JPH10231610A - Noncombustible siding and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain noncombustible siding which is light-weight and heat- insulative, by scattering inorganic pigment on the inside of a mold formed to have a tile-shaped pattern and pouring noncombustible phenol resin-foamed body compound therein and integrally molding the tile-shaped pattern and the backing base material of tiles with the noncombustible phenol resin-foamed body. SOLUTION: Inorganic pigment is scattered on the inside face of a mold formed in advance to have a tile-shaped pattern. Resol type phenol resin of 10 pts.wt., a foaming agent of 0.3-5.0 pts.wt., and a curing agent of 2-5 pts.wt. are mixed with ceramic fine hollow particles of 50-250 pts.wt., having 600kgf/cm<2> or more compressive strength, 0.3-0.5g/cm<3> bulk density, and 1500 deg.C or higher melting point, glass powder of 5-50 pts.wt., aluminum hydroxide of 10-100 pts.wt., and inorganic pigment, as chief constituting materials. The noncombustible phenol resin-foamed body compound mixed with water is poured in the mold and pressurized to form noncombustible siding in which the tile-shaped pattern 1 and the backing base material 2 of tiles are integrally molded.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-combustible siding made of a non-combustible phenol resin foam which is lightweight and has excellent heat insulating properties and is used for buildings and exteriors, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, there are a concrete panel and a lightweight concrete panel in which a tile used as an exterior material of a building is adhered to one side. Concrete panels with tiles stuck on one side, tile sheets in which a number of tiles are arranged and bonded to sheets are pasted on a formwork, concrete is poured on this tile sheet, and after normal temperature curing, demolding, In addition, the autoclave is cured at high temperature and pressure. However, such a concrete panel having a tile adhered to one side thereof deteriorates the quality of the tile due to the discoloration of the tile and loss of luster due to the alkali atmosphere of the autoclave curing. In addition, the panel itself is very heavy, requiring a great deal of labor for transportation and installation work.

[0003] In order to reduce the panel weight, some concrete panels use lightweight concrete panels instead of concrete panels. Lightweight concrete panels include so-called ALC, which is lightened by air bubbles, and lightened, using lightweight aggregates, and both require autoclave curing at high temperature and high pressure. Furthermore, because of the large expansion and contraction of the lightweight concrete panel during the manufacturing process, it has been difficult to attach tiles to produce a product of stable quality.
In addition, although lightweight, the weight was not very light.

There is also a method of forming a concrete panel, a lightweight concrete panel, an inorganic board, or the like, and then attaching a tile to the board with an adhesive or the like. there were.

[0005]

SUMMARY OF THE INVENTION The present invention has been made as a result of an intensive study to solve the above-mentioned problems. As a result, lightweight non-combustible phenolic resin foam as a substitute for concrete or lightweight concrete can be used as a tile and a backing substrate for the tile. The inventor found that the nonflammable siding and the manufacturing method thereof were completed.

[0006] The present invention is a nonflammable phenol resin foam made of a non-flammable phenolic resin foam which can be used for buildings, exteriors, etc., is lightweight, has excellent heat insulation properties, and has a tile-shaped pattern on one side and is integrally formed with a tile backing material. An object of the present invention is to provide a siding and a method for manufacturing the siding.

[0007]

Means for Solving the Problems A mold inner surface is prepared in advance in a tile-shaped pattern, and an inorganic pigment is sprayed on the mold inner surface formed in the tile-shaped pattern. A non-combustible phenolic resin foam composition is poured into a mold on which an inorganic pigment has been sprayed, and a non-combustible phenolic resin foam is formed by integrally molding a tile-shaped pattern and a tile backing substrate.

[0008] The non-combustible phenolic resin foam composition comprises 10 parts by weight of a resole type phenolic resin,
5.0 parts by weight, 2-5 parts by weight of curing agent, compressive strength 600k
gf / cm ² or more and bulk specific gravity of 0.3 to 0.5 g / cm ³ ,
Ceramic fine hollow particles having a melting point of 1500 ° C. or more 50 to 2
50 parts by weight, 5 to 50 parts by weight of glass powder, 10 to 100 parts by weight of aluminum hydroxide and an inorganic pigment as main constituent materials, to which water was added. This non-combustible phenolic resin foam composition is poured into a mold to produce non-combustible siding by pressure molding.

The surface finish of the tile-shaped pattern on the surface of the non-combustible siding is made by color powder by spraying the inorganic pigment in advance on the inner surface of the form, and pouring the non-combustible phenolic resin foam composition on the inorganic pigment. You can shake it. Furthermore, by adding an inorganic pigment to the non-combustible phenolic resin foam composition, various colors can be formed by the color of the tile pattern and the tile backing material and the dispersed pigment.

