JPS5839990B2 - flexible construction board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a lightweight, flexible building board useful as a covering material for ceilings, walls, and columns of buildings, and having excellent heat insulating properties and workability.

Conventionally, there is a V in the middle of flexible architectural boards, so-called board bodies.
Architectural boards are known in which a character shape is formed and this is used as a protruding corner, which is efficient and can be constructed even by an amateur.

For example, as in Utility Model Publication No. 28-9295, a middle board, a top board, etc. are laminated together with adhesive on the surface of the core material, V-shaped grooves are bored in arbitrary places, and V-shaped grooves are cut in arbitrary places. There are architectural parts that have been bent.

However, in the case of this member, the components are made of wood,
In addition, adhesive must be used to integrate them, and there are problems with weight, strength, brittleness, heat insulation, workability, changes in physical properties (changes over time), and workability, so it cannot be advantageously adopted industrially. There was a difficult side to it.

In view of this, it is thought that there are members of this type whose core material is made of polystyrene, glass wool, or the like.

However, this alone only partially improved the above-mentioned problems and was not satisfactory.

In order to solve these drawbacks, the present invention has a core material whose surface is flexible and also contains moisture, and is integrally formed through the self-adhesive properties of the core material when forming the foam. forming at least one V-shaped groove with a depth of 90 to 80% of the total thickness of the synthetic resin foam from the back side of the foam to the front surface of the synthetic resin foam; The foamed structure of the synthetic resin foam in the area where the sheet is in contact with the sheet material is an open-celled foam structure, making it lightweight, easy to work with, easy to process, and
We propose a flexible construction board with excellent workability.

DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of a flexible construction board according to the present invention will be described in detail below with reference to the drawings.

In FIG. 1, 1 is a synthetic resin foam (hereinafter simply referred to as foam) that mainly functions as a core material, heat insulator, and adhesive, and 2 is a sheet-like material that serves as a decorative material.
It has a structure that contains water within its tissue.

In particular, the back side has a structure where the material is directly exposed.

3 is a V-shaped groove, and the form 1 is cut at an arbitrary angle θ with a cutter (not shown) from the back side 1a of the form 1 to the front side.
It is formed by engraving to a depth D within 90 to 80% of the total thickness T.

To explain in more detail, the foam 1 mostly consists of a hard part with a closed cell structure and a soft part with an open cell structure in the vicinity of the sheet material 2 in contact with the sheet material 2, and the hard part and the soft part are in a continuous state. It is formed at the above-mentioned ratio to the total foam thickness T under the foamed structure.

In other words, the foam 1 is hard in the range of 90 to 80% of the thickness from the back surface 1a to the front surface 1b, and the remaining 10 to 20% of the thickness Δt is the foam that contacts the so-called sheet-like material 2. From the front side 1b of form 1 to the back side 1a of form 1
A portion corresponding to 10 to 20% of the total thickness T of the form 1 is a soft portion.

Furthermore, the soft portion of the foam 1 is formed when the foam 1 is formed.

Furthermore, the foam 1 also functions as an adhesive that adheres integrally to the sheet-like material 2 due to its self-adhesive properties when the foam 1 is formed.

To explain further, Form 1 is made by using a raw material having a proportion of polyisocyanate that is highly reactive with moisture, and by causing the polyisocyanate to react with the moisture present in the contact area of the sheet-like material 2 that comes into contact with the polyisocyanate. As described above, a soft part of the open cell structure different from the original structure is formed on a part of the surface in the same foam 1 in the distribution described above.

Furthermore, the softened foam structure has flexibility and cushioning properties, so it can be easily bent by about 90 degrees, and the structure does not break even when folded.Moreover, the cushioning property acts on the folded part, so it can be shaped like a sheet. It is possible to remove irregularities in the appearance of the bent portion of the object 2.

Therefore, specific examples of the above-mentioned foam 1 include polyurethane foam raw materials, polyisocyanurate foam raw materials,
These include polyimide foam raw materials, polyamide foam raw materials, etc.

