JPH10219972A - Building panel and composite board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a light building panel excellent in heat-insulation, fire- resistance, water-resistance, and workability, by forming a water-containing inorganic compound layer and a polymer cement layer on a base board made of an organic foamed body. SOLUTION: A 5-20mm thick water-containing inorganic compound layer is formed on a 5mm or thicker base board made of an organic foamed body and a 1-5mm thick polymer cement layer is formed thereon to form an architectural panel. This water-containing inorganic compound is obtained by mixing 10-300 pts.wt. of an inorganic compound containing water of crystallization against 100 pts.wt. of gypsum. Or a mixture in which 50-500 pts.wt. of inorganic compound particles emitting a noncombustible gas at 100-1000 deg.C is mixed with 100 pts.wt. of ettringite can be used. The polymer cement is made by mixing 1-20 pts.wt. of an organic binder with 100 pts.wt. of a mixture of inorganic cement and aggregate. In this way, a light building panel excellent in fire- resistance, water-resistance, and workability can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a building panel and a composite board, and more particularly to a building panel and a composite board excellent in waterproofness, heat insulation and durability.

[0002]

2. Description of the Related Art In order to improve the livability and the appearance of a building, exterior and inner walls of many buildings and the like are frequently used with architectural panels and composite boards for heat insulation, waterproofing, and decoration. BACKGROUND ART Conventionally, a structure in which an outer wall panel formed by laminating a refractory material made of, for example, styrofoam and cement on a plywood substrate is bonded to an outer wall portion of a building, and mortar is applied thereon is often used. ing.

When such a building panel is used, for example, as an outer wall of a wooden building, it is necessary to satisfy various standards specified in the Building Standard Law. For example, JI
A predetermined value must be satisfied in a fire protection test specified in SA 1301 and JIS A 1304 and a waterproof test specified in JIS A 1404. However, there is a problem in that the mortar coating structure does not have sufficient fire protection performance, and it is not possible to reduce the weight and space with the extension of the construction period and the cost. . For this reason, as an exterior wall panel with excellent fire protection performance and excellent workability, an exterior wall panel of a building in which a refractory material mainly composed of ettringite is laminated on a substrate (JP-A-8-42100), a rigid substrate A heat insulating panel of a wooden building in which a fireproof coating layer containing ettringite as a main component is provided on the outer surface of a plate-shaped heat insulating base material having a core layer made of organic foam and a heat insulating layer made of an organic foam.
-42099) and the like.

[0004]

However, there is a problem that the outer wall panel having a fire-resistant coating layer containing ettringite as a main component cannot sufficiently reduce the weight and the construction cost. That is, in the outer wall panels disclosed in JP-A-8-42099 and JP-A-8-42100, in addition to various types of plywood, various types of wood such as medium fiberboard (MDF) and particle board (PB) are used. A rigid board such as a fiber board or various resin boards is required, and since a fireproof coating layer is provided on the rigid board, it is difficult to reduce the weight of the rigid board to less than the weight thereof. There is a problem that it is difficult to easily cut the substrate according to the shape of the building material and the construction cost is increased.

A refractory coating layer containing ettringite which is a hydrated sulfate of calcium and aluminum containing a large amount of water of crystallization and having large voids between crystal skeletons has excellent fire resistance. However, there has been a problem that its water resistance has not been considered in the past.

SUMMARY OF THE INVENTION The present invention has been made to address such problems, and provides an architectural panel and a composite board which can achieve extremely excellent weight reduction, have low construction cost, and have excellent water resistance. The purpose is to do.

[0007]

A building panel according to the present invention is a building panel attached to a building frame.
It is characterized by having a substrate made of an organic foam, a hydrated inorganic compound layer formed on the substrate, and a polymer cement layer formed on the inorganic compound layer.

The first hydrous inorganic compound is gypsum 1
It is characterized by comprising at least 10 to 300 parts by weight of an inorganic compound containing water of crystallization with respect to 00 parts by weight.

