JPH10237982A - Composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a woody material such as a flame-retardant and corrosion- preventive woody building material. SOLUTION: An incombustible and corrosion-preventive material layer 2 consisting of the incombustible material of inorganic powder such as the powder of a silica substance such as shirasu, cement powder, bentonite, etc., artificial inorganic fibers such as glass fibers, ceramic fibers, rock wool, etc., and natural inorganic fibers such as wollastonite, etc., and a binder such as a phenol resin is formed on at least one surface of the laminate or plywood of wood chips or a woody core material 1 such as LVL. Accordingly, a woody building material having fire resistance, flame resistance, decay resistance and moistureproof and moss resistance is acquired.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-combustible or flame-retardant, wood-based composite material having antiseptic and insect repellent properties used for houses and the like.

[0002]

2. Description of the Related Art Conventionally, as wooden structural materials used for houses and other constructions, solid materials such as pine and hinoki, plywood, laminated wood, LVL, strand board, particle board and the like have been mainly used. These have the following advantages. . It was relatively inexpensive and easy to process, making it ideal for small buildings. . It is easy to obtain. . Although it burns in the event of a fire, its strength does not suddenly decrease due to high temperatures like iron. . It is said that the carbonization rate by burning in a fire is generally 1 mm per minute. It is also said that if the cross-sectional area has a certain degree or more, the formed carbonized layer becomes a kind of heat insulating material, and the subsequent carbonization speed is reduced. Therefore, if the structural material is manufactured with a cross-sectional area obtained by adding a burning portion at the time of fire to the minimum required cross-sectional area, sudden collapse of the building at the time of fire can be prevented. . Since wood has a high specific strength, the structure is finished relatively light. . Thermal insulation is better than building materials such as iron and aluminum, and there is no risk of dew condensation.

[0003]

However, since it is made of wood, it has the following problems. . It must be a flammable material. Therefore, it cannot be used as a structural material or an outer wall material in a building having a certain area or more and a place where a fire-resistant structure is required in a use area according to the Building Standards Law. . Water near the base may rot due to moisture and reduce strength. . When painting, regular repainting is necessary, especially when it is used outside, it is necessary to usually carry out at intervals of 5 to 10 years. And the like.

[0004] Therefore, steel frames that can be easily joined on site and can easily obtain a large span in warehouses and gymnasiums have come to be used in general. However, steel frames also had the following problems. . Iron is vulnerable to heat and does not burn in the event of a fire, but the high temperature can cause its strength to drop sharply and cause the building to collapse. . As a countermeasure, it is common practice to spray non-combustible and heat-insulating materials around the steel frame to provide a heat-insulating structure that also improves fire-prevention performance, but this must be done after steel-frame assembly work has been completed. That the construction is done twice. . Rock wool and glass wool used as heat insulators may cause damage to workers' skin, and asbestos is a cause of lung cancer. Since these heat insulating materials are installed later on at the construction site, there is a great risk of peeling and detachment due to long-term use.

[0005] Iron must be painted regularly, especially when it is used externally, usually at intervals of 5 to 10 years. In addition, there is always a risk of rust near the coast. . In the case of large-scale steel structures, radio interference may occur to nearby residents. . Because it is a good conductor of heat, it can reduce the effects of cooling and heating, and it is easy for dew condensation to occur. Etc. can be listed.

Further, as the inorganic noncombustible material, for example, shirasu and the like can be cited, but there are the following problems. . Weight is greater than wood. . Brittle and vulnerable to impact. . Poor holding power for nails and wood screws, requiring special screws such as anchor plugs. . It is better than iron, but less heat-insulating than wood, which reduces the effectiveness of cooling and heating.

[0007]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and uses a wood material as a core material by taking advantage of the characteristics of the wood material. In addition, a non-combustible / anticorrosive material layer is provided for improving decay resistance, insect damage resistance and weather resistance. That is, the composite material of the present invention is characterized in that a non-combustible / anticorrosive material layer is formed on at least one surface of a laminate of wood pieces or a wood core such as plywood or LVL.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In the present invention, the wood material to be used as a core material is not limited to the above-mentioned laminate of wood pieces, plywood and LVL, but may be solid wood or laminated wood such as plywood or LVL. Wood flour or a wood fiber layer may be formed or included on the surface or the intermediate layer. Further, a consolidation material obtained by compression-molding a solid material at a high temperature and a high pressure, a laminated material, a strand board, a fiber board and the like can be used. However, when applied to softwood such as radiator pine and Douglas fir as the material, the present invention exhibits particularly excellent effects.

