JPH10252182A - Fire resisting composite building material and manufacturing thereof - Google Patents

Fire resisting composite building material and manufacturing thereof

Info

Publication number
JPH10252182A
JPH10252182A JP9056296A JP5629697A JPH10252182A JP H10252182 A JPH10252182 A JP H10252182A JP 9056296 A JP9056296 A JP 9056296A JP 5629697 A JP5629697 A JP 5629697A JP H10252182 A JPH10252182 A JP H10252182A
Authority
JP
Japan
Prior art keywords
layer
thermosetting resin
gypsum board
building material
composite building
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
JP9056296A
Other languages
Japanese (ja)
Inventor
Kichiya Matsuno
吉弥 松野
Kenji Sato
健司 佐藤
Tetsuya Nishimura
哲也 西村
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Ibiden Co Ltd
Original Assignee
Ibiden Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ibiden Co Ltd filed Critical Ibiden Co Ltd
Priority to JP9056296A priority Critical patent/JPH10252182A/en
Publication of JPH10252182A publication Critical patent/JPH10252182A/en
Pending legal-status Critical Current

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  • Panels For Use In Building Construction (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)

Abstract

PROBLEM TO BE SOLVED: To provide fire resisting composite building materials excellent in mechanical strength, water resistance and fire protecting property at a low cost. SOLUTION: Plaster board 4 having a water resisting paper layer 2, reinforcing layers 3 containing inorganic fiber and thermosetting resin less than content 20wt.% formed respectively on both surfaces of the plaster board 4, a thermosetting resin impregnation core material layer 5 formed on the reinforcing layer 2 on one side of the plaster board 4 and a thermosetting resin impregnation pattern paper layer 6 are successively laminated on both sides of a plaster slab 1. Fire resisting composite building materials are equipped with face layer 7 wherein embossed recess sections 9 are formed and a packer layer 8 of the thermosetting resin impregnation core material formed on the reinforcing layer 2 on the opposite side of the plaster board 4.

Description

【発明の詳細な説明】DETAILED DESCRIPTION OF THE INVENTION

【0001】[0001]

【発明の属する技術分野】この発明は、耐火性を持つ複
合建築材料および、その複合建築材料の製造方法に関す
るものである。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite building material having fire resistance and a method for producing the composite building material.

【0002】[0002]

【従来の技術および発明が解決しようとする課題】耐火
性を持つ複合建築材料としては従来、壁材として使用さ
れる石膏ボードが一般に良く知られており、従来の市販
の石膏ボードは、耐水性および強度を与えるために石膏
板の両面に耐水紙を貼り付けた構造を有していて、安価
であるとともに、耐熱性や断熱性を持っている。しかし
ながら、かかる石膏ボードに関しては、石膏板自体が柔
らかいうえに耐水紙も強度が低いため、物が当たると凹
みが生じたり割れたりしてしまうという問題があり、ま
た、その石膏ボードの表面に一旦壁紙を貼ってしまうと
貼り替えができないという問題もあり、さらに、表面が
耐水紙で覆われているのみなので耐水性が低いという点
も問題となっていた。これがため従来の石膏ボードは、
何等かの改良を施す必要があった。
2. Description of the Related Art Gypsum board used as a wall material is generally well known as a composite material having fire resistance. Conventional commercial gypsum board is water-resistant. It has a structure in which waterproof paper is stuck on both sides of a gypsum board to give strength, and it is inexpensive and has heat resistance and heat insulation. However, with regard to such a gypsum board, since the gypsum board itself is soft and the strength of the waterproof paper is low, there is a problem that dents or breaks occur when an object hits, and the surface of the gypsum board once When the wallpaper is pasted, there is a problem that the wallpaper cannot be replaced, and furthermore, since the surface is only covered with water-resistant paper, water resistance is low. This is why conventional gypsum board is
Some improvement was needed.

【0003】そこで、上記石膏ボードの改良のため従来
から種々の提案がなされており、例えば特開平2−23
1135号公報には、石膏板からなる基材に、これも耐
火性を持つ膨張黒鉛シートを積層する技術が開示されて
いる。しかしながらかかる構造でも、石膏板自体が約30
0 円/m2と安価であるのに対し、そこに積層する膨張黒
鉛シートが2〜3万円/m2と非常にコストが高いため、
全体として極めて高価な建築材料になってしまうという
問題があり、また、表面に黒鉛シートを用いることか
ら、触れると黒鉛が付着して汚れてしまい、人の居住空
間を構成する壁材として使用するには適していないとい
う問題もあった。
Therefore, various proposals have conventionally been made for improving the above-mentioned gypsum board.
No. 1135 discloses a technique of laminating an expanded graphite sheet, which also has fire resistance, on a substrate made of a gypsum plate. However, even with such a structure, the gypsum plate itself is about 30
While the cost is as low as 0 yen / m 2 , the cost of the expanded graphite sheet laminated there is very high at 20,000 yen / m 2 ,
There is a problem that it becomes an extremely expensive building material as a whole, and since the graphite sheet is used on the surface, graphite adheres and gets dirty when touched, and it is used as a wall material that constitutes a living space for people There was also a problem that it was not suitable for.

【0004】ところで、特開平6−182917号公報
には、耐火性を持つフェノール樹脂発泡板の表面に、グ
ラスウール等の鉱物質繊維と合成樹脂との混合物を積層
する技術が開示されている。しかしながらこの構造で
は、基材としてフェノール樹脂発泡板を使用しているた
め、石膏板を使用した場合に比べてコストが格段に高く
なるという問題があった。
Japanese Unexamined Patent Publication (Kokai) No. 6-182917 discloses a technique in which a mixture of a mineral fiber such as glass wool and a synthetic resin is laminated on the surface of a phenol resin foam plate having fire resistance. However, in this structure, since a phenol resin foam plate is used as a base material, there is a problem that the cost is significantly higher than when a gypsum plate is used.