Further, the second hydrous inorganic compound is characterized in that at least 50 to 500 parts by weight of an inorganic compound powder which releases a nonflammable gas at 100 to 1000 ° C. is mixed with 100 parts by weight of ettringite. And

[0010] Further, the polymer cement is characterized in that 1 to 20 parts by weight of an organic binder is blended with 100 parts by weight of a mixture of inorganic cement and aggregate.

The construction panel of the present invention has a thickness of a substrate made of an organic foam of 5 mm or more, a thickness of a hydrated inorganic compound layer of 5 to 20 mm, and a thickness of a polymer cement layer of 1 to 5 mm.
It is characterized by being.

[0012] The composite board of the present invention is characterized in that at least one layer composed of a hydrated inorganic compound layer and a polymer cement layer is laminated on at least one main surface of an organic foam board.

The present invention requires a rigid substrate by combining an aqueous inorganic compound layer and a polymer cement layer, even for an organic foam, which has hardly been considered for use as a fire-resistant material or a fire-resistant material. It is based on the finding that it is possible to obtain a building panel or a composite board which maintains strength even without it, and is excellent in fire resistance, water resistance and durability.

That is, when a water-containing inorganic compound layer having excellent fire resistance is formed on an organic foam substrate, and a polymer cement layer having excellent water resistance is further formed thereon, the fire resistance and water resistance can be improved. The layers will share the functions,
Even an organic foam can sufficiently satisfy various standards defined in the Building Standards Law. In addition, an inorganic compound containing water of crystallization 10 to 100 parts by weight of gypsum
Since the hydrous inorganic compound layer contains at least 300 parts by weight, the hydrous inorganic compound layer firmly adheres to the organic foam due to the gypsum anchor coating effect. As a result, excellent fire resistance is exhibited together with the action of the inorganic compound containing water of crystallization. Further, since the hydrated inorganic compound layer contains at least 50 to 500 parts by weight of an inorganic compound powder that releases a nonflammable gas at 100 to 1000 ° C. with respect to 100 parts by weight of ettringite, it is a thinner hydrated inorganic compound layer. Also exhibits excellent fire resistance. Furthermore, since the polymer cement layer is obtained by mixing 1 to 20 parts by weight of the organic binder with respect to 100 parts by weight of the mixture of the inorganic cement and the aggregate, the water-containing inorganic compound layer having relatively poor water resistance can be replaced with an excellent water-resistant inorganic compound layer. The protective polymer cement layer provides protection, and excellent water resistance can be obtained. The building panel of the present invention has an organic foam substrate having a thickness of at least 5 mm, a thickness of the hydrated inorganic compound layer of 5 to 20 mm, and a thickness of the polymer cement layer of 1 to 5 mm. In addition to the lightweight performance and high heat insulation of the body, the fire resistance and water resistance will be more excellent.

The composite board of the present invention is lightweight and has excellent fire resistance and water resistance by laminating a water-containing inorganic compound layer and / or a polymer cement layer on an organic foam board. It can be used for many purposes such as construction, decoration, etc.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION The organic foam according to the present invention is formed by adding a foaming agent to an organic resin and molding using a gas generated during heating, or using a gas generated when a reactive resin reacts. Or by a foam molding method. Types of resin such as thermoplastic resin and thermosetting resin, foaming means such as decomposition type foaming agent and evaporative type foaming agent, molding methods such as injection foaming method and extrusion foaming method, low foaming with foaming ratio of 3 to 4 times or less The expansion ratio, such as high foaming of 10 to 70 times, and the cell structure, such as closed or open cells, can be variously selected depending on the type and use of the building panel or composite board. For example,
In particular, when water resistance is required, such as for outer walls, a closed cell structure is preferred. In the present invention, foamed polyolefins such as foamed polystyrene, foamed urethane, foamed polyethylene and foamed polypropylene are preferable, and foamed polystyrene having a foaming ratio of about 10 to 50 times is particularly preferable in terms of strength and weight reduction as building panels and composite boards. It is suitable for achieving.
Also, when strength is particularly required, the expansion ratio is 15 to 30.
Double is preferred.

