JPS5930543B2 - Composite panel with fire resistance - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention protects a combustible synthetic resin foam layer from high temperatures by stably laying a fireproof layer on the back side of the surface material in a composite panel exposed to high temperatures. The present invention relates to a composite panel having fire resistance.

In general, the heat resistance of synthetic resin foams, such as polyurethane resins, is said to be around 100° C. under normal continuous use. However, despite its low heat resistance, it is widely used as a core material for building materials due to its excellent physical properties, such as being lightweight, self-adhesive, and processable. There is. Many methods for improving this heat resistance have been published to date, but a common drawback of these methods is that they lead to a decrease in the expansion ratio of the resin. By adding so-called foreign substances having different specific gravity, bulk, and shape, or by adding a flame retardant, the expansion ratio can be significantly lowered than that of the resin alone. In other words, the increase in the amount of foam raw material adhering to these foreign materials, the reaction, and the foaming is slight, and the above foreign materials have an adverse effect on the foam raw material, which changes from a liquid state to a solid within 1 to 3 minutes. Since it is impossible to add the foam without adding it, the degree of contribution to the effective expansion ratio inevitably decreases, and the addition of two refractories causes an increase in cost due to the increase in the amount of resin used as a foam raw material.
3. Mixing refractory materials forces the resin body of combustible materials to become flame-retardant, which increases the amount of smoke generated; 4. Distributing the above-mentioned foreign substances evenly in the synthetic resin foam increases specific gravity, bulk, This is difficult due to the size, and conversely, uneven distribution increases weak points in fire resistance. Therefore, the overall fire resistance is reduced, and there is an urgent need to solve these problems. In addition, in composite panels, there are many oil cans (pekotsuki) that occur on the decorative surface of the surface material, which can be called the face, due to residual stress etc. during roll forming of the surface material, which is disadvantageous because it deteriorates the appearance and increases the rate of defective products. It was hot. The present invention is the result of extensive research aimed at easily solving these problems.

The first purpose is to upgrade the fire resistance, the second purpose is to minimize the problems 1 to 4 above, and the third purpose is to suppress oil can on the surface material and improve the mechanical strength of the panel. It is. The composite panel according to the present invention will be explained in detail below using the drawings.

FIG. 1 shows a schematic cross-sectional view of a composite panel according to the invention.
In the figure, 1 is a surface material made of a thin metal plate such as a surface-treated steel plate, an aluminum plate, a copper plate, a stainless steel plate, etc.
A large number of irregularities 3 are formed on the decorative surface 2.

As shown in the enlarged view in Figure 2, the shape of this unevenness can be a hemisphere (as shown), a rectangle, a square, a circle, or other irregular shapes (
(not shown), and one or more of these may be arranged randomly or systematically. The above-mentioned irregularities are provided to ensure that the refractory granules are present in a stable position, and also to apparently suppress the oil can. Furthermore, the surface material with the uneven shape can increase the rigidity due to work hardening and increase the bending stress due to the increase in the section modulus. In other words, the mechanical strength (bending strength, shear strength) is stronger than that of a flat plate, and when it becomes long (12 shaku), it becomes strong against buckling. Note that the height difference of this unevenness is up to about 1 cfrL, preferably 0.
It is about 3 to 0.7 mm. 4 is a fireproof layer that improves heat insulation and fire resistance and functions as a backup material for decorative surfaces.

A specific example thereof is provided with one layer or two or more layers (not shown), as partially enlarged in FIGS. 2a to 2d. That is,
Figure a shows a case where the fireproof layer 4 is composed of one type of refractory granules 5, inorganic porous particles 5a, and an inorganic material 6a that foams when heated, which is a type of inorganic material 6. Figure b shows a case where the fireproof layer 4 is composed of an inorganic material. When composed of porous grains 5a and special pearlite grains 5b, so-called refractory granules 5, and the above-mentioned inorganic material 6a, Fig. c shows that the refractory layer 4 is composed of inorganic porous grains 5a and glass fiber 6b which is one type of inorganic material 6. Figure d shows the case where the fireproof layer 4 shown in figure b is further mixed with glass fibers 6b. In addition, the inorganic material 6a and the glass fiber 6b that foam when heated are inorganic porous particles 5a or special pearlite particles 5.
It is interposed only between b and in such a way that it does not have too much of an adverse effect on the reaction of the resin, which will be described later. More specifically, the inorganic porous grains 5a are made of pearlite grains, fired vermiculite, and shirasu balloons, and the special pearlite grains 5b are inorganic materials that foam at high temperatures or non-foaming materials on the surface or internal voids of the inorganic porous grains 5a. impregnated with one or more of
Semi-impregnated, filled, or coated with PVA.
It is a granular material coated with resin such as CMC, acrylic resin, alkyd resin, paraffin, etc. To explain further, examples of the inorganic material 6a that foams upon heating include sodium silicate powder, sodium meta-silicate, sodium borate, sodium meta-borate,
Borax, a hydrated mixture of one or more of these, or an intermediate mixture thereof. Note that the intermediate product mixture is an appropriate combination of three components: XNa2O, YB263, and ZH2O. Also, x, Y. z is a coefficient. When this type of inorganic material is exposed to high temperatures, it releases crystal water and gradually foams and expands to form an inorganic foam layer.
Protect flammable synthetic resin. In addition, non-foaming inorganic materials include sodium carbonate, sodium bicarbonate, calcium sulfate, calcium hydroxide, aluminum hydroxide, alum, zinc borate, diatomaceous earth, and kaolin clay, which are used to replenish crystallized water at high temperatures. , Prevention of fluctuation of the inorganic porous particles 5a, so-called reaction of the synthetic resin raw material, lightweight materials with a specific gravity of about 0.3 during foaming usually move significantly due to the foaming pressure of the synthetic resin raw material, and suppress the increase in bulk. However, the movement of lightweight materials is appropriately suppressed using inorganic materials, and the weight is reduced despite the addition of refractory granules and inorganic materials. In addition, in order to impregnate, semi-impregnate, or fill inorganic porous particles with this kind of substance, substances that melt at 100°C or less or substances that are soluble in water should be melted and passed through the surface, pores, and pores of the porous particles to the interior of the porous particles. exist in the void. Also, impregnation, semi-impregnation, and filling are performed depending on the purpose. Impregnated means a state of coating that adheres only to the pores on the surface of the inorganic porous grains 5a, and semi-impregnated means a state in which the substance is present up to about half of the internal voids of the inorganic porous grains 5a. .
Moreover, filling means a state in which the substance is present in all the voids of the inorganic porous particles 5a. Reference numeral 7 denotes a synthetic resin foam layer, which fixes the components together through its self-adhesive properties when the synthetic resin raw material is foamed.

