JPH1113253A - Composite panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve lightweight performance, heat insulating performance and water nonabsorptivity, and easily join a decorative panel by fixing an engaging projection of an elastic raw material to a surface material of a backing panel using isocyanurate foam as a core material. SOLUTION: A composite panel A is composed of a backing panel B and a decorative panel C. A core material 3 inside which a fire resistant sheet D is interposed is heated/foamed by mixing a flame resistant material, a foaming material and a hardening material by using an isocyanurate resin as a main raw material, and is integrally formed with a surface material 1 and a back face material 2 by a self-adhesive property, and a backing panel B is constituted, and an engaging projection 4 of an elastic raw material is fixed to a surface of the surface material 1 by adhesion, fusion or the like. The decorative panel C is composed of an inorganic raw material such as a cement plate. The backing panel B is fixed to a wall backing α by a fixing tool β such as a nail, and the decorative panel C is fitted/adhered between engaging projections 4 of the backing panel B through an adhesive layer 11, and execution work is completed. Therefore, the composite panel A which is lightweight and is excellent in heat insulating performance, fire resistance and water nonabsorptivity, can be easily constituted.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to construction,
The present invention relates to a composite panel that can be used as an outer wall material or the like. More specifically, even if the core material of the base panel is an isocyanurate foam, the fire prevention structure (JIS-A-130)
1, JIS-A-1302) and fireproof structure (JIS-A-
1304). The present invention relates to a composite panel having no deformation such as swelling or warpage after production, and excellent in heat insulation and mechanical strength.

[0002]

2. Description of the Related Art In general, an inorganic decorative panel made of ceramics, tiles, or the like has a fire protection structure (JIS).
-A-1301, JIS-A-1302) and fire-resistant structure (JIS-A-1304) cannot be obtained. Is normal. However, in this case, in order to give priority to fire resistance and fire resistance, an inorganic base panel such as an extruded hollow cement plate or an ALC plate has been used. Also, there is a composite panel using a phenol foam having excellent fire resistance and fire resistance as a core material of a base panel.

[0003]

However, a composite panel using an extruded hollow cement board or an ALC board as a base panel has improved fire resistance and fire resistance.
The weight of the composite panel itself increased, and the construction became difficult, and the heat insulation performance could not be expected. In addition, in the case of a composite panel using phenol foam as the core material of the base panel, it is certainly lightweight and the fire resistance and fire resistance are improved, but the phenol foam itself has water absorption, and If the operation is poor, there is a drawback that rainwater infiltrates into the core material of the base panel and causes problems such as corrosion and generation of mold. Furthermore, phenol foam has poor adhesiveness and has a defect in integration with the surface material and the back surface material. To improve the adhesiveness, it is necessary to use a separate adhesive or to use an adhesive improving material such as a nonwoven fabric or a net. There was a disadvantage in terms of cost. Furthermore, a composite panel using only a nurate foam as a core material lacked fire prevention performance, and it was difficult to obtain a fire resistant structure (JIS-A-1304) using the composite panel alone.

[0004]

SUMMARY OF THE INVENTION In order to eliminate such disadvantages, the present invention improves the lightness, heat insulation and water absorption by using a core material of a base panel as a nurate foam.
In addition, a fireproof sheet is laminated in the core material to form a base panel with improved fire protection and fire resistance, and a decorative panel is laminated with a plurality of engaging projections formed on the base panel via an adhesive layer to form a composite panel. Therefore, a composite panel that can be easily composited is proposed.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a composite panel A according to the present invention will be described below in detail with reference to the drawings. That is, the composite panel A has a cross-sectional shape as shown in FIG. 1 and FIG. 2 which is an enlarged view of the connecting portion of FIG. 1, and is roughly divided into a base panel B and a decorative panel C.

The base panel B functions as a base / fixing material for a decorative panel C described later. As shown in FIG. 3, the core material 3 is sandwiched and integrated with the front material 1 and the back material 2. In addition, one or more layers of refractory sheet D
It is a long one interposed. In the figure, in order to prevent a thermal bridge, the front surface material 1 and the back surface material 2 are sandwiched so as not to contact with each other.

The surface material 1 and the back surface material 2 are thin metal sheets having excellent fire resistance and fire resistance, such as iron, aluminum, copper, stainless steel, titanium, aluminum / zinc alloy-plated steel sheets, galvalume steel sheets, enamel steel sheets, clad steel sheets, and laminated steel sheets. (PVC steel sheet, etc.), sandwich steel sheet (damping steel sheet, etc.),
(Of course, these include color plates painted in various colors)
Is formed by roll forming and press forming.