【0005】また、特開平7−329236号公報に
は、石膏ボードの表面に、繊維を配合した熱可塑性樹脂
からなる補強層を貼り付けた建築材料が開示されてい
る。しかしながらこの建築材料は、熱可塑性樹脂を使用
しているため、耐火性に劣るという問題があった。
Japanese Patent Application Laid-Open No. 7-329236 discloses a building material in which a reinforcing layer made of a thermoplastic resin containing fibers is attached to the surface of a gypsum board. However, since this building material uses a thermoplastic resin, there is a problem that fire resistance is poor.

【0006】この一方、ガラス繊維マットやガラス繊維
織布に熱硬化性樹脂液を含浸させた補強層も従来、例え
ば実公平2−17867号公報にて開示されているが、
先の特開平7−329236号公報中に「ガラス繊維マ
ット、ガラス繊維織布に熱硬化性樹脂を含浸させた基材
を石膏板に貼り付ける方法が提案されている。しかしな
がら、このような基材は、繊維含有率を高くして(逆に
いえば樹脂含有率を低くして)高強度化しようとすると
熱硬化性樹脂の含浸が悪くなり、また薄くすることも難
しく軽量、高強度化に限界がある。」と記載されている
ように、ガラス繊維マットやガラス繊維織布に熱硬化性
樹脂液を含浸させて熱圧すると樹脂含有率が20重量%を
越えてしまい、それゆえ上記のように熱硬化性樹脂液を
含浸させる方法では、低樹脂含有率の補強層を持つ、軽
量かつ高強度で防火特性の優れた石膏ボードを製造する
ことは困難であった。
On the other hand, a reinforcing layer obtained by impregnating a glass fiber mat or a glass fiber woven fabric with a thermosetting resin liquid has been conventionally disclosed, for example, in Japanese Utility Model Publication No. 2-17867.
In Japanese Patent Application Laid-Open No. 7-329236, there has been proposed a method of attaching a base material obtained by impregnating a glass fiber mat or a glass fiber woven fabric with a thermosetting resin to a gypsum board. When trying to increase the strength by increasing the fiber content (or, conversely, lowering the resin content), the impregnation of the thermosetting resin becomes worse, and it is difficult to reduce the thickness of the material. When a glass fiber mat or glass fiber woven fabric is impregnated with a thermosetting resin liquid and hot pressed, the resin content exceeds 20% by weight. In the method of impregnating a thermosetting resin liquid as described above, it was difficult to produce a gypsum board having a lightweight, high-strength, and excellent fire-resistant property, having a reinforcing layer with a low resin content.

【0007】しかして本願発明者らは、上述の問題点に
ついて研究を進めた結果、ガラス繊維シートに熱硬化性
樹脂液を含浸させるのではなく、ガラス繊維に熱硬化性
樹脂を付着させて、その熱硬化性樹脂がガラス繊維に付
着したガラス繊維マットを熱圧する事により、熱硬化性
樹脂でも補強層が得られることを知見した。この発明
は、かかる知見に基づいて、上記公報中で実現できない
とされている低樹脂含有率の無機繊維補強層を有する耐
熱性複合建築材料を提供することを目的とするものであ
る。
[0007] The inventors of the present application have conducted research on the above-mentioned problems, and as a result, instead of impregnating the glass fiber sheet with the thermosetting resin liquid, the thermosetting resin was attached to the glass fiber, It has been found that a reinforcing layer can be obtained even with a thermosetting resin by hot-pressing a glass fiber mat in which the thermosetting resin adheres to glass fibers. An object of the present invention is to provide a heat-resistant composite building material having an inorganic fiber reinforced layer having a low resin content, which is considered to be impossible to realize in the above-mentioned publication, based on such knowledge.

【0008】[0008]

【課題を解決するための手段およびその作用】この発明
の耐火性複合建築材料は、石膏板と、前記石膏板の両面
上にそれぞれ形成された、無機繊維および含有量20重量
%以下の熱硬化性樹脂を含む補強層とを具えてなるもの
である。
The fire-resistant composite building material according to the present invention comprises a gypsum board and a thermosetting resin having an inorganic fiber content of not more than 20% by weight formed on both sides of the gypsum board. And a reinforcing layer containing a conductive resin.

【0009】なお、この発明においては、前記石膏板の
両面と前記補強層との間に耐水紙層をさらに具えていて
も良く、また前記補強層上に、熱硬化性樹脂含浸パター
ン紙からなる化粧層または、熱硬化性樹脂含浸コア材お
よび熱硬化性樹脂含浸パターン紙を順次に積層してなる
化粧層をさらに具えていても良い。
In the present invention, a waterproof paper layer may be further provided between both sides of the gypsum board and the reinforcing layer, and the reinforcing layer is made of a thermosetting resin-impregnated pattern paper. The decorative layer may further include a decorative layer or a decorative layer formed by sequentially laminating a thermosetting resin-impregnated core material and a thermosetting resin-impregnated pattern paper.

【0010】さらにこの発明においては、前記化粧層
は、エンボス加工が施されたものであっても良く、また
前記化粧層を前記石膏板の片面側の補強層上だけに具え
るとともに、前記石膏板の反対側の面の補強層上に熱硬
化性樹脂含浸コア材からなるバッカー層を具えていても
良い。
In the present invention, the decorative layer may be embossed, and the decorative layer is provided only on the reinforcing layer on one side of the gypsum board. A backer layer made of a thermosetting resin-impregnated core material may be provided on the reinforcing layer on the opposite side of the plate.

【0011】そして、上記耐火性複合建築材料を製造す
るためのこの発明の製造方法は、無機繊維に熱硬化性樹
脂を付着させた無機繊維マットを熱圧することで、無機
繊維および含有量20重量%以下の熱硬化性樹脂を含む補
強層を石膏板の両面上にそれぞれ形成することを特徴と
するものである。
The manufacturing method of the present invention for manufacturing the refractory composite building material is characterized in that the inorganic fiber mat having a thermosetting resin adhered to the inorganic fiber is hot-pressed to obtain the inorganic fiber and the content of 20% by weight. % Of the thermosetting resin is formed on both sides of the gypsum board.