This synthetic resin is thermosetting, preferably room temperature curing type such as polyurethane resin. Reference numeral 8 denotes a sheet-like backing material, such as aluminum foil, a laminate of paper and metal foil, asbestos paper, a sheet-like material made of a laminate of asbestos paper and aluminum foil, and the like.

Next, an example will be explained. Example 1 polyurethane resin 100 parts by weight Inorganic porous grains (pearlite grains, flat,.

Inorganic material (borax, average grain size 3 mmφ) (borax, average particle size 150 mesh, 20 parts by weight) Therefore, hemispherical irregularities (depth 0.7 mm) as shown in Fig. 2 were formed on an iron plate (0.3 m TIL). Then, a refractory layer is formed thereon by interposing pearlite grains 5a and borax 6a in the spaces between the pearlite grains 5a, as shown in FIG. 2a.

Next, the above raw material is discharged and laminated on top of it, and 0.3
m77! Thick noncombustible sheet materials (made of asbestos paper and aluminum foil) are stacked and heated and pressurized using a caterpillar type molding machine (not shown) to form the cross section shown in Figure 1. A panel with a thickness of 10 mm was manufactured.

Therefore, we aimed the steel plate side of this panel toward the flame and
When the surface test of IS-A-11321) was conducted, the characteristics were found to pass. Example 2 Mixing Ratio These components were arranged in the structure shown in FIG. 2e.

Note that the pearlite grains 5a and special pearlite grains 5b are mixed, and glass fibers 6b are interposed between the grains. Therefore, when this was exposed to flame in the same manner as in Example 1, it exhibited performance that passed the test as a quasi-noncombustible material. Moreover, in this case, the sodium metaborate impregnated into the pearlite grains 5b is
It melts from about 4° C. and begins to flow out from the pearlite grains 5a.

Then, as a large amount of non-flammable gas (water vapor) is released, it gradually becomes viscous and begins to foam at 120 to 160°C, and the pearlite grains 5a are bridged with an inorganic foam layer mixed with glass fiber as a reinforcing material, and the iron plate and A heat-insulating, non-combustible, fire-resistant foam layer was formed between the resin foam layers, demonstrating sufficient fire-resistance performance. The characteristics of Examples 1 and 2 and the conventional example according to JIS-A-1321 are shown in the table below. The conventional example is a composite panel whose core material is a polyurethane foam in which only pearlite 5a is dispersed in an average amount of 20 parts by weight. What has been described above is only one embodiment of the present invention, and the adhesive may be applied and then the refractory granules may be laid down.

Furthermore, well-known catalysts, flame retardants, etc. can be added to the resin. In addition, the special pearlite grains 5b described above may be impregnated with an organic substance if necessary. The organic substances include PVA (polyvinyl alcohol), CMC (carboxymethylcellulose), starch, etc., and the impregnation and filling amount of the foaming inorganic material and non-foaming inorganic material are adjusted depending on the purpose. Furthermore, this organic substance suppresses a decrease in water content such as crystal water of these inorganic materials. As described above, according to the fire-resistant composite panel of the present invention, the unevenness is provided on the non-combustible base material in order to provide mechanical reinforcement and to stably support the fire-resistant/surrounding granular material, so that it appears that the oil can The defective rate has naturally disappeared.

In addition, the refractory granules are physically firmly fixed to form a refractory layer, thereby suppressing melting and combustion of the flammable resin foam. Of course, since the fireproof layer is provided inside the foam, it functions as a filler and aggregate, making the core material high-density, suppressing flexibility and improving rigidity through a synergistic effect. It also contributes to eliminating the cause of oil can.

[Brief explanation of drawings]

FIG. 1 is a cross-sectional view showing an embodiment of the composite panel according to the present invention, and FIGS. 2 a to 2 d are explanatory diagrams showing the parts indicated by 4 marks in FIG. 1 separately and enlarged. be. 1...Surface material, 3...Irregularities, 4...
...Fireproof layer, 6...Inorganic material, 8...
Back material.

Claims (1)

[Claims] 1 Consisting of a surface material with small irregularities formed on at least the decorative surface of a metal plate, refractory granules laid partially buried in the irregularities on the back surface of the decorative surface, and an inorganic material interposed only between the granules. It is composed of a fireproof layer, a synthetic resin foam layer that is laminated on the granular material and is made of a backing material made of a noncombustible base material, and the surface material and the granular material are fixed together by their self-adhesive properties. A composite panel with fire resistance.