JPS6220270Y2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a folded plate roofing material that is noncombustible and has excellent heat insulation properties, in which a sheet-like material made of a noncombustible fibrous material is laminated on a metal plate via a polymer foam.

Conventionally, folded plate roofing materials have been made by laminating an inorganic fiber-based heat insulating material to the back side of a metal plate via a polymer foam, and various types of such inorganic fiber-based heat insulating materials are known. However, one known example is a sheet-like product made by wet-forming inorganic fibers containing rock wool as a main component using a thermoplastic emulsion as a binder (Utility Model Publication No. 40022, No. 51-40). Such a heat insulating material is considered to be preferable as a heat insulating material for folded-plate roofing materials because it has dew condensation prevention properties and non-combustibility, but it has not yet been put to practical use. The reason for this is that when forming a sheet using the normal wet method, the constituent fibers are arranged in layers, and the binder distribution within the sheet layer is uneven, resulting in an insufficient amount of binder in the intermediate layer of the sheet (in this case, the amount of binder (Increasing the amount of heat will sacrifice the nonflammability of the sheet), so the interlaminar strength of the sheet is weak, and when laminated to a metal plate and folded, the inorganic fibers will be damaged and cracks will occur in the sheet.
An example of this is that it does not have satisfactory folded plate workability. In order to improve the interlaminar strength of the sheet, we created a carded web from inorganic fibers such as glass fiber.
It is also known to use a needle-punched sheet, but even with this method, the interlayer strength of the sheet is insufficient, and the problem of interlayer peeling of the sheet occurs during folded plate processing. (Unexamined Japanese Patent Publication No. 52-149829
In order to eliminate such conventional drawbacks, the inventors of the present invention have conducted intensive studies on improving the folding processability of sheets made of inorganic fibers, that is, improving the interlaminar strength of sheets. The present invention was achieved based on the discovery that, by selecting the appropriate binder, the degree of orientation of the constituent fibers of the sheet can be increased within the sheet layer, and the binder distribution can be made uniform, thereby achieving the object. In other words, the present invention is a)
Non-combustible fibrous material 80 whose main component is rock wool
~97% by weight and b) 3 to 20% by weight of a binder whose main component is a thermoplastic resin, wherein a) the degree of orientation of the fibrous material in the layer of the sheet is 31 to 80. b) The sheet-like material 3 in which the binder content in the intermediate layer of the sheet-like material is 2% by weight or more and 0.25 times or more of the average value of all the layers is passed through the polymer foam 2 to the metal plate. This is an insulating folded plate roofing material made by laminating 1 layer.

The folded-plate roofing material of the present invention is shown in Fig. 1. In the figure, 1 is a metal plate, 2 is a polymer foam, and 3 is a sheet-like material. The metal plate, polymer foam, and sheet-like material are laminated with suitable adhesives 4 and 5. The characteristic feature of the insulated folded-plate roofing material of the present invention is the sheet-like material, so the sheet-like material will be described first.

The non-combustible fibrous material constituting the sheet-like material of the present invention can be made of rock wool as the main component, with small amounts of asbestos, inorganic fibers such as glass fiber, alumina fiber, or carbon fiber added as necessary. . As rock wool, both natural rock and mineral slag (slag) can be used, and materials with a low particle content are preferably used, such as granular cotton or layered cotton. In some cases, part of the non-flammable fibrous material may be replaced with organic fibers such as cellulose and vinylon in order to increase elasticity and alleviate irritation to the skin without reducing fire retardancy. good.

In the sheet-like product of the present invention, as the binder for adhering the fibrous substances to form the sheet, it is necessary to use a binder whose main component is a thermoplastic resin from the viewpoint of the flexibility of the sheet. Examples of such resins include polyvinyl alcohol, polyacrylic acid, carboxymethyl cellulose, casein starch, ethylene-vinyl acetate copolymer, plasticized vinyl chloride-vinyl acetate copolymer, polyurethane, (meth)acrylic acid ester copolymer, Examples include ethyl acrylate copolymers.

The ratio of fibrous material to binder in the sheet material is 80 to 97% by weight of fibrous material and 20% by weight of binder.
~3% by weight is required. If the amount of binder is less than 3% by weight, the binder content is too small and the strength and flexibility required for laminating it on metal plates are unsatisfactory.On the other hand, if the binder amount is more than 20% by weight, it will not have the necessary incombustibility for roofing materials. Sexuality becomes insufficient.