The water-containing inorganic compound layer according to the present invention can be formed mainly of a water-containing inorganic compound capable of imparting fire resistance to an organic foam. Here, the hydrous inorganic compound is an inorganic compound containing water of crystallization at a fixed bonding ratio in a crystal, or an inorganic compound containing so-called fluorite water which is located in a space within a crystal lattice and continuously released by heating. Refers to a compound. Examples of the water-containing inorganic compound include gypsum, metal hydroxides such as aluminum hydroxide and magnesium hydroxide, ettringite, hydrated silicates, bentonite, sepiolite, and sodium bicarbonate. These can be used alone or as a mixture.

The first hydrous inorganic compound according to the present invention preferably contains gypsum as an essential component. This is because, while having fire resistance, on the surface of the organic foam, strong adhesiveness can be obtained due to anchor coat properties when cured. The gypsum according to the present invention refers to a hydrated salt or an anhydrous salt of calcium sulfate, and includes a hemihydrate, an anhydrate and the like. A hemihydrate that becomes a dihydrate and hardens when an appropriate amount of water is added is suitable for the present invention.

The first hydrous inorganic compound according to the present invention preferably contains at least another inorganic compound containing water of crystallization in the gypsum. As other inorganic compounds that are preferably used in combination with gypsum, aluminum hydroxide and / or magnesium hydroxide are particularly preferable. By these combinations, the fire resistance performance of the building panel or the composite board can be further improved. For example, a case in which gypsum and aluminum hydroxide are blended and cured will be described as an example. The reaction shown in Chemical Formula 1 occurs when gypsum hydrate and aluminum hydroxide are heated.

[0020]

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First, gypsum causes an endothermic reaction represented by the formula (1), heat conduction to the organic foam is suppressed, and aluminum hydroxide causes an endothermic reaction represented by the formula (2). As a result, the ignition of the organic foam can be suppressed for a predetermined time, and the fire resistance performance is improved.

The mixing ratio of the gypsum to the other inorganic compound containing water of crystallization is preferably 10 to 300 parts by weight of the inorganic compound containing water of crystallization with respect to 100 parts by weight of gypsum. It is up to 300 parts by weight. Inorganic compound containing water of crystallization per 100 parts by weight of gypsum 10
Up to 300 parts by weight prevents the transfer of heat to the organic foam due to the endothermic reaction of gypsum at 100 ° C or lower. The temperature rise of the organic foam is suppressed by the heat of vaporization. Further, due to the endothermic reaction of aluminum hydroxide or the like, further increase in temperature of the organic foam can be suppressed, and the fire resistance time can be extended, so that fire resistance performance is improved.

It is preferable that the second hydrous inorganic compound according to the present invention contains at least an inorganic compound powder which releases a nonflammable gas at 100 to 1000 ° C. in ettringite. Ettringite (3CaO.Al ₂ O ₃ .3Ca
SO ₄ · 32H ₂ O), as shown in Formula 2, Auin _{(3CaO · 3Al 2 O 3 ·} CaSO 4), several microns produced by hydration of free lime (CaO) and free gypsum (CaSO ₄₎ A large amount of water of crystallization is contained in the molecule.

[0024]

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When this ettringite is heated, water of crystallization starts to be released from the crystal skeleton at around 60 ° C., and a large amount of the water of crystallization is released as incombustible steam gas.
Even when the thickness of the water-containing inorganic compound layer is small, it is excellent in fire resistance performance.
When ettringite is kneaded with water, it becomes enamel and expands and hardens, so that it acts in the same manner as the above-mentioned gypsum. Ettringite may be either naturally occurring or artificially synthesized.

The inorganic compound particles that release a nonflammable gas at 100 to 1000 ° C. refer to inorganic compounds that release a nonflammable gas such as water vapor gas or carbon dioxide gas in a temperature range of 100 to 1000 ° C.
In particular, an inorganic compound capable of releasing at least 10% of its weight as a nonflammable gas is preferable. Specifically, 200 ° C ~
Aluminum hydroxide that produces steam gas at 250 ° C, about
Calcium carbonate that produces carbon dioxide at 800 ℃, about 900 ℃
For example, bentonite and sepiolite that generate steam gas at about 150 ° C., baking soda that generates steam gas and carbon dioxide gas at about 150 ° C., and magnesium hydroxide that generates steam gas at about 400 ° C. These can be used alone or as a mixture.

The mixing ratio of the ettringite and the inorganic compound powder which releases a nonflammable gas at 100 to 1000 ° C. is 100 parts by weight of the ettringite and 50 parts of the inorganic compound powder.
It is preferable to add at least 500 parts by weight. A more preferred range is 50 to 400 parts by weight. Within this range, a water-containing inorganic compound layer having more excellent curing performance and fire resistance can be formed.

The first and second hydrous inorganic compounds according to the present invention are stable and do not decompose even at a high temperature range.
Other inorganic compounds having an effect of blocking radiant heat, for example, titanium oxide powder and zinc oxide powder can be appropriately contained to such an extent that the fire resistance is not impaired. Further, other materials can be blended to such an extent that the fire resistance is not impaired. For example, hydraulic cement for strength improvement and cost reduction, and lightweight aggregate such as obsidian perlite, perlite perlite, calcined vermiculite, shirasu balloon, river sand, quartz sand, crushed gravel, and calcium carbonate carbonate to promote weight reduction Water glass to improve the strength, fibers such as alkali-resistant glass fibers and ceramic fibers to prevent cracks, and one or more water retention agents and viscosity modifiers to improve workability. Two or more kinds can be contained.

The polymer cement according to the present invention is obtained by mixing an organic binder with a mixture of inorganic cement and aggregate. Inorganic cements include hydraulic cements such as Portland cement, early-strength Portland cement, white Portland cement, alumina cement, calcined gypsum, and latent hydraulic cements such as blast furnace cement, high sulfate slag cement, lime slag cement, and keince cement. And mixed cements such as silica cement, fly ash cement, lime silica cement, alkali silicate, oxychloride cement, and phosphate cement. Among these, hydraulic cements and latent hydraulic cements are preferable in combination with aggregates and organic binders to improve the water resistance.

Examples of the aggregate to be mixed with the inorganic cement include river sand, silica sand, crushed gravel, calcium carbonate, obsidian perlite, perlite perlite, calcined vermiculite, and shirasu balloon. The mixing ratio of the inorganic cement and the aggregate is preferably 50 to 500 parts by weight of the aggregate with respect to 100 parts by weight of the inorganic cement.
When it is within this range, the hydration reaction of the inorganic cement is maintained,
Strength can be maintained.

The organic binder according to the present invention can be used as long as it is an organic polymer material that can be taken into the inorganic cement together with the hydration reaction of the inorganic cement and impart water resistance and durability. . For example,
Acrylic emulsion, polyvinyl acetate emulsion,
Examples thereof include polyvinyl acetate / veova copolymer emulsion.

The mixing ratio of the organic binder is preferably 1 to 20 parts by weight, more preferably 2 to 15 parts by weight, based on 100 parts by weight of the mixture of the inorganic cement and the aggregate. Within this range, water resistance and durability that can be used outdoors can be obtained.

The construction panel of the present invention has a structure in which the thickness of the substrate made of an organic foam is 5 mm or more, the thickness of the hydrated inorganic compound layer is 5 to 20 mm, and the thickness of the polymer cement layer is 1 to 5 mm.
It is characterized by being. When the thickness of the organic foam substrate is 5 mm or more, good heat insulation performance as a building panel can be obtained. The thickness can be adjusted to 5 mm or more and a predetermined substrate thickness required for a building panel, for example, 100 mm or less. The surface shape of the substrate made of the organic foam is
It can be of any shape depending on the application of the building panel. For example, it may be formed in a flat shape or a pattern may be formed in a relief shape. When the thickness of the water-containing inorganic compound layer is from 5 to 20 mm, the fire protection performance is excellent. For example, when used as an outer wall of a wooden building, it can satisfy various standards specified in the Building Standards Law. When the thickness of the polymer cement layer is 1 to 5 mm, waterproofness and durability can be maintained. The architectural panel of the present invention comprises:
With such a combination, even if an organic foam is used as a substrate, it has sufficient strength and durability, and furthermore has fireproof and waterproof properties.

The formation of the water-containing inorganic compound layer on the substrate made of the organic foam can be obtained by forming the first or second water-containing inorganic compound into a paint, applying the paint to the surface of the organic foam, and drying. Examples of the coating method include brush coating, spray coating, flow coating, dip coating, electrostatic coating, and roller coating. As a coating method suitable for the present invention, there can be mentioned a spray coating in which a water-containing inorganic compound layer having a uniform and strong adhesive force is obtained according to the surface shape.
Of the spray coatings, airless spray coating, which can easily maintain a vacuum state between the substrate and the water-containing inorganic compound layer during coating, is preferable. When the water-containing inorganic compound is formed into a coating material, it is preferable to use a coating material containing at least water capable of utilizing a curing reaction due to hydration of gypsum or the like. Particularly in the case of gypsum, since the hydrate generated by the curing reaction has needle-like crystals, it pierces the surface of the organic foam in a needle-like manner and exerts an anchor coating function, and a strong water-containing inorganic compound on the surface of the organic foam. A layer is formed.

The formation of the polymer cement layer on the hydrated inorganic compound layer can be performed in the same manner as the formation of the hydrated inorganic compound layer. In the building panel according to the present invention, a hydrated inorganic compound layer and a polymer cement layer may be formed on both surfaces of the organic foam.

In the composite board of the present invention, a hydrated inorganic compound layer and / or a polymer cement layer are laminated on one side or both sides of the above-mentioned plate made of an organic foam. The same material as described above can be used for the organic foam, the hydrated inorganic compound layer and the polymer cement layer. For example, when obtaining a composite board not requiring water resistance, the polymer cement layer can be omitted, and when fire resistance is not required, the water-containing inorganic compound layer can be omitted.

[0037]

【Example】

Examples 1 to 8, Comparative Examples 1 to 3 Styrofoam as an organic foam (independent foam, foaming rate)
20 to 25%) A plate is prepared, and a water-containing inorganic compound and a polymer cement coating solution prepared by the following method are sequentially applied to one surface of the substrate by a spray coating method, and a relative humidity of 80% or more and a temperature of 40 to 60 are applied. C. to obtain a building panel having the thickness shown in Table 1. 1) Preparation of a coating solution of a water-containing inorganic compound: A coating solution was obtained by adding water to a gypsum (hemihydrate) powder and an aluminum hydroxide powder at a ratio shown in Table 1 and kneading them. In addition, 5 parts by weight of the alkali-resistant glass fiber was mixed with the aqueous inorganic compound coating liquids of Examples 1 to 7. Further, Taika Aloc (trade name, manufactured by Stylite Industry Co., Ltd.) was prepared as a coating solution of a water-containing inorganic compound containing ettringite. 2) Preparation of polymer cement coating solution: A coating solution was obtained by adding water to Portland cement powder, aggregate (sand), and acrylic emulsion (20% by weight) at the ratio shown in Table 1 and kneading them.