Further, the sheet-like material 2 is integrally laminated on the surface 1b side of the form 1, and mainly contains the decorative material of the form 1,
Reinforcement material, e.g. reinforcement of bends in form 1, form 1
This is useful for reinforcing the mechanical strength of the foam 1 itself, and for softening the foam structure in the vicinity of the so-called surface 1b, the contact portion of the foam 1 with the sheet-like material 2, as described above.

That is, the sheet-like material 2 is a structure containing moisture, such as adsorbed water and free water, and this structure is the sheet-like material 2 exposed at least on the surface that contacts the foam 1, the so-called back surface 2a.

Specific examples of the sheet-like material 2 include asbestos paper, kraft paper, Japanese paper, felt, thin wood pieces, water-containing cloth (for example, glued), and sheet-like materials formed by laminating or corrugating these materials.

The thickness of the foam 1, which is altered or softened by the moisture in the sheet-like material 2, varies depending on its water content, but the thickness of the foam 1 changes from the surface 1b where the foam 1 is in contact with the sheet-like material 2 to the back surface 1a. The thickness Δt is within 10 to 20% of the total thickness T.

Furthermore, as shown in FIG. 2, the sheet-like material 2 may be laminated with a waterproof sheet 2' on the surface 2b of the sheet-like material, that is, the surface that does not contact the surface 1b of the foam 1, or a third
As shown in the figure, a film γ may be formed on the surface by waterproofing treatment to effectively block moisture from outside, reinforce the heat insulating layer, and improve the weather resistance of the sheet-like material 2. can.

As the waterproof sheet 2, polyethylene, polypropylene, nylon 1, vinyl chloride, metal foil, asphalt sheet, etc. are used.

In addition, as waterproofing treatment, synthetic resin such as transparent acrylic resin, polyester resin, etc. is applied to form a film.
Apply well-known waterproofing treatment.

Further, the V-shaped groove 3 is formed at an arbitrary angle θ, for example, 90, 12
It is engraved from the back side 1a of the form 1 toward the front side 1b using a knife at an angle such as 0° depending on the application.

The depth D of the V-shaped groove 3 is smaller than the total thickness T of the form 1 by Δ1=0.1 to 0.2T.

This is because the entire foam 1 is in a continuous state, and the continuous foam structure is made into a soft part so that it can be bent without any problem.

Of course, the number of V-shaped grooves 3 can be arbitrarily selected from 1 to n depending on the purpose.

Further, the V-shaped grooves 3 can be carved so that they intersect as shown in FIG. 4, or in a curved shape as shown in FIG. 5.

Next, a method for manufacturing a flexible construction board according to the present invention will be briefly explained using FIG. 6.

In the figure, 10 and 11 are endless upper and lower mold members, 12 is a mold, 13 and 14 are guide wheels, 15 and 16 are drive wheels, 17° and 18 are auxiliary wheels, and 19 is a sprayer for discharging synthetic resin. , mixer, or spray gun 20 with a raw material feeder 21.
22 have been contacted.

23 is a roller, and 24 is a guide roller.

Note that this device is set so that the mold 12 can be heated to about 0° C. to about 65° C. using a heating device (not shown).

Furthermore, the synthetic resin raw material is supplied heated to an appropriate temperature.

Therefore, it is assumed that this apparatus is used to manufacture a construction board having a cross section as shown in FIG. 7, that is, a sheet material 2 provided on both sides of a form 1.

Suppose now that the upper and lower mold members 10 and 11 move in the direction of the arrows, a certain width of asbestos paper is continuously moved from the left end, and the back surface 2a of this sheet-like material 2 reaches directly below the spreader 19. A mixer 20 discharges polyurethane resin, that is, polyol and polyisocyanate in a mixed state onto the back surface 2a of the sheet-like material 2 from the synthetic resin spreader 19.

Thereafter, a sheet-like material of the same or different quality as the sheet-like material 2 (same quality in the figure) is placed on top of this and transferred to the mold 12.