The features of the present invention are that the degree of orientation of the fibrous material in the layer is 31 to 80 degrees (preferably 40 to 70 degrees) as a sheet-like product, and the amount of binder in the intermediate layer is 2 degrees.
% by weight or more and 0.25 times the average value of all the layers. By doing so, the interlaminar strength of the sheet increases and it can withstand folding plate processing, and a small amount of Since the binder is effectively used, the non-combustibility of the sheet material is ensured. Furthermore, since the degree of orientation of the fibers is high, the density of the sheet-like product is low, and a lightweight product can be obtained. Here, the degree of orientation of the sheet-like material is a value determined by the following method.

The front and back surfaces of the sheet-like material of a predetermined size are bonded to a flat metal plate using an adhesive. Next, the upper and lower metal plates are grasped with a chuck, and the crosshead is raised at a constant speed to cause the sample to break. By doing the usual interlaminar fracture strength measurement, the sheet-like material can be measured using the nonflammable fibrous material in the layers. Cutting occurs from the oriented layered interface. The degree of orientation is determined by measuring the angle between the metal flat plate surface of the fractured test piece and the fracture surface. In a rock wool sheet obtained by the conventional wet papermaking method, the degree of orientation obtained by the above-mentioned measurement method is substantially 0, and the interlaminar strength is weak because the constituent fibers are aligned in the plane direction. In addition, a bracket-shaped insulation material for piping is also commercially available, which is made by cutting rock wool layered cotton into a certain length and pasting them together with the cut ends aligned so that the cut length corresponds to the thickness (that is, the degree of fiber orientation is 90 degrees). However, although such a heat insulating material has high flexibility, there is a problem in that its strength in the plane direction is too low, making it unsuitable as a sheet-like material for use in folded-plate roofs.

Further, the amount of binder in the intermediate layer of the sheet-like material is a value determined by the following method. Sheet material A
Several cylindrical specimens with a diameter of 20 to 50 mm are punched out centering on an arbitrary point of
8) Collect each layer cut into layers and number them 1 to n. Here, 1 and n correspond to the surface layer, and 2 to n-1 correspond to the intermediate layer. The samples were left in a digitizer at room temperature for a day and night, then placed in separate porcelain crucibles and heated in an electric furnace at 550 to 600°C for 30 minutes.
The weight loss of the m-th layer when baked for ~60 minutes is defined as Am weight %, and the weight loss of the m-th layer obtained in the same manner for sheet-like material B produced without using the binder at all is Bm. In this case, the amount of binder in the m-th layer can be determined as Xm=Am-Bm. When the organic content in the sheet-like material is only the binder, it may be determined as Xm=Am for convenience. The amount of binder in the entire sheet-like material is an average value of 1 to n, and the amount of binder in the intermediate layer is determined as an average value of 2 to n-1. The amount of binder in the sheet intermediate layer must be at least 2% by weight from the viewpoint of folding plate processability. In addition, even if the binder content is 2% by weight or more, the intermediate layer is likely to be destroyed if there is too much deviation between it and the surface layer. It is necessary to keep it.

Such sheet-like products are usually formed by a papermaking method, but an example of the manufacturing method is to disperse a nonflammable fibrous material such as rock wool together with a binder in water (dispersion concentration of 0.1 to 5% by weight) to form a slurry. Adjust stock solution. The thermoplastic resin used as the binder is preferably water-soluble, emulsion, or latex. Furthermore, as mentioned above, in order to improve the binder distribution within the sheet layer, crosslinking agents for thermoplastic resins (isocyanate compounds, zirconia compounds, etc. are used for polyvinyl alcohol, polyvinyl acetate, polyacrylate emulsions, etc. It is preferable to add a small amount of a modified polyamideimide epoxy resin, isocyanate emulsion, etc.) or a polymer flocculant (polyacrylamide, polyethyleneimine, sodium polyacrylate, etc.). The obtained slurry stock solution is supplied to the surface of a moving or rotating net-like or porous base material and formed into a sheet. In this case, the angle between the slurry stock solution and the surface of the base material is set at 5 to 60 degrees. (preferably 20-45
degree) and blowing fluid into the slurry stock solution on the base material surface so as to give turbulence to the slurry stock solution when papermaking the slurry stock solution on the base material surface. This is important in obtaining a sheet-like product. The obtained sheet-like material is dehydrated under reduced pressure, dried, and used for lamination with metal plates. Sheet-like products are usually produced with a thickness of 0.5 to 50 mm and an apparent density of 0.04 to 0.2 g/cm ³ . In the production of the above-mentioned sheet-like product, it is preferable to add a flame retardant to further improve the nonflammability of the sheet-like product. Particularly preferred flame retardants include 5 to 50 parts by weight of antimony compounds (antimony trioxide, etc.) per 100 parts by weight of the binder.
A combination with 10 to 100 parts by weight of an aromatic bromine compound (pentabromomethylbenzene, etc.) may be mentioned.
Further, in order to further improve the strength of the sheet-like article, it is also preferable to add a reinforcing material to the intermediate layer or surface of the sheet-like article. As the reinforcing material, various films, metal foils, etc. are suitable for improving moisture proofing/waterproofing properties, and cloth, paper, nonwoven fabrics, etc. are used when moisture permeability/hygroscopicity is required. In addition, in order to prevent itching (skin irritation caused by adhesion to the human body) caused by fibrous materials such as rock wool, a dispersion of organic fibers (pulp, regenerated cellulose, synthetic fibers, etc.) is formed on the sheet surface during papermaking. It is also effective to combine the prepared sheets and integrally mold them.