A non-combustible material for forming a non-combustible and anticorrosive material layer
As the anticorrosion material, those having nonflammability, flame retardancy, fire resistance and the like are used, and those having heat insulating properties together with these properties are preferable, for example, silica-based substance powder such as shirasu, cement powder, Examples include inorganic powders such as bentonite, artificial inorganic fibers such as glass fiber, ceramic fiber and rock wool, and natural inorganic fibers such as wollastonite. In particular, shirasu balloons and inorganic fibers are advantageous in that they can provide air insulation in the non-combustible material layer and thus provide heat insulation.

[0010] If necessary, the non-combustible material layer may contain a plant material such as wood flour, fine wood chips, and plant fibers. These materials are carbonized when the composite material of the present invention comes into contact with a flame, and act to delay the subsequent carbonization. An antifungal effect can be imparted. From these facts, the plant material mixed into the non-combustible / anticorrosion material layer is
It is preferable to use those which have been treated in advance with one or two or more kinds of preservatives, insect repellents, termite repellents, fire retardants, fungicides, and dimension stabilizers. The treatment with these treatment agents can be applied to inorganic noncombustible materials.

As a binder (adhesive) for forming the non-combustible / anticorrosive material layer, it is preferable to use a non-combustible or flame-retardant one. For example, a flame-retardant phenol resin, a melamine resin, a urethane resin or the like can be used. Can be mentioned.
In particular, phenolic resins are particularly preferable in terms of heat insulation and flame retardancy because they are inexpensive, have heat resistance, and can be foamed. As the phenol resin, either a novolak type resin or a resol type resin can be used. The binder may be of a powder type, a solution type or an emulsion (emulsion liquid) type, but an aqueous type is preferred. The ratio between the binder and the non-combustible / anticorrosive material varies depending on the type of the binder, the material and the shape of the non-combustible material, and the ratio of the binder to the non-combustible / anticorrosive material is 1: 9 to 9: 1, preferably 1: 1 to 1: 1.
It is selected in the range of 1: 5.

The incombustible / anticorrosive material layer is formed by mixing a woody material as a core material, for example, a premix compound (blended) in which a noncombustible / anticorrosive material and a binder are previously mixed on the surface of the laminated material at the time of production. It may be manufactured by placing it in a thickness and pressurizing it integrally.Also, the composition is preformed in a sheet shape in advance, and this preformed sheet is placed on a wood core material and pressed integrally. May be manufactured. As one method of producing a preformed sheet, for example, when the binder is a phenol resin, the blended binder resin is subjected to condensation polymerization in the B state to form a preformed sheet. Then, the binder resin is cured to an infusible and insoluble C state by heating when the sheet in the B state is integrally bonded to the wood core material, thereby obtaining a composite material. Another method is to heat-mold into a sheet with a thermoplastic resin that has been previously blended in a small amount into the composition, or pre-form the composition into a sheet with glue such as casein, starch, etc. And a method of bonding to a wood core material by a binder resin included in the above.

Since the composite material of the present invention forms the nonflammable and anticorrosive material layer integrally at the time of molding the wood core material, there is no danger of peeling and falling off at a later date. In addition, since the non-combustible and anticorrosive material layer is located outside the wood core, the fire resistance, insect resistance and antiseptic properties are remarkably improved. The surface of the non-combustible / anticorrosive material layer is usually finished to a flat surface, but if necessary, may be brought into contact with a press plate having a wood grain pattern, an uneven pattern (relief) or the like at the time of molding to finish it to a desired molded surface. The thickness of the incombustible / anticorrosive material layer varies depending on the material of the wood core material and the purpose of use, but is 10 mm or less, usually about 1 to 5 mm, for fire and flame resistance. For the purpose of termite control and the like, it is preferable to provide a thickness of about 5 to 10 mm.