Further, a fire prevention structure (JIS-A-1301,
Composite panel A that can acquire only JIS-A-1302)
In the fire prevention structural test, since there is no heating test from the back side, the backing material 2 is made of aluminum vapor-deposited paper, asbestos paper, kraft paper, asphalt felt, metal foil (A
l, Fe, Pb, Cu), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper, aluminum hydroxide paper, glass fiber non-woven fabric, etc., or a laminate of two or more kinds,
Alternatively, it can be formed from a sheet-like material subjected to a waterproof treatment and a flame retardant treatment.

The core material 3 mainly functions as a bulking material, a heat insulating material, and a fireproof material for the composite panel A. The core material 3 is made of an isocyanurate resin as a main material, and if necessary, a flame retardant material (water). Aluminum oxide, calcium silicate, ammonium polyphosphate, expandable graphite, etc.), foaming agent, and curing agent are mixed, and heated, reacted, cured, and cured to form a foam having a density of about 20 to 200 kg / cubic meter. It becomes. As a foaming agent, an alternative fluorocarbon (141b) may be used, but from the viewpoint of environmental protection, a foaming agent such as carbon dioxide or cyclopentane is used.
Non-fluorocarbon foam is preferred. The composite panel A integrates the surface material 1, the back surface material 2 and the core material 3 by the self-adhesive property of the core material 3.

Further, a flame retardant such as aluminum hydroxide or ammonium polyphosphate is mixed with the isocyanurate resin in a fixed ratio (about 3 to 30 parts by weight when the isocyanurate resin is 100 parts by weight) to form the core material 3. Thereby, the fire resistance and fire resistance performance of the core material 3 can be significantly improved.

As shown in FIGS. 1 and 2, a plurality of convex engaging projections 4 made of an elastic material are formed on the surface material 1 at arbitrary intervals. The engagement projections 4 function as a guide for attaching a decorative panel C described later, and also function as a joint filler between the decorative panels C.

The engaging projection 4 is made of, for example, a material having a certain degree of elasticity, such as foamed polyethylene, chloroprene rubber, EPT rubber, synthetic rubber bead, bond breaker,
It is a commercially available product such as EPDM and urethane foam. Furthermore, since the engaging projections 4 have a certain degree of elasticity, even if the decorative panel C described later is out of order due to manufacturing errors, deformation due to aging, and irregularities such as unevenness of the wall base α, it does not matter. It can follow and maintain the waterproofness and weather resistance, and does not impair the aesthetics. The pitch of the engaging projections 4 is determined in accordance with the width of the decorative panel C, which will be described later, and is attached to the surface material 1 by using an adhesive (not shown) separately or by using the engaging projections. 4 is integrally fixed by using a means such as self-adhesive property or heat fusion.

The refractory sheet D is placed in the core 3 (in the figure, the core 3
(Intermediate part of the core material). One or more layers are laminated, and are laminated together when the core material 3 is formed.

The structure of the refractory sheet D is, as shown in FIG. 4 (a), a long sheet having a total thickness of about 0.5 to 10 mm. A core 7 formed by binding at least a graphite component and an inorganic fiber with a synthetic resin is sandwiched between a skin 5 and a back skin 6 formed of a nonwoven fabric.

The skin 5 and the back skin 6 are made of a non-woven fabric. As the non-woven fabric, polyester-based, nylon-based, boron-based,
A sheet-like material made of carbon-based, alumina-based, silicon carbide-based, and aramid-based fibers, which serves as a protection and holding material for the refractory sheet D, and which functions as a protective layer for the core 7 as described below, while improving strength. It is.

The core 7 has a composition in which a graphite component and an inorganic fiber are bound with a phenol resin. The graphite component is made of, for example, a carbon compound such as graphite (expandable or non-expandable) or carbon black, and when heated, carbonizes to form a heat insulating layer and hinder heat conduction. The graphite component accounts for about 50 to 80% of the weight ratio of the entire core 7.

As an example of the inorganic fiber, a fibrous material 8 made of an inorganic compound having high heat resistance such as glass fiber, ceramic fiber, rock wool, and asbestos, as shown in FIGS. 5 (a) and 5 (b). By intertwining or twisting
The refractory sheet D has a function of imparting some strength, flexibility and elasticity (handling). By doing so, as shown in FIG. 4 (b), the refractory sheet D can be wound in a coil shape, and transport, transportation, and manufacture of the composite panel A are easy and efficient. The inorganic fibers occupy about 5% to 20% of the weight ratio of the core 7.

The phenol resin functions as a binder between the graphite component and the inorganic fiber, and has high fire resistance and fire resistance. Further, by binding the graphite component and the inorganic fiber with a synthetic resin phenolic resin, the refractory sheet D has flexibility,
Plasticity and elasticity are taken into account, and the refractory sheet D can be easily wound up or formed into a coil shape, and is very easy to handle. The phenolic resin accounts for about 10% to 30% of the weight ratio of the core 7.
%.

