JPS5940099B2 - Method for manufacturing flame-retardant synthetic resin insulation material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is a flame-retardant foam layer that is flammable but has high heat insulation properties and excellent workability, and is protected by a dense fire-resistant layer made of inorganic porous particles and a non-combustible plate member. The present invention relates to a method of manufacturing a synthetic resin heat insulating material.

Recently, it has become lightweight, has excellent insulation properties, and is easy to construct.
Synthetic resin foams, which have excellent adhesive properties, are widely used as heat insulating materials.

However, the biggest drawback of this synthetic resin foam is that it is flammable, melts and thermally decomposes at 200 to 300°C, easily burns, and sometimes generates toxic gas. Therefore, while the demand for heat insulating materials continues to grow, there is a need for some kind of flame retardant method. Taking the case of polyurethane foam as an example, countermeasures include 1) flame retardant use of raw materials, 2 additive flame retardants, 3 lower melting point methods, 4 post-treatment methods, 5 introduction of heat-resistant structures, and 6 specific treatments. Flame retardant methods have been proposed. However, all of the above flame-retardant methods not only have drawbacks such as a decrease in flame-insulating performance, roughness of the foam structure, and increased cost, but also have the fatal disadvantage of not being able to create an insulating material structure that guarantees flame retardancy. There were flaws. In other words, in the case of the above-mentioned item 2 with uncertain factors, for example, the organic or inorganic flame retardant is dispersed in the synthetic resin foam by addition and mixing, so uniform dispersion cannot be ensured. Of course, if a large amount is added, the flame retardant will be the main ingredient and the synthetic resin foam will simply act as a binder, and while flame retardancy will improve considerably,
Disadvantages such as a significant drop in insulation performance and an increase in specific gravity were evident, which obliterated the most important feature of synthetic resin foam and caused it to no longer function as a heat insulator. In addition, all other flame retardant methods only increase the heat resistance temperature of synthetic resin foams by about 100 to 200° C. compared to conventional methods, and their reliability is also questionable. In order to eliminate such drawbacks and difficulties, the present invention provides a non-combustible plate member,
The inorganic porous particles and the net-like material are laminated in this order, and then a synthetic resin raw material containing one or more inorganic substances that foams by heating is discharged, and these constituent materials are bonded with a synthetic resin foam layer and then placed on top of the fireproof layer. The present invention provides a method for manufacturing a heat insulating material having excellent heat insulating properties and flame retardancy by integrally forming a synthetic resin foam layer on the heat insulating material.

In the present invention, the noncombustible plate member 1 is a member formed into an appropriate size and shape, such as a cement mortar board, a plaster board, a wood wool cement board, or a metal plate.

The inorganic porous particles 2 include one or more types of shirasu balloons, pearlite grains, glass balloons, anti-firestone, talc, coke, and artificial porous stone, or so-called modified porous particles obtained by subjecting these to fireproofing and heat-resistant treatment. . The synthetic resins that mainly form the synthetic resin foam layer 3 and also function as a binder include polyurethane resins, epoxy resins, melamine resins, acrylic resins, fluorine resins, urea resins, and ABS resins. Inorganic substances 4 that foam when heated and added to this synthetic resin include:
These include borax, sodium metaborate, sodium silicate, sodium metasilicate, dibasic sodium phosphate, borax, potassium silicate, and a mixture of sodium metasilicate and borax, silicate and magnesium acetate. Note that sodium silicate and sodium borate also include so-called processed boron and sodium silicate, which are obtained by controlling crystallization water or by heating slowly at a temperature that does not destroy the molecular structure. Further, this inorganic substance is discharged onto the net-like material described below in a state containing these substances through any means such as when being discharged onto the synthetic resin raw material or in a mixed state. The net-like material 5 may have various structures such as knitted synthetic resin, cotton, hemp thread, wire mesh, glass fiber, etc., formed into a non-woven fabric, or crimped or fused into a net-like material using a press. The size of the network of the net-like material varies depending on the size of the inorganic porous particles and the inorganic powder particles, but it is such that at least the inorganic porous particles 2 do not pass through the mesh of the net-like material 5. The backing material 6 is made by laminating one or more of asbestos paper, kraft paper, asphalt felt, waterproof paper, metal foil, and the like. Further, the adhesive 7 may be water glass, dendritic resin, or the like. Next, a method for manufacturing a flame-retardant synthetic resin heat insulating material (hereinafter simply referred to as a heat insulating material) according to the present invention will be explained using the drawings.