【0012】この発明の耐火性複合建築材料によれば、
熱硬化性樹脂および無機繊維を含む補強層が石膏板の両
面上に形成されているので、その補強層が高い強度を持
つことから、その建築材料に物が当たった場合でも、凹
みや割れが生ずるのを防止することができ、またその補
強層が熱硬化性樹脂および無機繊維を含むことから、そ
の上に壁紙を張っても剥がすことができ、そして熱硬化
性樹脂の含有量を20重量%以下としていることから、防
火特性を向上させることができ、かつ材料コストを比較
的安く抑えることができるとともに重量を軽量化するこ
とができ、さらに、石膏板の両面を熱硬化性樹脂および
無機繊維を含む補強層が覆っていることから、石膏板を
具えた建築材料の耐水性と耐火性とを共に高めることが
できる。なお、熱硬化性樹脂の含有量を15重量%以下と
すれば、より好適である。
According to the fire-resistant composite building material of the present invention,
Since the reinforcing layer containing thermosetting resin and inorganic fiber is formed on both sides of the gypsum board, the reinforcing layer has high strength, so that even when the building material is hit by an object, dents and cracks may occur. Can be prevented, and since the reinforcing layer contains thermosetting resin and inorganic fiber, it can be peeled off even if wallpaper is put on it, and the content of thermosetting resin is 20% by weight. % Or less, the fire prevention properties can be improved, the material cost can be kept relatively low, the weight can be reduced, and both sides of the gypsum plate can be made of a thermosetting resin and an inorganic material. Since the reinforcing layer containing the fiber is covered, it is possible to increase both the water resistance and the fire resistance of the building material provided with the gypsum board. It is more preferable that the content of the thermosetting resin is set to 15% by weight or less.

【0013】また、この発明の耐火性複合建築材料によ
れば、石膏板の両面と補強層との間に耐水紙層をさらに
具えている場合には、さらに高い強度を得ることができ
る。そして、補強層上に、熱硬化性樹脂含浸パターン紙
からなる化粧層または、熱硬化性樹脂含浸コア材および
熱硬化性樹脂含浸パターン紙を順次に積層してなる化粧
層をさらに具えている場合には、取り付けた建築材料の
上に表面装飾のために化粧紙等を貼り付ける必要がない
ので、施工性を向上させることができる。さらに、その
化粧層にエンボス加工が施されている場合には、より高
い装飾効果をもたらすことができる。また、化粧層を石
膏板の片面側の補強層上だけに具えるとともに、その石
膏板の反対側の面の補強層上に熱硬化性樹脂含浸コア材
からなるバッカー層をさらに具えている場合には、化粧
層の硬化の際の収縮力をバッカー層の硬化の際の収縮力
が相殺して、当該建築材料の反りの発生を防止すること
ができる。
According to the fire-resistant composite building material of the present invention, when a waterproof paper layer is further provided between both sides of the gypsum board and the reinforcing layer, higher strength can be obtained. And, further comprising a decorative layer made of a thermosetting resin impregnated pattern paper or a decorative layer formed by sequentially laminating a thermosetting resin impregnated core material and a thermosetting resin impregnated pattern paper on the reinforcing layer. Since it is not necessary to attach decorative paper or the like for surface decoration on the attached building material, workability can be improved. Further, when the decorative layer is embossed, a higher decorative effect can be provided. Further, when the decorative layer is provided only on the reinforcing layer on one side of the gypsum board, and the backing layer made of a thermosetting resin-impregnated core material is further provided on the reinforcing layer on the opposite side of the gypsum board. Thus, the contraction force at the time of curing the backer layer is offset by the contraction force at the time of curing of the decorative layer, so that the building material can be prevented from warping.

【0014】この一方、この発明の耐火性複合建築材料
の製造方法によれば、無機繊維に熱硬化性樹脂を付着さ
せた無機繊維マットを熱圧することで、無機繊維および
含有量20重量%以下の熱硬化性樹脂を含む補強層を石膏
板の両面上にそれぞれ形成するので、従来は形成し得な
かった無機繊維および含有量20重量%以下の熱硬化性樹
脂を含む補強層を形成し得て、上記したこの発明の耐火
性複合建築材料ひいては上記したその種々の有利な効果
をもたらすことができる。
On the other hand, according to the method for producing a fire-resistant composite building material of the present invention, an inorganic fiber mat having a thermosetting resin adhered to an inorganic fiber is hot-pressed, whereby the inorganic fiber and the content are 20% by weight or less. Since the reinforcing layer containing the thermosetting resin is formed on both sides of the gypsum board, it is possible to form the reinforcing layer containing the inorganic fiber and the thermosetting resin having a content of 20% by weight or less which could not be formed conventionally. Thus, the above-described fire-resistant composite building material of the present invention and the various advantageous effects thereof described above can be obtained.

【0015】[0015]

【発明の実施の形態】以下に、この発明の実施の形態を
実施例によって、図面に基づき詳細に説明する。ここに
図1は、この発明の耐火性複合建築材料の基本的な実施
形態の一つを示す断面図であり、また図2は、その図1
に示す基本的な実施形態の複建築材料に化粧層を設けた
他の基本的な実施形態を示す断面図である。そして図3
は、この発明の耐火性複合建築材料の実際的な実施形態
の一つとしてのガラス繊維強化石膏ボードを示す断面図
であり、また図4は、その図3に示す実際的な実施形態
の複建築材料としてのガラス繊維強化石膏ボードに化粧
層を設けた他の実際的な実施形態を示す断面図である。
さらに図5は、その図4に示す実際的な実施形態の複建
築材料としてのガラス繊維強化石膏ボードの化粧層にエ
ンボス加工を施した他の実際的な実施形態を示す断面図
である。
Embodiments of the present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a cross-sectional view showing one of the basic embodiments of the fire-resistant composite building material of the present invention, and FIG.
It is sectional drawing which shows the other basic embodiment which provided the decorative layer in the double building material of the basic embodiment shown in FIG. And FIG.
FIG. 4 is a sectional view showing a glass fiber reinforced gypsum board as one of the practical embodiments of the fire-resistant composite building material of the present invention, and FIG. 4 is a sectional view of the practical embodiment shown in FIG. It is sectional drawing which shows the other practical embodiment which provided the decorative layer on the glass fiber reinforced gypsum board as a building material.
Further, FIG. 5 is a cross-sectional view showing another practical embodiment in which the decorative layer of the glass fiber reinforced gypsum board as the composite building material of the practical embodiment shown in FIG. 4 is embossed.

【0016】図1〜図5中、符号1は通常の石膏板、符
号2は補強層をそれぞれ示し、これらの実施形態の複合
建築材料における補強層2は、無機繊維としてのガラス
繊維と、含有量20重量%以下の、熱硬化性樹脂としての
フェノール樹脂とからなるものであり、この補強層2を
形成するためのガラス繊維としては、未硬化状態のフェ
ノール樹脂をあらかじめその繊維表面に付着させたマッ
ト状のガラス繊維を使用する。
1 to 5, reference numeral 1 denotes a normal gypsum board, and reference numeral 2 denotes a reinforcing layer, respectively. The reinforcing layer 2 in the composite building material of these embodiments includes glass fiber as inorganic fiber, An amount of 20% by weight or less of a phenolic resin as a thermosetting resin. As a glass fiber for forming the reinforcing layer 2, an uncured phenolic resin is previously adhered to the fiber surface. Use matted glass fiber.

【0017】上記のような未硬化状態のフェノール樹脂
を繊維表面に付着させたマット状のガラス繊維は、ガラ
ス原料の溶融体をノズルから流出させて、遠心法または
ブローイング法により繊維化すると同時に、フェノール
樹脂溶液を霧状にしてそのガラス繊維に吹き付け、その
後に集綿する等の、公知の方法にて製造することができ
る。
[0017] The mat-shaped glass fiber having the uncured phenol resin adhered to the fiber surface as described above is made to flow out from the nozzle of the melt of the glass raw material, and is formed into a fiber by a centrifugal method or a blowing method. The phenol resin solution can be produced by a known method such as spraying the phenol resin solution onto the glass fiber and then collecting the cotton fiber.

【0018】このマット状ガラス繊維の重量は、ノズル
からのガラス溶融体の流出量と集綿速度とによりコント
ロールすることができる。またこのマット状ガラス繊維
は、未硬化状態のフェノール樹脂を繊維表面に付着させ
てあるので、成形時にフェノール樹脂を含浸させなくて
も、130 〜160 ℃の温度で熱圧(ホットプレス)するこ
とにより、石膏板1や石膏ボード4の表面上で板状の補
強層2に成形することができる。なお、上記の方法によ
れば、マット状ガラス繊維中のフェノール樹脂含有量を
30重量%程度まで任意に調節することができ、上記各実
施形態の補強層2では7〜12重量%とした。
The weight of the glass fiber mat can be controlled by controlling the amount of the glass melt flowing out from the nozzle and the cotton collecting speed. Since the matted glass fiber has an uncured phenol resin adhered to the fiber surface, it should be hot-pressed at a temperature of 130 to 160 ° C without impregnating the phenol resin during molding. Thereby, the plate-like reinforcing layer 2 can be formed on the surface of the gypsum board 1 or the gypsum board 4. According to the above method, the phenol resin content in the mat-like glass fiber is
It can be arbitrarily adjusted up to about 30% by weight, and is set to 7 to 12% by weight in the reinforcing layer 2 of each of the above embodiments.

【0019】図1および図2に示す基本的実施形態で
は、石膏板1の両面上にそれぞれ補強層2を直接形成し
てあるが、図3〜図5に示す実際的実施形態としてのガ
ラス繊維強化石膏ボードでは、石膏板1の両面上にそれ
ぞれ耐水紙3を貼り付けてなる石膏ボード4を使用し、
その石膏ボード4の両面の耐水紙3上にそれぞれ補強層
2を形成してある。
In the basic embodiment shown in FIGS. 1 and 2, the reinforcing layers 2 are directly formed on both sides of the gypsum board 1, respectively. However, the glass fiber as a practical embodiment shown in FIGS. In the reinforced gypsum board, a gypsum board 4 in which waterproof paper 3 is stuck on both sides of the gypsum board 1 is used,
The reinforcing layer 2 is formed on each of the waterproof papers 3 on both sides of the gypsum board 4.

【0020】そして図2および図4にそれぞれ示す実施
形態では、その石膏板1の片面(図では上面)上に形成
した補強層2上に、熱硬化性樹脂としてのフェノール樹
脂をコア材としてのクラフト紙に含浸させてなるフェノ
ールコア層5と、これも熱硬化性樹脂としてのメラミン
樹脂を模様や色彩を印刷したクラフト紙であるパターン
紙(PA)に含浸させてなるパターン層6とを順次に積層
して化粧層7を形成する一方、その石膏板1の反対側の
面(図では下面)上に形成した補強層2上に、パターン
層6の熱硬化性樹脂と同一種類の熱硬化性樹脂であるメ
ラミン樹脂をコア材としてのクラフト紙に含浸させてな
るバッカー層8を形成してある。なお、ここで設けたフ
ェノールコア層5は、パターン層6を補強する機能を果
たすものである。
In the embodiments shown in FIGS. 2 and 4, a phenol resin as a thermosetting resin is used as a core material on a reinforcing layer 2 formed on one side (the upper surface in the figure) of the gypsum board 1. A phenolic core layer 5 made by impregnating kraft paper and a pattern layer 6 made by impregnating melamine resin, which is also a thermosetting resin, on pattern paper (PA), which is a kraft paper printed with patterns and colors, are sequentially formed. And the decorative layer 7 is formed on the reinforcing layer 2 formed on the opposite surface (the lower surface in the figure) of the gypsum plate 1 on the same type of thermosetting resin as the thermosetting resin of the pattern layer 6. A backer layer 8 is formed by impregnating kraft paper as a core material with a melamine resin as a conductive resin. The phenol core layer 5 provided here functions to reinforce the pattern layer 6.