The skin 5, back skin 6, core 7, and fibrous material 8 can also be impregnated, dusted, or mixed with aluminum hydroxide powder or phenol resin particle powder. The size of the aluminum hydroxide powder is about 10 to 1000 μm, and releases water of crystallization under high heat to cool the surroundings. The phenol resin particles function as a cushioning material, a heat insulating material, and a refractory material, and have a size of about 10 to 1000 μm, and are carbonized under high heat and function as a skeleton of a carbonized layer.

When the surface of the composite panel A is heated and exposed to a high temperature, when the given heat reaches the refractory sheet D, the refractory sheet D transfers the heat to the refractory sheet D. It has the property of causing heat to propagate in the horizontal direction. This prevents heat from reaching the back side,
It has a very high heat resistance effect.

The decorative panel C mainly functions as a decorative material on the surface, and is formed in a long plate shape, for example, as shown in FIG.
It comprises a decorative surface 9 and a back surface 10. The decorative surface 9 is a portion that appears on the front surface as a decorative surface of the entire composite panel A, and the back surface 10 is provided with an adhesive layer 11 as shown in FIG.
It is a portion that is mounted and fixed between the engaging projections 4 on the surface material 1 of the base panel B, and is thereby integrated as a composite panel A including the base panel B and the decorative panel C.

The adhesive layer 11 is for integrally fixing the decorative panel C to the base panel B, and is formed in a layer shape, a line shape, a net shape, and a wave shape with a thickness of about 0.2 to 5 mm. In particular, cement mortar, epoxy mortar, or other synthetic resin adhesive is used as the adhesive layer 11, but is soft just before the adhesion, facilitates adjustment of the mounting position of the decorative panel C, and has a large adhesive force by pressing. It is preferable that the properties are accelerated, and that the ingredients do not deteriorate due to moisture or vibration. Specific examples of the adhesive layer 11 include:
For example, an epoxy resin-based adhesive that is a two-part, room-temperature curing type is used.

The adhesive used for the adhesive layer 11 includes, for example, a main component of an epoxy resin and an inorganic filler, and a main component of a curing agent comprising a modified polyamidoamine and an inorganic filler.
Liquid type, initial curing time 5 minutes to 1 day, tensile shear adhesive strength 1800 to 2200 (N / cm ² ), T
Mold peel adhesion strength 5-60 (N / 25 mm), water absorption rate 0.
Use about 1 to 3.0%. The adhesive layer 11
By using a material that does not fall off or slip off even immediately after attaching the decorative panel C, the workability can be greatly improved.

The decorative panel C is made of an inorganic raw material such as a cement plate, a calcium carbonate plate, a calcium silicate plate, a ceramic plate, a wood chip cement plate, a magnesium carbonate plate, etc., or glass fiber, whisker,
Aramid fiber, steel fiber, carbon fiber, various mineral fibers, various aggregates, etc. are mixed and formed by extrusion molding, press molding, injection molding, papermaking method, etc., or various fibers are cross-shaped or three-dimensionally formed. Weaving, impregnating this with cement, clay, etc. and drying it into a panel shape,
It is made of steam cured and fired.

Next, an example of construction of the composite panel A according to the present invention will be described. First, as shown in FIG. 7, the edges of the base panel B are sequentially laid on the wall base α in the direction from the base toward the eaves, and the upper and lower ends of the base panel B are fixed with a fixing tool β such as a nail. Use and fix. At this time, it is preferable to attach a waterproof tape E to the joint between the base panels B in order to improve waterproofness and airtightness.

Then, as shown in FIG.
Brushing the adhesive layer 11 on the surface material 1 between the engaging projections 4 of
It is formed by spraying or the like. Then, as shown by the arrow, the back surface 10 of the decorative panel C is brought into contact with the adhesive layer 11,
The decorative panel C is fitted between the engaging projections 4 and pressed to attach and fix the decorative panel C to the base panel B, thereby completing the construction.

The above is an embodiment of the composite panel A according to the present invention. The composite panel A may be a combination of the members shown in FIGS.

That is, the composite panel A shown in FIG. 9 is one in which the decorative panel C is fixed on the surface material 1 of the base panel B in advance at the factory shipment stage. In this case, only the decorative panel C that straddles the connecting portion between the base panels B needs to be installed, which improves the efficiency of the installation.

FIGS. 10 and 11 are cross-sectional views showing other examples of the base panel B. FIG. 10A shows an example in which a refractory sheet D is laid on the surface material 1 inside the core material 3. FIG. 10B shows an example in which a plurality of layers of the refractory sheet D are laminated in the core material 3.
FIG. 10C shows an example in which the tongue piece 12 is formed by bending each of the surface material 1 and the back surface material 2 at both ends of the base panel B into an L shape so that the core material 3 does not appear on the surface. ) Is an example of the base panel B which can be used as a waterproofing material, an airtight material, and a cushioning material at the joint of the base panels B by attaching a packing material 13 made of the same material as the engaging projections 4 to at least one end. It is.