[0010]

The phenolic resin used in the resole type phenolic resin foam of the present invention includes phenols such as phenol, cresol, xylenol, paraalkylphenol, paraphenylphenol, resorcinol and modified products thereof, and formaldehyde, paraformaldehyde, furfural, acetaldehyde. Is a resol type produced by reacting aldehydes such as sodium hydroxide, potassium hydroxide, calcium hydroxide, hexamethylenetetramine, trimethylamine and triethylamine with an alkaline catalyst.

The blowing agent used in the production of the non-combustible phenolic resin foam of the present invention is, for example, methylene chloride, carbonate, pentane, hexane, isopropyl ether, methylene chloride, etc., based on 10 parts by weight of the resole type phenolic resin. 0.3 to 5.0 parts by weight are added. Examples of the curing agent used for the resol-type phenol resin foam include inorganic acids such as sulfuric acid and phosphoric acid, and organic acids such as benzenesulfonic acid, naphtholsulfonic acid and phenolsulfonic acid.

The fine hollow ceramic particles used in the present invention have a particularly high compressive strength as compared with conventional fine hollow foams, and are resistant to high stress and shear force generated in the process of producing a noncombustible phenolic resin foam. Can withstand. Furthermore, by casting and molding, it is possible to obtain a dense non-combustible phenol resin foam despite its light weight.

The compressive strength of the ceramic fine hollow particles or the fine hollow foam is synonymous with the water pressure resistance. The compressive strength is measured by pressing the fine hollow foam in water and applying the pressure applied to the water to the fine hollow foam. The pressure transmitted to the foam and broken by the fine hollow foam is defined as the compressive strength.

A non-combustible phenol resin foam capable of exhibiting excellent performance must be sufficiently stirred and kneaded, and is particularly important for a high-quality non-combustible phenol resin foam with a uniform product. . When the composition is sufficiently stirred and kneaded as in the present invention, the stress and shear force applied to the ceramic fine hollow particles are about 400 kgf.
/ Cm ² . None of the conventional fine hollow foams could withstand such a high pressure, and none of them could be used as such non-combustible phenolic resin foams to obtain sufficient performance. That is, most of them are destroyed.

Next, when the ceramic fine hollow particles are used in a non-combustible phenolic resin foam, an important factor is thermal conductivity. The fine hollow foam generally depends on the particle size.
It is around 1 (kcal / mhr ° C), and when half of the filled fine hollow foam is broken, the thermal conductivity drops to about 0.2 (kcal / mhr ° C). Excellent effects can only be obtained if a completely fine hollow foam which is not destroyed is used. The ceramic fine hollow particles used in the present invention have significantly higher compressive strength than conventional fine hollow foams such as shirasu balloon, glass balloon, silica balloon, fly ash balloon, etc. The fine hollow particles of the body are 100% perfectly spherical. The compressive strength of a conventional fine hollow foam is 80 to 300 kgf / cm ² .

The melting point of the hollow ceramic fine particles used in the present invention is 1500 ° C. or higher. Naturally, the fine ceramic hollow particles are caused by their material, but generally, the higher the melting point, the higher the compressive strength. Compressive strength 600k
If gf / cm ² or more, the melting point becomes 1500 ° C. or more.

As described above, the ceramic fine hollow particles used in the present invention are composed of 50-60% of silica and 40% of alumina.
, A foamed ceramic composition consisting of 1.5% to 2.5% and a compression strength of 700 kgf / cm ² , a melting point of 1600 ° C., and a bulk density of 0.3 to 0.3%. 5 g / cm ³ , thermal conductivity 0.1 (kcal
/ Mhr ° C) and consists only of completely hollow particles.
The particle diameter of the ceramic fine hollow particles is in the range of 5 to 350 μm, and is fine 5 to 75 μm, medium 75 to 15 μm.
It is mixed and used by adjusting the particle size to 0 μm and coarse 150-350 μm. The bulk specific gravity is heavy for fine particles and light for rough ones. For this reason, the range of the bulk specific gravity is 0.3-0.
It becomes 5 g / cm ² .

The foaming agent is used in an amount of 0.3 to 5.0 parts by weight and the curing agent is used in an amount of 2 to 5 parts by weight based on 10 parts by weight of the resole type phenol resin.
0 to 250 parts by weight. If the amount is less than 50 parts by weight, the fire resistance and heat insulation properties of the non-combustible phenol resin foam cannot be sufficiently exhibited, and if the amount is more than 250 parts by weight, the strength is greatly reduced. The amount of the ceramic fine hollow particles can be adjusted according to the required physical strength and specific gravity of the non-combustible phenolic resin foam.