【0021】さらに、図5に示す実際的実施形態として
のガラス繊維強化石膏ボードでは、上記化粧層7のパタ
ーン層6に枡目状の凹部9のエンボス加工を施して、そ
のパターン層6の表面形状をタイル状に突出するものと
してある。
Further, in a glass fiber reinforced gypsum board as a practical embodiment shown in FIG. 5, the pattern layer 6 of the decorative layer 7 is embossed with a mesh-shaped concave portion 9 to obtain a surface of the pattern layer 6. The shape is projected in a tile shape.

【0022】なお、図2,図4および図5に示す実施形
態における化粧層7とバッカー層8とは、フェノール樹
脂を含浸させて乾燥させるとともに未硬化状態(Bステ
ージ状態)とした、フェノールコア層5を形成するため
のクラフト紙と、メラミン樹脂を含浸させて乾燥させる
とともに未硬化状態(Bステージ状態)とした、パター
ン層を形成するためのパターン紙とを上記図1や図3に
示す実施形態の建築材料の片面上に順次に重ねるととも
に、これもメラミン樹脂を含浸させて乾燥させるととも
に未硬化状態(Bステージ状態)とした、バッカー層8
を形成するためのクラフト紙を上記建築材料の反対側の
面上に重ねた後、温度160 ℃、圧力7〜10kg/cm2にて10
〜20分間ホットプレスすることにより、一度に形成する
ことができる。
The decorative layer 7 and the backer layer 8 in the embodiment shown in FIG. 2, FIG. 4 and FIG. 5 are formed by impregnating a phenol resin and drying the phenol core to form an uncured state (B-stage state). The kraft paper for forming the layer 5 and the pattern paper for forming the pattern layer, which is impregnated with melamine resin and dried and in an uncured state (B stage state), are shown in FIGS. 1 and 3 described above. A backer layer 8 that is sequentially overlaid on one side of the building material of the embodiment, is also impregnated with a melamine resin, is dried, and is in an uncured state (B-stage state).
After superimposed on the opposite surface of the building material kraft paper to form a temperature 160 ° C., at a pressure 7~10kg / cm 2 10
It can be formed at once by hot pressing for ~ 20 minutes.

【0023】[0023]

【実施例】以下には、図3に示すこの発明の実際的実施
態様としてのガラス繊維強化石膏ボードの三種類の実施
例と、それらと対比するための二種類の比較例とについ
て特性を測定した結果を示す。ここに実施例1〜3と比
較例1,2とは、以下の方法で製造した。
In the following, characteristics of three examples of glass fiber reinforced gypsum boards as practical embodiments of the present invention shown in FIG. 3 and two kinds of comparative examples for comparison with them are measured. The results are shown. Here, Examples 1 to 3 and Comparative Examples 1 and 2 were manufactured by the following methods.

【0024】(実施例1) 石膏板の両面上にそれぞれ耐水紙を貼り付けてなる市
販の石膏ボード(厚さ12.5mm、比重0.70) を300mm 角に
切り出し、その石膏ボードの表裏両面にフェノール樹脂
溶液を片面当り13g (固形分換算)の割合でそれぞれ塗
布した。 前記フェノール樹脂含有量7重量%のマット状ガラス
繊維(重量350g/m2)を300mm 角に2枚切り出し、上記フ
ェノール樹脂溶液を塗布した石膏ボードの表裏両面にそ
れぞれ重ねた後、温度150 ℃、圧力0.5kg/cm2 にて15分
間ホットプレスすることにより、この実施例1の複合建
築材料を得た。なお、この実施例1での補強層の最終的
なフェノール樹脂含有量は10.2重量%となった。
Example 1 A commercially available gypsum board (thickness: 12.5 mm, specific gravity: 0.70), in which water-resistant paper is stuck on both sides of a gypsum board, is cut into a square of 300 mm, and phenol resin is applied to both sides of the gypsum board. The solution was applied at a rate of 13 g per solid (in terms of solid content). The glass fiber (weight: 350 g / m 2 ) having a phenolic resin content of 7% by weight was cut out into two pieces of 300 mm square and laid on both the front and back surfaces of a gypsum board coated with the phenolic resin solution. The composite building material of Example 1 was obtained by hot pressing at a pressure of 0.5 kg / cm 2 for 15 minutes. The final phenol resin content of the reinforcing layer in Example 1 was 10.2% by weight.

【0025】(実施例2)前記フェノール樹脂含有量9
重量%のマット状ガラス繊維の重量を500g/m2 とすると
ともにフェノール樹脂溶液塗布量を片面当り26g (固形
分換算)とする以外は実施例1と同様にして、この実施
例2の複合建築材料を得た。なお、この実施例2での補
強層の最終的なフェノール樹脂含有量は14.8重量%とな
った。
(Example 2) The phenol resin content 9
The composite building of Example 2 was carried out in the same manner as in Example 1 except that the weight of the mat-like glass fiber was 500 g / m 2 and the amount of the phenol resin solution applied was 26 g per one surface (in terms of solid content). The material was obtained. The final phenol resin content of the reinforcing layer in Example 2 was 14.8% by weight.

【0026】(実施例3)前記フェノール樹脂含有量12
重量%のマット状ガラス繊維の重量を1000g/m2とすると
ともにフェノール樹脂溶液塗布量を片面当り30g (固形
分換算)とする以外は実施例1と同様にして、この実施
例3の複合建築材料を得た。なお、この実施例3での補
強層の最終的なフェノール樹脂含有量は19.7重量%とな
った。
Example 3 The phenolic resin content was 12
The composite building of Example 3 was carried out in the same manner as in Example 1 except that the weight of the mat-like glass fiber was 1000 g / m 2 and the amount of the phenol resin solution applied was 30 g per one side (in terms of solid content). The material was obtained. Note that the final phenol resin content of the reinforcing layer in Example 3 was 19.7% by weight.