[0014]

EXAMPLES The present invention will be described below with reference to examples, but the present invention is not limited to these examples.

Embodiment 1 FIG. 1 is a sectional view showing an example of the composite material of the present invention.
2 is an example of a composite material in which a non-combustible / corrosion-proof material layer 2 is formed on the front and back surfaces. FIG. 2 is a view showing an example of a method for producing a composite material, and is a configuration diagram of the composite material before being integrated. A shirasu balloon having a particle size of 100 mesh previously used as a non-combustible and anticorrosive material, and phenol resin powder was added as a binder and blended in a mixer. Mat 2 for non-combustible and anticorrosive material layer 2
a is formed. For the wood core material 1, a veneer 1a obtained by removing a radiata pine log using a rotary lace and drying a veneer having a thickness of 3.0 mm using a drier to a water content of 3%. It was used. Next, as shown in FIG. 2, an adhesive (manufactured by Oshika Kogyo Co., Ltd .; resin PB1201) was applied on the mat 2a on the base 4 at a rate of 20 g / size ² (22
0g / m ² ) A predetermined number (5) of the laminated veneers 1a applied
The mat 2 placed on top of the mat 2
a is placed. Non-combustible and anticorrosive materials obtained in this way +
Wood core material + non-combustible and anti-corrosive material, that is, mat 3a + laminated veneer 1a, 1a ‥‥ + mat 2a, and three-layered body are hot-pressed at 180 ° C. by pressing machine 5 to have 3 mm thick non-combustible and anti-corrosive material. Non-combustible and anticorrosive material layer 2 with material layer + wood core 1 + non-combustible
A composite material 3 including the anticorrosion material layer 2 was obtained.

When importance is placed on fire resistance and flame retardancy in the above, the thickness of the non-combustible / anticorrosive material layer 2 may be increased.
If fire resistance or the like is not so required, the thickness may be reduced. The configuration of the wood core material 1 is not limited to the above-described veneer radiata pine (coniferous tree) having a thickness of 3.0 mm, and the tree species may be hardwood or coniferous. As other examples, as a tree species, any of dakura fur, beech, kapole, lauan, etc. can be used, and although there is a slight increase or decrease in strength, a composite having the same fire resistance, flame retardancy, insect resistance, and antiseptic properties Wood is obtained.

Embodiment 2 FIG. 3 shows an example in which a non-combustible / anticorrosive material layer 2 is formed on one surface of a wood core material 1. Both the wood core material and the non-combustible material are not particularly limited, and can be appropriately selected according to the purpose. As an example, rock wool was used as a non-combustible and anticorrosive material, LVL having a laminated thickness of 15 mm was used as a wood core material, and the following foamable phenol resin composition was used as a binder. As the foamable phenolic resin composition, 100 parts (weight, the same applies hereinafter) of a liquid resol type phenolic resin (PI-260: manufactured by Honen Corporation), a surfactant (L-5)
340: A product (emulsion) comprising 4 parts of Nippon Unicar Co., Ltd. and 20 parts of a blowing agent Freon-R113 (trichlorofluoroethane) was used. After a predetermined amount of rock wool was added to the phenol resin composition and mixed well, a flame-retardant acid curing agent (70% paratoluenesulfonic acid / 85% orthophosphoric acid = 9/100 parts) was added to 100 parts of the phenol resin composition. 1) was added at a ratio of 20 parts and stirred to prepare a foamable composition.

The foamable composition is applied to the surface of a wood core in the form of a mat having a thickness of about 2.5 mm, heated to 70 ° C. and prefoamed. To 100
The composition was heated at a temperature of 3 ° C. for 3 minutes to complete the curing, thereby obtaining a composite material in which the foamed noncombustible material layer 2 having a thickness of about 3 mm was formed on the surface of the wood core material 1. The resulting composite is light in weight compared to its thickness,
As a result of a surface test of flame retardant class A of IS A-1321, a smoke emission coefficient (CA) of 10 or less and no afterflame (0
Sec), and good results were obtained without surface deformation and cracking.
In addition, both the surface strength and the compressive strength (2 kg / cm ² or more) of the non-combustible material layer were good, and were sufficiently resistant to use of building materials and the like. Also, since the non-combustible material layer is a foam layer,
The heat insulation and the heat retention were good as compared to LVL having the same thickness. In this example, when the phenolic resin composition is a low-viscosity liquid, a foamed resin composition prepared by adding an acid curing agent to the foamed resin composition is mat-like non-flammable. A method of applying and impregnating the surface of the anticorrosion material to foam and harden may be used.