First, in the first step, as shown in FIG. 1a, inorganic porous particles 2 are dispersed on one side 1a of a noncombustible plate member 1 in a dense distribution using any means. The second step is the first
As shown in Figure b, a net-like material 5 is stretched over the inorganic porous particles 2. This net-like material 5 prevents the porous particles from being displaced and moved by the foaming of the synthetic resin raw material as described below, and has a reinforcing function, and as a result, the inorganic substance 4 contained in the synthetic resin raw material. This net-like substance is used as a filter and is distributed more densely than other parts. The third step is to mix the unfoamed synthetic resin raw material with the inorganic substance 4 and discharge it evenly onto the net-like material 5. In this case, the inorganic substance 4 and the synthetic resin raw material can be mixed, for example, by mixing the synthetic resin raw material and the inorganic substance 4 and then discharging it onto the net-like material 5, or by sprinkling the inorganic substance 4 on the discharge area of the raw material and discharging it during foaming. There are various methods such as mixing by foaming pressure and flow. In the fourth step, as shown in FIG. 1d, the synthetic resin raw material is foamed, the inorganic substance 4 is distributed more densely in the net-like material 5 than in other foamed layer parts, and the inorganic porous particles 2 are foamed. At the same time, the foamed synthetic resin layer 3 containing the inorganic substance 4 is formed on the net-like material 5 at once. At this time, some of the inorganic substance 4 is distributed between the inorganic porous particles depending on its fluidity. Next, this synthetic resin foam layer is laminated with a backing material 6 during foaming, is fed into a mold such as a caterpillar, and is taken out after curing for several minutes. A heat insulating material produced in this manner is shown in FIG. 1e. Another invention of the method for manufacturing a heat insulating material according to the present invention is to provide an adhesive 7 application step as shown in FIG. 2a before the step a in FIG. As shown in Figure 1a, it is densely dispersed, and as a result, the second
It was formed as shown in FIG. b, and the subsequent steps were performed in the same manner as in FIG.

Next, an example will be explained. Therefore, we used a colored iron plate with a thickness of 0.27 mm as a noncombustible plate member, an asbestos sheet as a backing material, and a polyurethane resin (100 mm) as a synthetic resin.
(parts by weight), 30 meshes of borax (10 parts by weight) and 30 meshes of sodium metaborate (20 parts by weight) as inorganic substances are prepared.