【0027】(比較例1) 石膏板の両面上にそれぞれ耐水紙を貼り付けてなる市
販の石膏ボード(厚さ12.5mm、比重0.70) を300mm 角に
切り出した。 マット状ガラス繊維(重量1000g/m2) を300mm 角に2
枚切り出し、フェノール樹脂溶液中に浸漬して、そのマ
ット状ガラス繊維中にフェノール樹脂溶液を含浸し、そ
のマット状ガラス繊維を石膏ボードの表裏両面にそれぞ
れ重ねた後、温度150 ℃、圧力0.5kg/cm2 にて15分間ホ
ットプレスすることにより、この比較例1の複合建築材
料を得た。なお、この比較例1での補強層の最終的なフ
ェノール樹脂含有量は38重量%となった。
Comparative Example 1 A commercially available gypsum board (thickness: 12.5 mm, specific gravity: 0.70) in which water-resistant paper was stuck on both sides of a gypsum board was cut into a square of 300 mm. Matte glass fiber (weight 1000g / m 2 ) into 300mm square 2
Cut out and immersed in a phenolic resin solution, impregnated the phenolic resin solution in the mat-like glass fiber, and laid the mat-like glass fiber on both the front and back surfaces of the gypsum board, at a temperature of 150 ° C and a pressure of 0.5 kg. The composite building material of Comparative Example 1 was obtained by hot pressing at / cm 2 for 15 minutes. The final phenol resin content of the reinforcing layer in Comparative Example 1 was 38% by weight.

【0028】(比較例2)上記市販の石膏ボード(厚さ
12.5mm、比重0.70) を300mm 角に切り出し、それをガラ
ス繊維、フェノール樹脂などは使用せずそのままの状態
として、この比較例2の複合建築材料を得た。
Comparative Example 2 Commercially available gypsum board (thickness)
A composite building material of Comparative Example 2 was obtained by cutting a 12.5 mm, specific gravity 0.70) into a 300 mm square and leaving it as it was without using glass fiber, phenol resin or the like.

【0029】このようにして作成した本発明の実施例1
〜3および比較例1,2の複合建築材料について、乾燥
時の曲げ強度と、24時間清水中にて吸水させた状態での
曲げ強度とを、JIS A6901 に規定された方法に準じて測
定し、また防火特性を、JISA1321 に規定されている表
面加熱試験方法に準じて測定した。これらの測定結果は
以下の表1に示す。
Example 1 of the present invention thus prepared
With respect to the composite building materials of Comparative Examples 1 to 3 and Comparative Examples 1 and 2, the flexural strength when dried and the flexural strength in a state where water was absorbed in clear water for 24 hours were measured according to the method specified in JIS A6901. The fire resistance was measured according to the surface heating test method specified in JISA1321. The results of these measurements are shown in Table 1 below.

【0030】[0030]

【表1】 [Table 1]

【0031】表1に示す結果から明らかなように、本発
明の実施例1〜3の建築材料は何れも、比較例2に示す
従来の石膏ボードと比較して、乾燥時及び吸水時の曲げ
強度が大幅に優れている。また何れもフェノール樹脂含
有率を20重量%以下とした本発明の実施例1〜3の建築
材料は何れも、比較例1に示すガラス繊維にフェノール
樹脂を含浸させて高樹脂含有率のガラス繊維補強層を形
成した建築材料と比較して、温度時間面積値(燃え易さ
の指標)も発煙係数値も何れも大幅に小さいことから防
火特性が大幅に優れている。
As is clear from the results shown in Table 1, all of the building materials of Examples 1 to 3 of the present invention, when compared with the conventional gypsum board shown in Comparative Example 2, were bent during drying and water absorption. The strength is significantly better. Further, in all of the building materials of Examples 1 to 3 of the present invention in which the phenolic resin content was 20% by weight or less, the glass fiber shown in Comparative Example 1 was impregnated with a phenolic resin and the glass fiber having a high resin content was obtained. Both the temperature-time area value (indicator of flammability) and the smoke generation coefficient value are significantly smaller than the building material having the reinforcing layer, so that the fire protection characteristics are significantly excellent.

【0032】上述したように、この発明の上記各実施形
態の複合建築材料によれば、フェノール樹脂およびガラ
ス繊維からなる補強層2が石膏板1の両面上に形成され
ているので、その補強層2が高い強度を持つことから、
その建築材料に物が当たった場合でも凹みや割れが生ず
るのを防止することができ、またその補強層2がフェノ
ール樹脂およびガラス繊維からなることから、その上に
壁紙を張っても剥がすことができ、そして補強層2のフ
ェノール樹脂含有量を20重量%以下としていることか
ら、防火特性を向上させることができ、かつ材料コスト
を比較的安く抑えることができるとともに重量を軽量化
することができ、さらに石膏板1の両面をフェノール樹
脂およびガラス繊維からなる補強層2が覆っていること
から、石膏板1を具えた建築材料の耐水性と耐火性とを
共に高めることができる。
As described above, according to the composite building materials of the above embodiments of the present invention, since the reinforcing layers 2 made of phenol resin and glass fiber are formed on both sides of the gypsum board 1, the reinforcing layers Because 2 has high strength,
Even if an object hits the building material, it can prevent dents and cracks from occurring, and since the reinforcing layer 2 is made of phenolic resin and glass fiber, it can be peeled off even if wallpaper is put on it. Since the phenolic resin content of the reinforcing layer 2 is set to 20% by weight or less, the fire prevention characteristics can be improved, the material cost can be relatively reduced, and the weight can be reduced. In addition, since both sides of the gypsum board 1 are covered with the reinforcing layer 2 made of phenol resin and glass fiber, both the water resistance and the fire resistance of the building material provided with the gypsum board 1 can be enhanced.