FIGS. 11 (a) to 11 (c) show a male connector 14 and a female connector 15 formed at both ends to enhance the connection force. FIG. FIG.
FIG. 11B shows an example of the base panel B formed in an insertion shape, and FIG.

FIG. 12 is an explanatory view showing another example of the adhesive layer 11, in which a double-sided adhesive tape is used as the adhesive layer 11. That is, at the construction site, the adhesive layer 11 can be easily formed simply by peeling off the release paper 16 as indicated by the arrow, and the workability is improved.

FIG. 13 is an explanatory view showing another example of the refractory sheet D. FIG. 13A shows an example in which a plurality of through holes 17 are formed, and FIG. And it is an example of the refractory sheet D consisting only of the core 7.

FIG. 14 is an explanatory view showing another example of the decorative panel C, in which an antibacterial layer 18 subjected to antibacterial treatment is integrally laminated on the surface of the decorative surface 9. This antibacterial layer 18
For example, it is made of a silver-based inorganic antibacterial material, and is obtained by blending silver ions with glaze, applying the mixture to the surface of the decorative panel C, and firing the panel. The silver ions kneaded in the glaze suppress the propagation bacteria adhered to the surface by the oligodynamic effect, thereby preventing the growth, and these effects act semipermanently.

Further, the same antibacterial effect can be obtained by baking and fixing a thin film of titanium oxide or a copper compound on the surface of the decorative panel C instead of the glaze containing silver ions. Of course, these members can be combined to form a composite panel A.

[0035]

As described above, according to the composite panel of the present invention, since the core material of the base panel is made of a nurate foam, it is excellent in light weight, easy in construction, heat insulating performance is improved, and water absorption is improved. The problem of is solved. Since the fireproof sheet is laminated in the core material of the base panel, the fireproof sheet propagates heat in the horizontal direction, prevents heat from being transmitted to the back of the base panel, improves heat resistance, and foams the fireproof sheet. By doing so, a carbonized layer can be formed, and high fire resistance can be maintained over a long period of time, so that a composite panel that can obtain a fire prevention structure and a fire resistance structure even when the core material is a nullate foam. Since the decorative panel is fitted between the engaging projections of the base panel and integrated as a composite panel,
The workability is improved, and a composite panel that is easy to composite is obtained. The engaging projections have a certain degree of elasticity, so even if the decorative panels are out of order due to manufacturing errors, deformation due to aging, or irregularities such as irregularities in the wall base, they can follow the irregularities and are waterproof. While maintaining the weatherability and weather resistance
There is no loss of aesthetics. There are features and effects such as.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a typical example of a composite panel according to the present invention.

FIG. 2 is an explanatory view showing a typical example of a composite panel according to the present invention.

FIG. 3 is an explanatory diagram illustrating an example of a base panel.

FIG. 4 is an explanatory view showing an example of a fireproof sheet.

FIG. 5 is an explanatory view showing an example of a fireproof sheet.

FIG. 6 is an explanatory diagram showing an example of a decorative panel.

FIG. 7 is an explanatory view showing a construction example.

FIG. 8 is an explanatory view showing a construction example.

FIG. 9 is an explanatory diagram showing another example of the composite panel.

FIG. 10 is an explanatory view showing another example of the base panel.

FIG. 11 is an explanatory diagram showing another example of the base panel.

FIG. 12 is an explanatory diagram showing another example of the adhesive layer.

FIG. 13 is an explanatory view showing another example of the fireproof sheet.

FIG. 14 is an explanatory view showing another example of the decorative panel.

[Explanation of symbols]

 Reference Signs List A Composite panel B Base panel C Decorative panel D Fireproof sheet E Waterproof tape α Wall base β Fixture 1 Surface material 2 Back material 3 Core material 4 Engagement protrusion 5 Skin 6 Back skin 7 Core 8 Fiber 9 Decorative surface 10 Back surface 11 Adhesive layer 12 Tongue piece 13 Packing material 14 Male connector 15 Female connector 16 Release paper 17 Through hole 18 Antibacterial layer

Claims (1)

[Claims] 1. A core material made of isocyanurate foam is sandwiched between a surface material and a back material, and a plurality of convex engaging projections made of an elastic material are formed on the surface material at arbitrary intervals. A composite panel comprising: a base panel in which a refractory sheet is integrally laminated in a material; and a thin, inorganic decorative panel laminated between engagement projections formed on a surface material of the base panel.