Example 3 For wall materials, as shown in Examples 1 and 2,
The anticorrosion material layer 2 is a front and back surface of the wooden core material 1 or a simple type.
Although only a surface may be provided, in the case of a column material or a beam girder material, it is advantageous to provide it on four surfaces because fire resistance and flame resistance are basically improved. FIG. 4 shows an example in which a non-combustible and anticorrosive material layer 2 is provided on four surfaces of a solid pillar as a wood core material 1.
When the wooden core is a beam girder, a non-combustible / anticorrosive material layer may be provided on the left and right sides and the lower surface. The non-combustible / anticorrosive material layer may be formed on the upper and lower surfaces in the same manner as in Example 1, and then formed on the left and right surfaces.
In addition, in the case of pillar materials and beam girders, both ends are supported and held in a simple mold, and the non-combustible and anticorrosion material composition applied to the surface of the pillar material and the like are foamed and cured to form a foam and non-combustible material. An anticorrosion material layer can also be formed. As the foamable resin, a urethane resin or the like can be used in addition to the phenol resin.

When the composite material is used as a pillar material or a beam girder material, since the non-combustible and anticorrosive material layer is mainly made of an inorganic material, it is unlikely to cause insect damage by termites or damage by wood corrosive bacteria. Even better results can be obtained by using a non-combustible / anticorrosive material treated with an agent, termiticide, fungicide or the like. Therefore, in addition to the beam girder,
It can be preferably used as a base material, a joist, an underfloor material and the like, particularly a member which is easily affected by rot, ant damage, etc. due to humidity around the foundation. In addition to the above-described solid materials, the present invention can be similarly applied to column materials and beam beams made of laminated materials. When the nonflammable / corrosive material layer is a non-foamed layer, the composite material having the nonflammable / corrosive material layer on the surface can be obtained by heating and pressurizing simultaneously with the production of the laminated material as in the case of the first embodiment. When using a compacted material that is compression molded at high temperature and pressure as the core material, use a low viscosity resin solution as the binder for the non-combustible and anticorrosive material layer. -In addition to strengthening the bond between the anticorrosion material layer and the core, the strength of the core can be improved. In the composite material of this example, the non-combustible and anticorrosive material layer formed around the wood core material does not need to have the same thickness on all four surfaces, and the surface that is more exposed to flames and insect damage is thicker than the other surfaces. It may be a non-combustible / anticorrosive material layer.

Embodiment 4 In the case where the surface is required to have decorativeness such as an interior wall material, a thin decorative layer 6 may be provided on the surface of the non-combustible / anticorrosive material layer 2 as shown in FIG. . As the decorative layer 6, a wooden veneer having a thickness of about 0.3 mm or less is usually used.
If a veneer veneer is coated or impregnated with a fire retardant or a flame retardant, the fire resistance is good, but it is not particularly necessary because it is thin. In addition, a resin such as a melamine resin may be simply applied as a decorative layer, or a resin-impregnated paper may be laminated. When using fine particles or powdery materials such as shirasu balloons as non-combustible and anticorrosive materials, shirasu has inherently fragile properties. Since the film strength of the non-combustible / anticorrosive material layer is improved and the core material is less liable to fall off, it is particularly effective for a fire during an earthquake. Also, when a decorative veneer is laminated on the surface of the incombustible / anticorrosive material layer, the plant fiber in the incombustible / anticorrosive material layer acts as an anchor to the bonding adhesive, and the adhesiveness of the decorative veneer is reduced. It has effects such as improvement.