【0033】そして特に図3〜図5に示す実施態様によ
れば、石膏板1の両面と補強層2との間に耐水紙層3を
さらに具えているので、さらに高い強度を得ることがで
き、また特に図2,図4および図5に示す実施態様によ
れば、補強層2上に、フェノール樹脂をクラフト紙に含
浸させたフェノールコア層5およびメラミン樹脂をパタ
ーン紙に含浸させたパターン層6を順次に積層してなる
化粧層7をさらに具えていることから、取り付けた建築
材料の上に表面装飾のために化粧紙等を貼り付ける必要
がないので、施工性を向上させることができる。そして
特に図5に示す実施態様によれば、その化粧層7に表面
形状をタイル状とするエンボス加工が施されているの
で、より高い装飾効果をもたらすことができる。
In particular, according to the embodiment shown in FIGS. 3 to 5, since the waterproof paper layer 3 is further provided between both sides of the gypsum board 1 and the reinforcing layer 2, higher strength can be obtained. According to the embodiments shown in FIGS. 2, 4 and 5, in particular, on the reinforcing layer 2, a phenol core layer 5 made of kraft paper impregnated with phenol resin and a pattern layer made of melamine resin impregnated on patterned paper. Since a decorative layer 7 formed by sequentially laminating 6 is further provided, there is no need to attach decorative paper or the like for surface decoration on the attached building material, so that workability can be improved. . In particular, according to the embodiment shown in FIG. 5, the decorative layer 7 is embossed so that the surface shape is tiled, so that a higher decorative effect can be obtained.

【0034】また特に図2,図4および図5に示す実施
態様によれば、化粧層7を石膏板1の片面側の補強層2
上だけに具えるとともに、その石膏板1の反対側の面の
補強層2上にパターン層6の熱硬化性樹脂と同一種類の
熱硬化性樹脂であるメラミン樹脂をコア材としてのクラ
フト紙に含浸させたバッカー層8をさらに具えているの
で、化粧層7の硬化の際の収縮力をバッカー層8の硬化
の際の収縮力が相殺して、当該建築材料の反りの発生を
有効に防止することができる。
In particular, according to the embodiments shown in FIGS. 2, 4 and 5, the decorative layer 7 is provided on one side of the gypsum board 1 by the reinforcing layer 2.
A melamine resin, which is the same kind of thermosetting resin as the thermosetting resin of the pattern layer 6, is formed on a kraft paper as a core material on the reinforcing layer 2 on the opposite side of the gypsum board 1 while being provided only on the top. Since the backing layer 8 is further impregnated, the shrinking force at the time of curing the decorative layer 7 is offset by the shrinking force at the time of curing the backing layer 8, thereby effectively preventing the building material from warping. can do.

【0035】以上、図示例に基づき説明したが、この発
明は上述の例に限定されるものでなく、例えば、補強層
に用いる無機繊維としては、上記のガラス繊維の他、ロ
ックウールやセラミックファイバー等も使用することが
でき、また補強層その他に用いる熱硬化性樹脂として
は、上記のフェノール樹脂やメラミン樹脂の他、ユリヤ
樹脂やウレタン樹脂、エポキシ樹脂等も使用することが
できる。
Although the present invention has been described with reference to the illustrated examples, the present invention is not limited to the above examples. For example, as the inorganic fibers used for the reinforcing layer, in addition to the above glass fibers, rock wool and ceramic fibers And the like. As the thermosetting resin used for the reinforcing layer and the like, urea resin, urethane resin, epoxy resin and the like can be used in addition to the above-mentioned phenol resin and melamine resin.

【0036】そして補強層の形成に際しては所要に応
じ、無機繊維中に、石膏、水酸化アルミニウム、炭酸カ
ルシウム、シリカ等の無機充填材や、ゴム、パルプ等の
有機充填材を加えても良い。また上記実施例では化粧層
7をフェノールコア層5とパターン層6とで構成した
が、化粧層7をパターン層6のみで構成しても良い。
When forming the reinforcing layer, an inorganic filler such as gypsum, aluminum hydroxide, calcium carbonate, silica, or the like, or an organic filler such as rubber or pulp may be added to the inorganic fibers as required. Although the decorative layer 7 is composed of the phenol core layer 5 and the pattern layer 6 in the above embodiment, the decorative layer 7 may be composed of only the pattern layer 6.

【0037】[0037]

【発明の効果】かくしてこの発明によれば、機械的強
度、耐水性、防火特性に優れた安価な耐火性複合建築材
料をもたらすことができ、かかる耐火性複合建築材料
は、一般住宅や非住宅建築物の、外壁下地材、屋根下地
材、床下地材、内装下地材、天井材等に使用することが
でき、しかも、表面に各種の化粧加工を容易に施すこと
ができるので、一般住宅や非住宅建築物の内装材として
も好適に使用することができる。
As described above, according to the present invention, an inexpensive fire-resistant composite building material having excellent mechanical strength, water resistance, and fire protection properties can be provided. It can be used for exterior wall materials, roof materials, floor materials, interior materials, ceiling materials, etc. of buildings, and it can be easily subjected to various kinds of decorative processing on the surface, so it can be used for ordinary houses and It can also be suitably used as an interior material for non-residential buildings.

【図面の簡単な説明】[Brief description of the drawings]

【図1】この発明の耐火性複合建築材料の基本的な一実
施形態を示す断面図である。
FIG. 1 is a sectional view showing a basic embodiment of a fire-resistant composite building material according to the present invention.

【図2】図1に示す基本的実施形態の複建築材料に化粧
層を設けた他の基本的実施形態を示す断面図である。
FIG. 2 is a sectional view showing another basic embodiment in which a decorative layer is provided on the composite building material of the basic embodiment shown in FIG.

【図3】この発明の耐火性複合建築材料の実際的な一実
施形態としてのガラス繊維強化石膏ボードを示す断面図
である。
FIG. 3 is a sectional view showing a glass fiber reinforced gypsum board as one practical embodiment of the fire-resistant composite building material of the present invention.

【図4】図3に示す実際的な実施形態の複建築材料とし
てのガラス繊維強化石膏ボードに化粧層を設けた他の実
際的な実施形態を示す断面図である。
FIG. 4 is a cross-sectional view showing another practical embodiment in which a decorative layer is provided on a glass fiber reinforced gypsum board as a composite building material of the practical embodiment shown in FIG.

