and a slurry-like inorganic curable substance is applied thereto and dried to form an inorganic layer. It can strengthen the bond between the body and the inorganic layer.

The honeycomb composite panel according to the present invention is useful for building interior and exterior materials such as wall materials.

[0012]

The present invention will be described in detail below with reference to examples, but the present invention is not limited to these examples. [Example 1] Water was added to gypsum and mixed to form a slurry. On the other hand, a novolac-type phenol resin was foam-filled into a cylindrical kraft paper honeycomb having a diameter of 14 mm and a thickness of 20 mm to obtain a molded body having a density of 0.1 g / cm ³ and a thickness of 20 mm. One side of this molded body was subjected to concave processing, the above slurry was applied to a thickness of 10 mm and dried for 24 hours to obtain a panel having a thickness of 25 mm (FIG. 2). [Comparative Example 1] A cylindrical kraft paper honeycomb having a diameter of 14 mm and a thickness of 25 mm was foam-filled with a novolac-type phenol resin to obtain a molded body having a density of 0.1 g / cm ³ and a thickness of 25 mm. A panel of Comparative Example was prepared without forming an inorganic layer on this molded body.

The compression strength and fire resistance of the panels of Example 1 and Comparative Example 1 are compared and shown in Table 1 and FIG.

[0014]

[Table 1] Compressive strength * The fire resistance test was performed according to JIS K1304, and the time until the back surface temperature of the test piece reaches 260 ° C. is shown in FIG.

The panel shown in Example 1 has higher compressive strength and improved fire resistance than the panel of Comparative Example 1.
In particular, the fire resistance has a performance comparable to that of heating for 1 hour.

[0016]

EFFECTS OF THE INVENTION The honeycomb composite panel according to the present invention comprises a honeycomb structure filled with and cured with a phenol resin foam and an inorganic layer, and has excellent heat resistance and fire resistance and high strength.

[Brief description of drawings]

FIG. 1 is an example of a perspective sectional view of a honeycomb composite panel.

[Description of sign]

 1 phenol foam 2 honeycomb structure 3 inorganic layer

FIG. 2 is a cross-sectional view of a honeycomb composite panel.

FIG. 3 is a graph showing a temperature rising rate of a surface on the side opposite to the heating surface in a fire resistance test.

[Description of sign]

 1 Temperature of Heating Surface 2 Temperature of Backside of Panel of Example 1 3 Temperature of Backside of Panel of Comparative Example 1

 ─────────────────────────────────────────────────── --- Continuation of the front page (72) Inventor Takenari Nakayama 700 Sukudaiji-cho, Takasaki-shi, Gunma Gunei Chemical Industry Co., Ltd.

Claims (3)

[Claims] 1. A honeycomb composite panel in which an inorganic layer is formed on at least one surface of a honeycomb structure filled and cured with a phenol resin foam. 2. The honeycomb composite panel according to claim 1, wherein the phenol resin foam comprises a novolac type phenol resin or a resol type phenol resin having foamability. 3. The honeycomb composite panel according to claim 1, wherein the inorganic layer is made of a hydraulic material such as gypsum and cement.