One of a preservative, an insect repellent, a termitic repellant, a fire retardant, a fungicide, and a dimension stabilizer may be added to the adhesive to be used, the noncombustible material layer, the wood core material and, if necessary, the decorative layer. 2
By mixing or impregnating more than one kind of treatment chemicals, the durability is improved. In addition, as the treatment chemical used here, those which can be generally used for plant materials are used. For example, the following treatment chemicals are exemplified, but not limited thereto.

Preservative: Sampras (3-bromo-2,3
-Diiodide-2-propenylethyl carbonate),
1F1000, S-421, xylazan AL, etc. Insect repellent: foxime, fenitrothion, dichlorofenphos, etc. Fire retardant: boron-based flame retardant, phosphorus-nitrogen-based flame retardant, etc. Antifungal agent: 1F1000, xylazan AL, troysan,
Dimension stabilizers such as KB-9: low molecular weight phenolic resin, thermosetting polyethylene glycol resin, etc.

[0024]

The composite material obtained as described above has the following features. . Excellent fire resistance. Generally, a metal material does not burn, but its strength rapidly decreases when the temperature rises. Therefore, in a steel-frame building, the periphery of the steel frame must be strictly covered with a heat insulating material. However, although the wood material burns, the strength does not decrease even when the temperature rises. It is said that the rate of carbonization of glued laminated wood at the time of fire is about 1 mm per minute, but it is certain that this speed will be further reduced because the wood material is integrated with non-combustible material surrounding it. . Therefore, when used as a structural material, the number of burnout portions is reduced, and the area of a cross-sectional defect due to burnout can be reduced. Therefore, it is also useful for weight reduction.

[0025] light. By using an adhesive that foams during curing, such as a urethane adhesive, as the adhesive of the core material, the void portion relatively increases, and the weight of the product is small. . Good heat insulation. The thermal conductivity of wood is 347 kcal for iron.
While m · h ° C. and concrete are 0.86 kcal / m · h · ° C., it is about 0.08 to 0.14 kcal / m · h · ° C. For this reason, it is excellent in heat insulation and there is no dew condensation.

[0026] Good durability. By mixing preservatives, insect repellents, termiticides, fire retardants, fungicides, and dimensional stabilizers into the adhesive, these active ingredients are evenly distributed, leading to an improvement in durability. . Large specific strength: Since they are integrated, there is no delamination, and the strength such as bending is large relative to the weight. . A wood screw can be used: The wood screw does not work on the surface shirasu layer, but works on the laminated veneer layer beneath it in the same way as conventional wood, so there is no need for a special anchor plug or the like.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing one embodiment of the present invention (a composite material having a non-combustible material layer on both sides).

FIG. 2 is an explanatory view showing an example of a method for producing a composite material of the present invention.

FIG. 3 is a sectional view showing another embodiment of the present invention (a composite material having a non-combustible material layer on one surface).

FIG. 4 is a cross-sectional view showing another embodiment of the present invention (a composite material having a noncombustible material layer on four sides).

FIG. 5 is a sectional view showing another embodiment of the present invention (a composite material having a decorative layer on the surface of a non-combustible material layer).

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Wood core material 2 Noncombustible / anticorrosion material layer 3 Composite material 6 Decorative layer

Claims (7)

[Claims] 1. A composite material comprising a non-combustible and anticorrosive material layer provided on at least one surface of a laminate of wood pieces or a wood core such as plywood or LVL. 2. The non-combustible / anticorrosive material is a natural or synthetic powder, fine-grained, fibrous, non-combustible or flame-retardant material or a composite thereof.
The composite material as described. 3. The composite material according to claim 1, wherein the non-combustible and anticorrosive material layer comprises a non-combustible material and an inorganic or organic adhesive and, if necessary, a plant material such as a plant powder or a plant fiber. . 4. The composite material according to claim 1, wherein the wood core material and the nonflammable / anticorrosive material layer are simultaneously heat-pressure integrated. 5. The method according to claim 1, wherein the plant material mixed with the non-combustible / anticorrosive material is preliminarily treated with one or more treating agents of a preservative, an insect repellent, a termite, a fire retardant, a fungicide, and a dimensional stabilizer. The composite material according to claim 3, which has been treated. 6. The composite according to claim 3, wherein the adhesive is a foamable adhesive. 7. The composite material according to claim 1, wherein the surface is molded.