The glass powder used in the present invention is most preferably a silicate glass in an oxide glass obtained by powdering a soda-lime glass of Na ₂ O—CaO—SiO ₂ system. A flux such as soda ash, sodium nitrate, or borate may be added to the glass powder. The particle size of the glass powder is 5-10
The range of 0 μm is preferable, and it is effective as a binder for improving the fire resistance when the non-combustible phenol resin foam is heated. The addition amount of the glass powder is 5 to 50 parts by weight based on 10 parts by weight of the resole phenol resin. If the amount is less than 5 parts by weight, the effect as a binder exhibiting fire resistance cannot be exhibited, and if the amount is more than 50 parts by weight, the strength decreases.

Aluminum hydroxide easily loses water when heated to become aluminum oxide, and is effective for improving the noncombustibility and fire resistance of the noncombustible phenolic resin foam. Moisture percentage is 0-30%
And a particle size of 100 μm or less and a purity of 99% or more are preferable. 1 to 10 parts by weight of resole type phenol resin
0 to 100 parts by weight are blended.

The inorganic pigment to be sprayed in advance on the inner surface of the mold and the inorganic pigment to be added to the non-combustible phenol resin foam composition include titanium oxide, zinc white, graphite, zinc yellow, and the like.
Barium chromate, calcium leadate, red iron oxide, lead oxide, cerulean blue, calcium carbonate, barium sulfate, alumina, silica powder, clay, talc, mica,
Zinc powder, silicon nitride, silicon carbide, aluminum, benite, zirconium oxide, slaked lime, potassium titanate, magnesium carbonate, zirconia, zinc chromate, calcium leadate, barium carbonate, calcium silicate, glass wool, and the like, Complex oxide pigments such as titanium yellow, cobalt blue, cobalt aluminum blue, and copper chromium black can also be used.

These inorganic pigments may be of the same type or different from those previously sprayed on the inner surface of the mold and those added to the non-combustible phenolic resin foam composition. This is because each of them can exhibit an excellent decorative pattern. It is because it is desirable to use the amount of the inorganic pigment in various ways, and it is possible to exhibit excellent color patterns depending on the amount of the pigment. When added to the non-combustible phenolic resin foam composition, it is 5-150
A range of parts by weight is preferred. If the amount is less than 5 parts by weight, a sufficient color pattern cannot be exhibited, and if the amount is 150 parts by weight or more, the amount of the pigment becomes too large. An appropriate amount of the inorganic pigment to be sprayed on the inner surface of the mold may be used.

The non-combustible phenolic resin foam is extremely lightweight because its high strength ceramic fine hollows are joined together and this portion is fixed with phenolic resin, and its specific gravity is 0.4 to 0.6 g / cm ^3. Becomes Also at the time of molding 10
Even higher compression strength intensity becomes dense for applying extruding or pressing at ~500kgf / cm ² becomes 100 kgf / cm ² or more.

Since the high-strength ceramic fine hollow particles can be completely present in the form of a hollow body in the non-combustible phenolic resin foam, the ceramic fine hollow particles are fixed to each other by point-joining. It has been found that there are countless capillary air flow holes.

The air flows from the surface even with a low air pressure of only about 1 kgf / cm ^{2 due} to the infinite number of mesh-like capillary air flow holes stretched in a mesh shape. In other words, the air from the front surface flows not only on the back surface but also on four rounds. Particularly, in the case of hot air, most of the air flows upward and to the left and right from the front surface and dissipates from the entire surface of the noncombustible phenol resin foam, so that the back surface temperature does not increase. Therefore, even if the flame is applied to the non-combustible siding according to the present invention, the high-heat air due to the flame is
Flows evenly throughout the non-combustible phenolic foam. Therefore, the rise of the back surface temperature is small and the whole functions as a heat sink.

In addition to the main constituent materials of the non-combustible phenolic resin foam, a dispersant, an antibacterial / antifungal agent,
An admixture such as a stabilizer or an inorganic extender is used. A thickener such as methylcellulose, carboxymethylcellulose or the like is added for the purpose of press formability and cast pressure formability. Titanium powder, alumina powder and the like may be added for improving fire resistance and physical properties.

The pattern of the non-combustible siding surface tile shape pattern may be any, and can be freely selected, for example, loading in the UK, loading in the French garden, loading in the longitudinal direction, loading in the quarter, and the like.

The joints between tiles on the non-combustible siding surface are extremely tough because the non-combustible phenolic resin foam becomes a joint material in the gaps and is formed integrally with the tile backing substrate. Moreover, the color of the non-combustible phenolic resin foam can be arbitrarily selected by adding a pigment, and the color of the joint material can be freely changed. Further, in order to protect the lightweight siding board from acid rain and the like, a backing-integrated joint material can be formed by using a color powder which is particularly resistant to acid.

In the noncombustible siding, since a lightweight noncombustible phenolic resin foam is used for the base material of the tile, even if it has a large size and shape, there is no problem in terms of transportation and construction. For example, it is also possible to produce non-combustible siding of a large size such as 900 mm wide, 1800 mm high, 1200 mm wide, and 2400 mm high.