In addition, the inorganic porous particles are pearlite particles with a particle size of 5 m, and the net-like material is glass fiber nonwoven fabric with a mesh size of about 10 mm.
Metsuyu was used. Using this component, the heat insulating material shown in FIG. 1e was manufactured by sequentially performing the first to fourth steps. When this heat insulating material is cut and observed, it can be seen that the pearlite particles 2 are reliably laid in a dense distribution between the one side 1a of the noncombustible plate member 1 and the net-like material 5 without any so-called absent areas (defect areas). The voids between the particles were filled and bonded with a portion of the synthetic resin. In addition, the inorganic substance 4 is distributed more densely in the net-like material 5 as a filter than in the other synthetic resin foam layer parts, and a second fireproof layer is formed due to the fluidity during foaming. Ta. Furthermore, the synthetic resin foam layer 3 containing an inorganic substance formed above the net-like material 5 has a foam structure that is not very rough, exhibits considerable heat insulation performance, and also has a certain degree of flame retardancy.
Furthermore, since the synthetic resin raw material was used to combine all components at once, the integration was ensured. In addition, in terms of resin economy, the oil-absorbing pearlite grains 2 were brought into contact with areas where the formation of a synthetic resin foam layer was not expected, using a so-called binder, resulting in a significant improvement. Next, when observing the flame retardancy, the color iron plate surface was 900'
It was exposed to the direct flame of C for 5 minutes and then cut. In this case, almost no smoke or ignition was observed. Then, when the colored iron plate was peeled off and observed, it was found that the skin layer 3a of a synthetic resin with a low foaming structure that was in contact with the colored iron plate had partially turned dark black, but had not decomposed. Moreover, some inorganic substance 4 was mixed in this skin layer as well. And borax is 7
It melts at 5℃, and sodium metaborate melts at 54℃, so it melts due to the above heat, and its moisture cools the surrounding area,
The viscosity of the melt gradually increased, and a slight inorganic foam layer was formed using the synthetic resin foam layer as a skeleton. Furthermore, when the colored iron plate was peeled off and this surface was exposed to 900°C for 10 minutes, most of the synthetic resin between the pearlite particles was burned, and a large amount of inorganic material 4 present in the net-like material 5 was replaced. It melts and flows out, adheres to the outer periphery of pearlite, and reliably fills pearlite particles through an inorganic foam layer.
It was a bridge. Moreover, the pearlite grains are fired at 15,000C or higher, and the inorganic foam layer has a heat resistance of 900 to 9,600C. Therefore, the synthetic resin foam layer located deeper than this was protected by this inorganic heat insulating layer, and no smoke or ignition was observed. What has been described above is only one example of the method for producing a heat insulating material according to the present invention, and the present invention also includes a method for producing a heat insulating material to which an inorganic substance that does not foam when heated, such as pearlite grains or aluminum hydroxide is added. included in.

As described above, according to the method for manufacturing a heat insulating material according to the present invention, an inorganic heat insulating layer made of inorganic porous particles can be reliably formed between one synthetic resin foam layer and a noncombustible plate member without defects.

In other words, the lightweight inorganic porous particles with high bulk specific gravity can be held down by the net-like material without displacement or movement during foaming of the synthetic resin. 2. A second fireproof layer can be formed on the net-like part by utilizing the behavior of the synthetic resin raw material.

3. Excellent fire resistance because the inorganic material that foams under high heat is densely distributed near the layer of inorganic porous particles.

4.Inorganic substances that contribute to improving flame retardancy are distributed in the synthetic resin foam layer that acts as a heat insulating layer at a low density without damaging the foam structure, improving resin economy.

5. Workability, processability, and mechanical strength were significantly improved because all the constituent materials were bonded together using the unfoamed synthetic resin raw material, and a high heat insulating layer could be formed all at once.

[Brief explanation of drawings]

FIGS. 1a-e and 2 are enlarged vertical cross-sectional views for explaining the method of manufacturing a flame-retardant heat insulating material according to the present invention. 1...Nonflammable plate member, 2...Inorganic porous particles, 3...Synthetic resin foam layer, 4...
・Inorganic substances, 5...Net-like substances.

Claims (1)

[Scope of Claims] 1. A first step of dispersing inorganic porous particles on one side of a noncombustible plate member in a dense distribution, and a mesh-like net that prevents the particles from passing over the inorganic porous particles. a second step of stretching a net-like material; a third step of discharging an unfoamed synthetic resin raw material containing one or more types of inorganic substances that foam by heating onto the net-like material; The non-combustible plate member, the inorganic porous particles, and the net-like material are bonded together, and the inorganic substance, etc. is distributed at high density in the net-like material portion by the fluidity during foaming, and the inorganic material, etc. is distributed on the net-like material. A fourth layer forming a synthetic resin foam layer containing
A method for producing a heat-retardant synthetic resin insulation material, comprising the steps of: 2. The flame-retardant synthetic resin according to claim 1, further comprising an adhesive coating step of spraying and fixing inorganic porous particles after spraying a non-flammable adhesive on one side of the non-flammable plate member. Method of manufacturing insulation material.