The obtained building panel was evaluated by the following method. Table 1 shows the results. B) Fire prevention test: A test specified by the Building Standards Act was performed by heating according to JIS A1301. B) Waterproof test: The amount of water per hour was measured by a water permeability test according to JIS A1404. Permeability 5mg
The following were judged as good and those exceeding 5 mg were judged as bad.

[0039]

[Table 1]

As shown in Table 1, the building panel of the present invention is superior in fire resistance and water resistance as compared with the comparative example.
Furthermore, weight reduction was achieved because a substrate such as plywood was not used. In Comparative Example 3, since the thickness of the Styrofoam plate was less than 5 mm, the bending strength in a three-point bending test at a load speed of 5 mm / min and a span of 90 mm was 10 kgf / c.
m, and the insulation performance did not meet the standards required for building panels.

The architectural panel obtained in Example 1 was used as a composite board for an exterior material, a display material, an interior material, a decorative material, a partition plate, and the like. Was also excellent. Further, in Example 1, when a styrofoam plate was obtained without forming a polymer cement layer, it had sufficient fire resistance in interior material applications that did not require water resistance, and also had a water-containing inorganic compound layer only on one side. In this case, the thickness of the composite board can be reduced, so that the interior space can be widened as an interior building material.

[0042]

Since the building panel of the present invention has a water-containing inorganic compound layer and a polymer cement layer on a substrate made of an organic foam, it is excellent in heat insulation, fire resistance and water resistance. In addition, since it is made of an organic foam as a base material, it is lightweight, easy to cut and the like, and is excellent in workability.

Further, the water-containing inorganic compound is used in an amount of 10 to 300 parts by weight with respect to 100 parts by weight of gypsum or 100 to 1000 parts by weight with respect to 100 parts by weight of ettringite.
Inorganic compound powder that emits nonflammable gas at ℃ 50 to 500
At least 1 part by weight, and / or 1 to 20 parts by weight of an organic binder with respect to 100 parts by weight of a mixture of an inorganic cement and an aggregate with polymer cement. An architectural panel with excellent adhesive strength is obtained.

Further, since the thickness of the substrate is 5 mm or more, the thickness of the water-containing inorganic compound layer is 5 to 20 mm, and the thickness of the polymer cement layer is 1 to 5 mm, better heat insulation, fire resistance and water resistance are obtained. Is obtained.

Since the composite board of the present invention is formed by laminating at least one layer composed of a hydrated inorganic compound layer and a polymer cement layer on at least one main surface of an organic foam board, it is lightweight and has excellent heat insulation and fire resistance. Has water resistance and water resistance.

Claims (6)

[Claims] 1. A building panel attached to a building frame, comprising: a substrate made of an organic foam; a water-containing inorganic compound layer formed on the substrate; and a polymer cement formed on the water-containing inorganic compound layer. An architectural panel having a layer. 2. The building panel according to claim 1, wherein the water-containing inorganic compound comprises at least 10 to 300 parts by weight of an inorganic compound containing crystallization water with respect to 100 parts by weight of gypsum. 3. The hydrated inorganic compound is characterized by comprising at least 50 to 500 parts by weight of an inorganic compound powder that releases a nonflammable gas at 100 to 1000 ° C. per 100 parts by weight of ettringite. The architectural panel according to claim 1. 4. The polymer cement according to claim 1, wherein 1 to 20 parts by weight of an organic binder is mixed with 100 parts by weight of a mixture of the inorganic cement and the aggregate. The architectural panel according to claim 1. 5. The method according to claim 1, wherein the thickness of the organic foam substrate is 5 or less.
5 mm or more, wherein the thickness of the hydrous inorganic compound layer is 5 to 20 mm, and the thickness of the polymer cement layer is 1 to 5 mm. panel. 6. A composite plate comprising at least one main surface of an organic foamed plate and at least one layer composed of a hydrated inorganic compound layer and a polymer cement layer laminated thereon.