JP2003082808A - Heat resistant panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a heat-resistant material widely used for building materials having excellent flame retardancy, heat resistance and heat insulation by integrally laminating a specific face material on a phenol resin foam layer. The purpose is to make a panel. SOLUTION: Silica is 65 to 75 wt%, magnesium hydroxide is 15 to 25 wt%, and zinc borate is 5 to 10 w.
30% to 80% by weight of magnesium silicate and 5 to 25 watts of glass fiber on one or both sides of the phenolic resin foam layer via an inorganic layer formed by mixing at a ratio of t%.
This is a heat-resistant panel formed by integrally bonding and laminating non-combustible soft face materials prepared by mixing t% and pulp at a ratio of 10 to 30 wt%.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel widely used in building materials and the like, which is excellent in flame retardancy, heat insulation and heat resistance, and in particular, an inorganic layer having a predetermined composition on one side or both sides of a phenol resin foam layer. The present invention relates to a heat resistant panel which is formed by sequentially laminating a noncombustible soft surface material.

[0002]

2. Description of the Related Art Conventionally, heat-resistant panels, heat-insulating panels and flame-retardant heat-insulating panels used for building materials such as ceiling panels are generally heat-resistant on one or both sides of a foamed resin such as phenol resin foam. It is constituted by integrally adhering and laminating face materials having heat resistance and flame retardancy.

Regarding such heat-resistant panels, heat-insulating panels and the like, for example, JP-A-55-63255 (first known technology), JP-A-55-77562 (second known technology), and JP-A-5-77562. Panels having various structures are known as exemplified in Japanese Patent Publication No. 8-1854 (third known technique) and the like.

According to the above-mentioned first known technique, aluminum hydroxide, magnesium hydroxide, boric acid, sodium hydrogencarbonate, calcium carbonate, between a phenol resin foam layer and a face material composed of an aluminum plate, an incombustible asbestos plate, etc. It is a technique relating to a heat-resistant phenol resin foam laminated plate constituted by interposing an inorganic filler made of one or more substances selected from antimony trioxide.

The above-mentioned second known technique uses a fire-resistant paint made of an inorganic paint, a foaming fire-resistant paint, or the like on one or both sides of a plate-like material made of phenol resin foam, or metal, asbestos, glass fiber, or cement. It is a technology related to fireproof building materials constructed by laminating selected inorganic materials.

The above-mentioned third known technique comprises a core layer made of a phenol resin foam, an inorganic filler mainly composed of an inorganic hollow body on one or both sides of the core layer, and a binder of a water glass composition. Is a technology for a fire-resistant board that can be used in a building material or the like that is formed by stacking the following inorganic surface layers.

[0007]

However, in the conventional known techniques shown in the above-mentioned first known technique to the third known technique, the face material is stuck and laminated on one side or both sides of the phenol resin foam. In this case, since the adhesive was not particularly considered in the case of integrated construction, the heat resistance of the bonded part is insufficient, and problems occur when heated. There was a problem such as being rejected.

The heat-resistant panel according to the present invention is a completely new technology developed in view of many problems of the above-mentioned conventional panel, and in particular, one side or both sides of the phenol resin foam layer is made of an inorganic material made of a specific substance. A panel constituted by sequentially laminating a layer and a non-combustible soft surface material in order, and imparting double non-combustibility and heat resistance to the panel by the inorganic layer and the non-combustible soft surface material. It provides a new technology that can be done.

[0009]

The heat-resistant panel according to the present invention is an invention that has fundamentally improved the above-mentioned conventional problems. The gist of the first invention is one side of a phenol resin foam layer or Is composed of an inorganic layer formed by mixing silica, magnesium hydroxide and zinc borate on both sides, and a non-combustible soft surface material formed by mixing magnesium silicate, glass fiber and pulp in that order. It is a heat resistant panel characterized by the above.

The heat-resistant panel according to the first aspect of the present invention is such that a phenol resin foam layer is laminated on one or both sides with an inorganic layer containing silica, magnesium hydroxide and zinc borate, and further, magnesium silicate, Since the non-combustible soft surface material formed by blending glass fiber and pulp is integrally laminated, even when the panel is heated to a very high temperature, the inorganic layer and the non-combustible soft surface material are Since it is laminated in two layers, heat resistance, nonflammability and flexibility can be maintained.

Further, since the non-combustible soft face material used in the present invention is made by making a slurry containing magnesium silicate, glass fiber and pulp, it is compared with the conventional face material having a large amount of inorganic content. In this case, it is possible to form a face material having excellent heat resistance and combustion resistance despite the fact that the organic component of pulp is mixed. Furthermore, since the non-combustible soft face material used in the present invention is formed by mixing the face material with the organic component as described above, it is possible to impart mechanical strength and flexibility to the face material. As a result, it is possible to easily perform integral molding or post-bonding molding by continuous lamination with a foamed resin such as phenol resin foam, and to mass-produce at low cost.