The sheet-like material obtained in the above manner is laminated with a metal plate via a polymer foam. Polymer foams such as foamed polyethylene and polyurethane are flexible and have excellent heat insulation properties. Any value can be used as long as it is 0.5 to 60.
A thickness of mm is used. This thickness is determined based on the balance between heat insulation and fire protection. Further, as the metal plate, iron plates such as galvanized iron plates specified in JIS A6514 and stainless steel plates are preferable, and aluminum plates and copper plates can also be used in some cases. The thickness of the metal plate is approximately 0.6 to 2.0 mm. Lamination of the metal plate, polymer foam, and sheet-like material is performed using an adhesive. Such adhesives include inorganic adhesives such as silicic acid compounds represented by water glass, phosphoric acid and acidic metal phosphates, silica alumina compounds, zirconia compounds, silicon compounds, titanium compounds, boron compounds, and antimony compounds. Organic solvent-based adhesives such as phenol-based, chloroprene-based adhesives, and heat-melting adhesives such as polyethylene-based and polyvinyl acetate-based adhesives are used.
From the viewpoint of flame retardancy, it is preferable to mix the above-mentioned flame retardant into the adhesive.

Folded plate roofing material is a composite plate made by laminating a sheet material and a polymer foam in advance and then laminating a metal plate, or by laminating a polymer foam and a metal plate in advance and then laminating a sheet material. It can also be formed into a predetermined shape (V-shape, U-shape, etc.) using a folding plate processing roller, or by laminating a polymer foam and a sheet material on a metal plate that has been folded in advance. Obtainable. Such roofing materials are shown in Figures 2 and 3.
As shown in the figure, a fire-resistant roof structure can be obtained by joining adjacently by a seam method or a stacking method. Figure 2 shows a cross-sectional view of the joint part of a roof structure in which a composite plate-like material in which metal plates and sheet-like materials are laminated is folded into a predetermined shape and then joined adjacently by the seam method. FIG. 3 shows a cross-sectional view of a joined portion of roof structures that are joined adjacently by the overlapping method using tightening bolts 6.

By configuring the present invention as described above, damage to the sheet during processing of folded plates (cutting of fibers, occurrence of sheet cracks), which was a problem with conventional inorganic fiber sheets, is eliminated, and the roll pressure during processing is reduced. The restoring force of the sheet-like material is sufficient even when the sheet-like material is affixed to a metal plate, and then the folding process can be performed efficiently. In addition, since the sheet-like material contains only a small amount of binder, it is nonflammable, and the folded plate roofing material thus obtained is nonflammable (it is classified as a "noncombustible material" or "semi-noncombustible material" based on the Building Standards Act Enforcement Ordinance). with equivalent performance),
It has excellent heat insulation, anti-condensation, and soundproofing properties.

[Brief explanation of the drawing]

Fig. 1 is an enlarged cross-sectional view showing the structure of the roofing material of the present invention, and Fig. 2 is a cross-section of a joint portion of a roof structure in which folded plate roofing materials of the present invention are joined adjacently by the seam method. FIG. 3 is a cross-sectional view of the stacking method. In the figure, the symbols indicate the following. 1...Metal plate, 2...Polymer foam, 3...Sheet-like material,
4, 5...Adhesive, 6...Tightening bolt.

Claims (1)

[Scope of utility model registration request] A) A sheet-like material consisting of 80 to 97% by weight of a non-flammable fibrous material whose main component is rock wool and b) 3 to 20% by weight of a binder whose main component is a thermoplastic resin, the sheet-like material comprising: a) the sheet-like material; (b) a sheet in which the degree of orientation of the fibrous material in the layer is 31 to 80 degrees, and b) the amount of binder in the intermediate layer of the sheet-like product is 2% by weight or more and 0.25 times the average value of all the layers. This is a heat insulating folded plate roofing material made by laminating a metal plate 1 with a metal plate 1 via a polymer foam 2.