[0030]

Embodiments of the present invention will be described below in detail, but the present invention is not limited to the embodiments without departing from the gist thereof.

EXAMPLE A commercially available two-piece thickness of 6 was formed on the inner surface of the mold.
A tile shape pattern having a thickness of 8 mm and a joint width of 8 mm was prepared by quarterly stacking tiles having a thickness of mm. The thickness of the tile-backing base material is 15 mm, the tile surface is 21 mm including the tile surface, and the dimensions of the noncombustible siding are 600 mm in width and 1800 mm in width. A non-combustible phenolic resin foam composition was poured into the mold, and after press-molding at a pressure of 100 kgf / cm ² , 6
After curing for 30 minutes at 0 ° C., a non-combustible siding with a tile-shaped pattern was prepared.

The non-combustible phenolic resin foam composition used in the examples was 10 parts by weight of a resole type phenolic resin,
Compressive strength 70 to 1.5 parts by weight of methylene chloride as blowing agent
0 kgf / cm ² , bulk specific gravity 0.3-0.5 g / cm ³ ,
Melting point 1600 ° C, thermal conductivity 0.1 (kcal / mhr)
C), 220 parts by weight of ceramic fine hollow particles composed of only completely hollow particles, 20 parts by weight of glass powder, 60 parts by weight of aluminum hydroxide, an inorganic pigment, and a dispersant, a stabilizer and the like in water and an admixture. After adequately stirring and kneading the composition added in an appropriate amount, 6 parts by weight of a phosphoric acid-based curing agent is added, and the mixture is further sufficiently stirred and kneaded. The inorganic pigment used was a mixture of titanium oxide and zinc white at a ratio of 4: 1 for both the inside of the mold and the addition of the non-combustible phenol resin foam composition.
An appropriate amount was sprayed on the surface of the mold and 23 parts by weight of the non-combustible phenol resin foam composition was added to 100 parts by weight of the composition.

The noncombustible siding according to the embodiment is one in which a tile-shaped pattern and a tile backing substrate are integrally formed, and joints are also integrally formed. It was confirmed that the specific gravity of the noncombustible siding was 0.48, which was extremely light, had good nailing properties, and was excellent in workability.

The non-combustible siding had a water absorption of 2% or less, had no abnormal weather resistance after 1000 hours of sunshine carbon arc lamp, and showed no abnormalities in freeze-thaw performance even after 300 cycles. It has been confirmed that both the base material test and the surface test specified in the flame retardancy test method of the interior materials and the construction method of the building No. 1828 of the Ministry of Construction show excellent performance.

[0035]

As described above, the non-combustible siding using the non-combustible phenolic resin foam according to the present invention is achieved by using ceramic fine hollow particles, glass powder and aluminum hydroxide as the phenol resin filler. The surface smoothness that could not be obtained with the conventional phenolic resin foam could be obtained. In addition, conventional phenol resin foams are only foams of the phenol resin itself, and therefore become open cells, are porous, have high water absorption, and have insufficient physical strength. The surfaces of the ceramic fine hollow particles are point-joined by phenolic resin, and the gap between the ceramic fine hollow particles is filled with glass powder. It is possible to obtain a non-combustible siding in which a tile-shaped pattern formed of a non-combustible phenolic resin foam having low physical properties, high physical strength, and excellent heat insulation and a backing substrate are integrally formed. did it.

Further, by spraying an inorganic pigment on the surface of the mold and adding the inorganic pigment to the non-combustible phenolic resin foam composition, the tile-shaped pattern exhibits an excellent decorative effect such as natural stone and is beautiful. A tiled pattern could be formed.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of nonflammable siding

FIG. 2 Surface view of nonflammable siding

[Explanation of symbols]

 1. 1. Tile shape pattern 2. Tile backing substrate Joint part

──────────────────────────────────────────────────の Continued on front page (51) Int.Cl. ⁶ Identification code FI B29K 105: 04

Claims (2)

[Claims] An inorganic pigment is sprayed on the inner surface of a mold formed into a tile-shaped pattern, and a non-combustible phenolic resin foam composition is poured into the tile-shaped pattern to form a non-combustible phenolic resin foam. Non-combustible siding characterized by being integrally molded with. 2. A resol type phenol resin (10 parts by weight), a foaming agent (0.3 to 5.0 parts by weight) and a curing agent (2 to 5 parts by weight) having a compressive strength of 600 kgf / cm ² or more and a bulk specific gravity of 0.3 to
0.5 g / cm ^3, 50 to 250 parts by weight of a melting point 1500 ° C. or more ceramic fine hollow particles, glass powder 5-50 parts by weight, the inorganic pigment as the main constituent material to aluminum hydroxide 10 to 100 parts by weight, this water The method for producing noncombustible siding according to claim 1, wherein the noncombustible phenolic resin foam composition to which is added is cast into a mold.