In this mold, the resin chemically reacts to form the form 1, and the self-adhesive properties at this time fix the constituent materials together.

In addition, in the resin raw material that is in contact with asbestos paper, a portion of polyincyanate, which has a strong dehydration effect and reactivity with water, is contained in asbestos paper prior to reaction with the polyol fraction in the contact area. Moisture, e.g. adsorbed water,
Reacts with free water.

As a result, the percent (7' reaction does not result in a urethane bond, but instead results in a urea bond.

In other words, the urea bond forms a foamed structure (soft) of open cells and has flexibility and appropriate elasticity, and such a foamed structure forms the back surface 2a of the sheet-like material 2.
It is formed by continuously changing from hard to soft at the portion where the surface 1h of the foam 1 having a closed cell structure (hard) contacts.

Next, V is placed at appropriate positions on the flexible construction board formed in this way.
Two grooves 3 are carved using a V-shaped knife (90°) as shown in FIG. 2, for example.

Note that the depth D at this time is under the conditions described above.

In order to use this flexible construction board as a ceiling board, for example, it is bent as shown in FIG.

What has been described above is only one embodiment of the present invention, and the surface of the sheet-like material 2 or the surface of the waterproof sheet 2 may be printed with an arbitrary pattern, or may be lysed using resin, inorganic substances, granules, etc. Of course, it is also possible to apply cosmetic treatments to enhance the appearance.

As described above, according to the flexible construction board according to the present invention,
■Thermal insulation properties of the core material (thermal conductivity approx. 0.0145Kcal/m
Since it has a high h'C) and is a closed cell, that is, the micro air layer is partitioned by a thin film, it has an unprecedented effect on sound absorption.

@The specific gravity of the core material is about 0.015 to 0.04, which makes it extremely lightweight, and the bulk is about 40 to 50, which is the above ■, @
contributes significantly to

In terms of bending of flexible construction boards, that is, workability and processability, since the foam is the core material, it is easy to create V-shaped grooves, and the foam layer at the bending part is soft, so the foam is easy to work with. There is no breakage due to brittleness, and the physical properties of the sheet-like material are effectively utilized to greatly improve the flexibility of the folded portion, reinforcement of mechanical strength, and improvement in appearance aesthetics.

@The advantage is that the sand inch structure does not cause the deterioration that occurs over time in wooden components.

Since the structural members are fixed together by the self-adhesive properties of the foam and the foam is formed all at once, there is no need for an adhesive, which greatly improves productivity.

O When using a sheet-like material coated with a waterproof sheet-like material,
There is almost no intrusion of moisture from the outside, and there is a great advantage in terms of the service life of flexible construction boards.

[Brief explanation of the drawing]

FIGS. 1 to 3 are longitudinal cross-sectional views showing one embodiment of the flexible building board according to the present invention, and FIGS. 4 and 5 are perspective views showing other embodiments of the above-mentioned building board. , FIG. 6 is a schematic configuration diagram showing an example of an apparatus for manufacturing flexible construction boards, FIG. FIG. 8 is a perspective view showing an example of use of the flexible construction board according to the present invention. 1...Synthetic resin foam, 2...Sheet-like material, 3...V-shaped groove.

Claims (1)

[Claims] 1. A plate-shaped, closed-cell synthetic resin foam in which polyisocyanate is a part, and one surface of the foam has flexibility and is adhered integrally with self-adhesive properties during the formation of the foam. The synthetic resin foam is composed of a sheet-like material containing moisture, and the foam structure in the vicinity of the synthetic resin foam that is in contact with the back surface of the sheet-like material is reduced by 10% of the total thickness of the synthetic resin foam due to the moisture. A portion within ~20% changes in quality and becomes an open cell structure, and one or more V-shaped grooves are formed from the back surface of the synthetic resin foam toward the surface toward the open cell structure, leaving the open cell structure. A flexible construction board characterized by being provided with the following features: