JPS6055471B2 - Inorganic-based foam molding with excellent fire retardant performance - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an inorganic-based foamed product having excellent fireproof performance.

More specifically, 30-55% by weight of dihydrate gypsum powder, 25
The present invention relates to an inorganic-based foamed product that is composed of ~% by weight of calcium carbonate powder, 4-13% by weight of inorganic short fibers, and 4-1% by weight of a binder, and is foamed to a specific gravity of 0.6 or less. Conventionally, gypsum board, rock wool board, or polyurethane foam to which inorganic salts have been added have been used as backing materials for metal siding materials. However, gypsum board and rock wool board have a heavy weight of 8 to 12 to 9/9, and are not easy to handle. In addition, foamed polyurethane with inorganic salts added thereto is lightweight, but has the disadvantage of being easily flammable due to its high organic content. In view of these circumstances, the inventors of the present invention conducted extensive research to obtain a backing material for metal siding materials that is lightweight, easy to handle, flammable and has excellent fire prevention performance. ,
An inorganic-based foamed product that is composed of 25-5% by volume of calcium carbonate powder, 4-1% by weight of inorganic short fibers, and 4-1% by volume of a binder, and is foamed to a specific gravity of 0.6 or less. , it was discovered that this method gave good results, and the present invention was achieved.

Note that the term "foamed molded product" as used herein means a sheet-like or plate-like molded product having a foamed structure. The dihydrate gypsum powder used in the present invention may be any commonly used gypsum, such as flue gas desulfurization gypsum, acid-prone gypsum, titanium byproduct gypsum, and natural gypsum.

There are no particular restrictions on particle size, particle size distribution, etc., but particles with a particle size of 200 μm or less are preferred. As the calcium carbonate powder used in the present invention, any of commonly used heavy and light calcium carbonates can be used. Also, grains
Although there are no particular restrictions on the diameter, particle size distribution, etc., particles with a particle size of 100 μm or less are preferred. In the foam molded product of the present invention, it is necessary that the total content of gypsum dihydrate and calcium carbonate is 55% by weight or more (preferably 70% by weight or more).

Further, the mixing ratio of gypsum dihydrate/calcium carbonate needs to be in the range of 35/65 to 70/30 on a weight basis. If it deviates from these ranges, sufficient fire protection performance cannot be obtained. Therefore, the content of dihydrate gypsum powder and calcium carbonate powder in the foamed molded product is 30-5% by weight for dihydrate gypsum powder and 25-5% by weight for calcium carbonate powder.
%, and if it is within these ranges, the above conditions will always be satisfied. In the present invention, it is necessary to use inorganic short fibers in order to obtain a foamed molded product with a specific gravity of 0.6 or less.

If inorganic short fibers are not used, it is difficult to keep the raw material of the molded product stable in a foamed state, making it difficult to produce the foamed molded product of the present invention with constant quality. Moreover, using inorganic short fibers instead of inorganic short fibers improves the foamability, but this is not preferable because the fireproofing performance of the molded product decreases. Specific examples of the inorganic short fiber include rock wool, glass fiber, asbestos, etc., but rock wool is preferred from the viewpoint of low specific gravity effect of molded products, workability, and safety and hygiene. Rock wool here refers not only to glassy fibers manufactured using natural rocks (basalt, serpentine, etc.) as raw materials, but also to mineral wool (slag wool) manufactured using iron slag as raw materials. wool). The average fiber length of the inorganic short fibers is preferably 0.5 mm or more, and the amount used should be 4 to 13% by weight in the molded product. If the amount is more than 1%, it is not preferable because not only the mold and workability deteriorate, but also the contents of dihydrate gypsum powder and calcium carbonate powder become low, resulting in poor fire protection performance.

Furthermore, if the inorganic short fibers are less than 4% by weight, the foaming stability will not be sufficient, which is undesirable. Examples of the binder used in the present invention include a water-soluble polymer mono-crosslinking agent system and a thermoplastic resin emulsion; however, migration of the resin during molding and drying is unlikely to occur; and the molded product has excellent water resistance. Thermoplastic resin emulsions are preferred because they have excellent drying efficiency during molding and drying.

Examples of thermoplastic resin emulsions include vinyl acetate polymer emulsions, acrylic polymer emulsions, vinyl chloride polymer emulsions, vinylidene chloride polymer emulsions, urethane polymer emulsions, and styrene-butadiene copolymer emulsions. Among them, vinyl acetate polymers are particularly preferred. Furthermore, as vinyl acetate polymers, in addition to vinyl acetate homopolymers, for example, copolymers with ethylene, (meth)acrylic esters, (meth)acrylic acid, maleic esters, or maleic acid can be used. It will be done. Most preferably, the vinyl acetate content is 60-95% by weight.
It is an ethylene-vinyl acetate copolymer. The content of the binder in the foamed molded product is suitably in the range of 4 to 10% by weight. If it is less than 4% by weight, the nobinder effect will not be sufficient and the foamed molded product will become brittle, which is not preferable. Also, 1
If the content exceeds 1% by weight, the fireproofing properties will decrease, which is not preferable. In addition to the above-mentioned essential ingredients, the foamed molded product of the present invention contains inorganic lightweight microspheres, a bubble entraining agent, a surfactant, a water repellent, a fungicide, a pigment, a thermosetting resin, a reinforcing material, and a heat absorption adjuvant. (boric acid, etc.) etc. can also be used in combination. In particular, the inorganic lightweight microspheres preferably have the effect of increasing the compressive strength of the foamed molded product. Inorganic lightweight microspheres include both inorganic lightweight microspheres and inorganic hollow microspheres, such as spherical pearlite, vermiculite, expanded shale, silica-alumina microballoons, microglass balloons, and microspheres. You can give whitebait balloons, etc. Silica-alumina microballoons are most preferred in terms of workability, moldability, fireproofing performance of molded products, mechanical properties, and the like. When using inorganic lightweight microspheres, it is appropriate to mix them in a range of 2 to 2 weight percent. If it is less than 2% by weight, the effect will not be sufficiently expressed, and if it is more than 2% by weight, the fireproofing performance of the molded product will deteriorate, which is not preferable.

The foam molded product of the present invention can be produced, for example, by the method described below. That is, in a suitably sized container equipped with a stirrer, binder components (e.g. thermoplastic resin emulsion), water repellent, curing agent, pigment, fungicide, various stabilizers for improving moldability, if necessary,
After adding the thickener, water, etc., while continuing to stir and mix, gradually add dihydrate gypsum powder, calcium carbonate powder, inorganic short fibers, and, if necessary, inorganic lightweight microspheres to prepare a slurry. do. Next, the specific gravity of the slurry is reduced by kneading and foaming under pressure. Next, the slurry is passed through a high-speed rotary foaming machine while injecting an emer to further foam and lower the specific gravity, and then, for example, by a doctor blade method or an extrusion method, it is cast onto a sheet base material that has been released and dried. do. At this time, to make it easier to handle, we also combined non-woven fabrics, or combined aluminum foil or aluminum-crust paper to further improve insulation! You can also. The reason why the foam molded product of the present invention has excellent fire retardant properties is not clear, but it is probably due to the heat absorption effect due to the release of crystal water of gypsum dihydrate, the heat absorption effect due to the decarbonation reaction of calcium carbonate, and the foam structure. This is presumed to be due to the synergistic effect of the heat insulation effect.

The foam molded product of the present invention is not only used as a backing material for metal siding materials, but also has a wide range of uses as a building material, either alone or in combination with other materials.

The present invention will be specifically described below with reference to Examples, but these are not intended to limit the present invention in any way.

Regarding the fire retardant properties of materials, please refer to the Ministry of Construction Notification No. 25, Showa 3.
It was tested and evaluated using the method described in No. 45.
That is, one powder from one side of the test is heated from room temperature to 840°C along the standard heating curve, the temperature is lowered again, and the maximum temperature of the side opposite to the heated side (maximum temperature of the back side) is measured. The fire resistance was evaluated. Therefore, the lower the maximum temperature on the back side, the better the fire protection. Note that all parts in the examples are based on weight.

Example 1 Dihydrate gypsum produced as a by-product from the flue gas desulfurization process is dried and passed through a 16-mesh sieve.

This gypsum dihydrate44. ? and 40.6 parts of heavy calcium carbonate (NS#100 manufactured by Nitto Funka Co., Ltd.) and 8.6 parts of Matenku Wool (S-Fiber manufactured by Nippon Steel Chemical Co., Ltd.) as an inorganic short fiber.
part, vinyl acetate-ethylene copolymer emulsion (Kuraray Panflex 0M-700) as a binder component.
0) was used as a resin, and a small amount of a bubble entraining agent, a thickener, a blowing agent, a crosslinking agent, and an organic short fiber were added, and after thorough mixing, the mixture was stirred at high speed and foamed to give a specific gravity of 0.0. 38y/Cl
1 slurry was prepared and placed on a base sheet with excellent mold releasability at a clearance of 13.4? The coating was cast using a doctor blade to form a composite non-shrinkable fabric, and then dried in a dryer at 120'C for 1 hour and 40 minutes to a thickness of 12.1Wr! n
A board-like product having a specific gravity of 0.285y/CTlt was obtained. When this sample was subjected to a fire retardant test, the maximum temperature on the back surface was 233'C. By the way, the specific gravity is 0.725
y/Cll and heavy commercially available gypsum board, each with a thickness of 9
79! The maximum temperature on the back side of the 12-meter heating test was 2862°C and 1245°C, respectively. Example 2 A slurry having a specific gravity of 0.430 Da/al obtained in the same manner as in Example 1 was coated and cast to obtain a board-like product having a specific gravity of 0.30 and a thickness of 10.0 wn.