【図5】図4に示す実際的な実施形態の複建築材料とし
てのガラス繊維強化石膏ボードの化粧層にエンボス加工
を施した他の実際的な実施形態を示す断面図である。
5 is a cross-sectional view showing another practical embodiment in which the decorative layer of the glass fiber reinforced gypsum board as the composite building material of the practical embodiment shown in FIG. 4 is embossed.

【符号の説明】[Explanation of symbols]

1 石膏板 2 補強層 3 耐水紙 4 石膏ボード 5 フェノールコア層 6 パターン層 7 化粧層 8 バッカー層 9 凹部 DESCRIPTION OF SYMBOLS 1 Gypsum board 2 Reinforcement layer 3 Waterproof paper 4 Gypsum board 5 Phenol core layer 6 Pattern layer 7 Decorative layer 8 Backer layer 9 Depression

───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.6 識別記号 FI E04C 2/26 E04C 2/26 R ──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. 6 Identification code FI E04C 2/26 E04C 2/26 R

Claims (6)

【特許請求の範囲】[Claims] 【請求項1】 石膏板と、 前記石膏板の両面上にそれぞれ形成された、無機繊維お
よび含有量20重量%以下の熱硬化性樹脂を含む補強層
と、 を具えてなる、耐火性複合建築材料。
1. A fire-resistant composite building comprising: a gypsum board; and a reinforcing layer formed on both sides of the gypsum board, the inorganic fiber and a thermosetting resin having a content of 20% by weight or less. material.
【請求項2】 前記石膏板の両面と前記補強層との間に
耐水紙層をさらに具えることを特徴とする、請求項1記
載の耐火性複合建築材料。
2. The fire-resistant composite building material according to claim 1, further comprising a waterproof paper layer between both sides of the gypsum board and the reinforcing layer.
【請求項3】 前記補強層上に、熱硬化性樹脂含浸パタ
ーン紙からなる化粧層または、熱硬化性樹脂含浸コア材
および熱硬化性樹脂含浸パターン紙を順次に積層してな
る化粧層をさらに具えることを特徴とする、請求項1ま
たは2記載の耐火性複合建築材料。
3. A decorative layer comprising a thermosetting resin impregnated pattern paper or a decorative layer formed by sequentially laminating a thermosetting resin impregnated core material and a thermosetting resin impregnated pattern paper on the reinforcing layer. A fire-resistant composite building material according to claim 1 or 2, characterized in that it comprises:
【請求項4】 前記化粧層は、エンボス加工が施された
ものであることを特徴とする、請求項3記載の耐火性複
合建築材料。
4. The fire-resistant composite building material according to claim 3, wherein the decorative layer is embossed.
【請求項5】 前記化粧層を前記石膏板の片面側の補強
層上だけに具えるとともに、前記石膏板の反対側の面の
補強層上に熱硬化性樹脂含浸コア材からなるバッカー層
をさらに具えることを特徴とする、請求項3または4記
載の耐火性複合建築材料。
5. The backing layer comprising a thermosetting resin-impregnated core material is provided on the reinforcing layer on one side of the gypsum board, and the decorative layer is provided only on the reinforcing layer on one side of the gypsum board. The fire-resistant composite building material according to claim 3, further comprising:
【請求項6】 無機繊維に熱硬化性樹脂を付着させた無
機繊維マットを熱圧することで、無機繊維および含有量
20重量%以下の熱硬化性樹脂を含む補強層を石膏板の両
面上にそれぞれ形成することを特徴とする、請求項1か
ら5までの何れか記載の耐火性複合建築材料の製造方
法。
6. An inorganic fiber mat in which a thermosetting resin is adhered to an inorganic fiber is hot-pressed to obtain an inorganic fiber and a content thereof.
The method for producing a fire-resistant composite building material according to any one of claims 1 to 5, wherein a reinforcing layer containing 20% by weight or less of a thermosetting resin is formed on each side of the gypsum board.
JP9056296A 1997-03-11 1997-03-11 Fire resisting composite building material and manufacturing thereof Pending JPH10252182A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP9056296A JPH10252182A (en) 1997-03-11 1997-03-11 Fire resisting composite building material and manufacturing thereof

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP9056296A JPH10252182A (en) 1997-03-11 1997-03-11 Fire resisting composite building material and manufacturing thereof

Publications (1)

Publication Number Publication Date
JPH10252182A true JPH10252182A (en) 1998-09-22

Family

ID=13023161

Family Applications (1)

Application Number Title Priority Date Filing Date
JP9056296A Pending JPH10252182A (en) 1997-03-11 1997-03-11 Fire resisting composite building material and manufacturing thereof

Country Status (1)

Country Link
JP (1) JPH10252182A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000049246A1 (en) * 1999-02-16 2000-08-24 Ibiden Co., Ltd. Composite building material and production method thereof and comosite floor material
JP2001239617A (en) * 1999-12-20 2001-09-04 Targor Gmbh Frontal part comprising a decorative member
CN103938804A (en) * 2014-05-13 2014-07-23 景泰县金龙化工建材有限公司 Combined-type fiber gridding rib layer product and preparation method thereof
JP2017080906A (en) * 2015-10-22 2017-05-18 凸版印刷株式会社 Noncombustible moistureproof decorative laminate and fitting

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2000049246A1 (en) * 1999-02-16 2000-08-24 Ibiden Co., Ltd. Composite building material and production method thereof and comosite floor material
JP2001239617A (en) * 1999-12-20 2001-09-04 Targor Gmbh Frontal part comprising a decorative member
CN103938804A (en) * 2014-05-13 2014-07-23 景泰县金龙化工建材有限公司 Combined-type fiber gridding rib layer product and preparation method thereof
CN103938804B (en) * 2014-05-13 2017-03-15 景泰县金龙化工建材有限公司 Composite fibre grid ribs layer product and preparation method thereof
JP2017080906A (en) * 2015-10-22 2017-05-18 凸版印刷株式会社 Noncombustible moistureproof decorative laminate and fitting

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