Next, aluminum foil (20 μm thick) was attached to this board using a rubber thread adhesive (Cybinol SR-690 manufactured by Saiden Chemical Co., Ltd.) to prepare a sample. When a heating test was conducted on this sample, the maximum temperature on the back surface was 247C. Comparative Example 1 Instead of using dihydrate gypsum and calcium carbonate, only 85.5 parts of dihydrate was used, and the other conditions were the same as in Example 1, with a specific gravity of 0.
．． A slurry of 38 y/d was prepared and molded under the same conditions as in Example 1 to a thickness of 12.2 Tfr! n specific gravity 0.29
A board-like product of 4y/Cll was obtained.

The sample was subjected to the heating test described above, and the maximum temperature on the back surface was 320°C. In this way, when only gypsum dihydrate is used as a filler, sufficient fireproofing performance is not achieved. Comparative Example 2 Heavy calcium carbonate (1) Tofunka NS instead of dihydrate gypsum
#100) Thickness: 11.8Wrfn1 Specific gravity: 0
．． A board-like product of 311f/al was obtained.

A similar heating test was conducted on this sample, and the maximum temperature on the back surface was 308°C. Even when only calcium carbonate is used as a filler, sufficient fire protection performance is not achieved. Comparative Example 3 A foam molded product was made under the same conditions as Example 1, except that the amount of dihydrate gypsum powder was 65 parts and the amount of calcium carbonate powder was 20.5 parts, and the thickness was 11.9T.
A molded product having a specific gravity of 0.296 q/d and a specific gravity of 0.296 q/d was obtained.

When a heating test was conducted on the sample, the maximum temperature on the back surface was 285°C. As described above, even if dihydrate gypsum and calcium carbonate are used in combination, sufficient fire protection cannot be obtained outside the scope of the present invention. Comparative Example 4 A foam molded product was made under the same conditions as in Example 1, except that the amount of gypsum dihydrate powder was 25.5 parts and the amount of calcium carbonate powder was 1 part, and the thickness was 12.0 parts. Specific gravity 0.290J/CT
A foam molded product of I was obtained.

When the above-mentioned heating test was performed on the sample, the back surface temperature was 303°C. As described above, even if dihydrate gypsum powder and calcium carbonate powder are used outside the scope of the present invention, where the amount of dihydrate gypsum is too small and the amount of calcium carbonate is too large, sufficient fire protection performance will not be achieved. . Example 3 Dihydrate gypsum produced as a by-product from the flue gas desulfurization process was dried and passed through a 16-mesh sieve, and 41.8 parts of this dihydrate gypsum, 37.7 parts of heavy calcium carbonate Tianjin powdered NS#100), and Inorganic lightweight silica alumina microphone al〈Rune (Kyucel #200, manufactured by Philadelphia Ear Quartz Co., Ltd.) 8.4 parts,
6.3 parts of rock wool (S fiber manufactured by Nippon Steel Chemical Co., Ltd.) was used as the inorganic short fiber, and 5.8 parts of vinyl acetate-ethylene copolymer emulsion (Panflex 0M-7000 manufactured by Kuraray) was used as the binder component. In addition, a small amount of bubble entraining agent, thickener, foaming agent, crosslinking agent, and organic short fibers are added, and after thorough mixing, the slurry with a specific gravity of 0.45 y/d is foamed by stirring at high speed. On the seat! Nursing clearance 12.7? The nonwoven fabric was composited using a doctor blade and dried for 1 hour and 40 minutes in a dryer at 120°C to obtain a board-like product with a thickness of 12.2Tfn1 and a specific gravity of 0.290y/d. .

When a heating test was performed on the sample, the maximum temperature on the back surface was 225°C. Example 4 Same as Example 3 except that 8.4 parts of spherical pearlite (manufactured by Toho Pearlite) was used instead of the silica-alumina microballoon. Thickness: 12.0 WR1 Specific gravity: 0.293
A board-like product of y/al was obtained.

When the obtained sample was subjected to a heating test, the maximum temperature on the back surface was 230°C. In addition, Examples 3 and 4
The compressive strength of the foamed molded product obtained in Example 1 was superior to that obtained in Example 1. Table 1 summarizes the above results.
Shown below.

Claims (1)

[Claims] 1. Consists of 30-55% by weight of dihydrate gypsum powder, 25-50% by weight of calcium carbonate powder, 4-13% by weight of inorganic short fibers and 4-10% by weight of a binder. , an inorganic-based foamed product foamed to a specific gravity of 0.6 or less. 2 30-55% by weight of dihydrate gypsum powder, 25-50% by weight of calcium carbonate powder, 4-13% by weight of inorganic short fibers, 2-20% by weight of inorganic lightweight microspheres, and 4-20% by weight of inorganic lightweight microspheres.
An inorganic-based foamed product that is composed of 10% by weight of a binder and foamed to a specific gravity of 0.6 or less.