The gist of the second invention according to the present invention is that the inorganic layer laminated on one side or both sides of the phenol resin foam layer contains 40 to 90 wt% of silica, 10 to 30 wt% of magnesium hydroxide, and zinc borate. Is blended in a ratio of 2 to 20 wt%, and the non-combustible soft surface material is 30 to 80 wt% of magnesium silicate and 5 to 25 of glass fiber.
The heat-resistant panel according to the first aspect of the invention is characterized in that the heat-resistant panel is composed by mixing wt% and pulp at a ratio of 10 to 30 wt%.

In the above-mentioned second invention, the inorganic layer used in the first invention is composed of 40 to 90 wt% of silica, 10 to 30 wt% of magnesium hydroxide, and 2% of zinc borate.
The composition of the non-combustible soft surface material used in the first invention is 30% by weight to 20% by weight.
-80 wt%, glass fiber 5-25 wt%, and pulp 10-30 wt% are mixed, so that the panel can be provided with extremely sufficient heat resistance, nonflammability, and flexibility.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION One embodiment of the constitution of the heat resistant panel according to the present invention will be specifically described as follows. That is, in the present invention, the inorganic layer for adhering the face material to the phenol resin foam layer was constituted by the following composition.

[Example of Compounding Range of Inorganic Layer] Component range wt% Silica 40-90 Magnesium hydroxide 10-30 Zinc borate 2-20

An inorganic layer obtained by adding water to the above-mentioned constituents and mixing it is added in an amount of 30 to 300 g / m ² (more preferably 50 to 150 g / m ² ) in terms of solid content on one side of the phenol resin foam layer. Alternatively, a non-combustible soft face material having a constitution to be described later is laminated on both surfaces and laminated on the inorganic layer, and the face material is integrated with the phenol resin foam layer through the inorganic layer. The heat-resistant panel of the present invention was manufactured by laminating the layers.

As the non-combustible soft surface material laminated on the phenol resin foam layer through the inorganic layer compounded as described above, those shown in the following compounding range examples were used.

[Example of blending range of noncombustible soft surface material] Component range wt% Silicate magnesium 30-80 Glass fiber 5-25 Pulp 10-30

Blending the above-mentioned constituents in a fixed ratio
To make a slurry, and use this slurry with a wet paper machine.
And basis weight is 50-300g / m² Paper making so that
A non-combustible soft face material was manufactured in a continuous state. Said silicic acid
Generally, sepiolite (Magnesium)
Hydrous inosilicate mineral of sium, Mg₈H₂(Si_FourO
₁₁)₃・ 3H₂O] was used.

[Examples] In practicing the heat-resistant panel of the present invention specifically, first, a non-combustible soft surface material is manufactured by the following steps, and the manufactured non-combustible soft surface material is The phenolic foam layer was integrally laminated on one side or both sides using an inorganic layer prepared by the following composition.

[Production Example of Non-combustible Soft Surface Material] Sepiolite 61 wt% Glass fiber 14 wt% Pulp 18 wt% Antimony pentoxide sol 2 wt% Binder 5 wt% Slurry containing the above-mentioned components was used to prepare a wet paper machine to produce The amount is 160 g / m ² The non-combustible soft surface material according to the present invention was manufactured by making paper into the following manner.

[Production and Application Example of Inorganic Layer] Silica 35 wt% Magnesium hydroxide 10 wt% Zinc borate 5 wt% Water 50 wt% In applying the inorganic layer produced by the above-mentioned formulation to the surface of the face material layer, The coating amount was 160 g / m ² , the weight after drying was 80 g / m ² , and the dry curing condition was 60 ° C. for 30 minutes.

A specific example of joining the non-combustible soft face material and inorganic layer having the above-mentioned structure to the phenol resin foam layer as the base material is as follows. That is, first, a silicone surfactant (polyalkylsiloxane-polyoxyalkylene copolymer: Paint 32 manufactured by Dow Corning Asia Co., Ltd.) is dissolved in a resole resin at a ratio of 3.5 g per 100 g of the resole resin.

Next, the resol resin mixture, a blowing agent containing 1.1, 1.2-tetrafluoroethane (HFC-134a manufactured by Daikin Industries, Ltd.) containing 0.3% by weight of nitrogen dissolved therein, and cured. As a catalyst, a mixture of 70% by weight of paratoluenesulfonic acid hydrate (manufactured by Wako Pure Chemical Industries, Ltd.) and 30% by weight of diethylene glycol (manufactured by Wako Pure Chemical Industries, Ltd.), 100 parts by weight of a resole resin mixture and a foaming agent, respectively. 16 parts by weight of the curing catalyst and 17 parts by weight of the curing catalyst are supplied to a pin mixer with a temperature control jacket, and well mixed in this mixer by stirring.

Further, the mixture discharged from the mixer is poured into a mold lined with the above face material and inorganic layer,
After uniformly adjusting the final product thickness to 50 mm,
The upper surface was covered with the same surface material and an inorganic layer, and the mold frame was covered.
Next, the same mold was placed in an oven at 70 ° C and held for 30 minutes, then in an oven at 90 ° C for 1 hour, and then at 100 ° C
The heat resistant panel according to the present invention was manufactured by holding it in the oven for 1 hour.

The heat-resistant panel manufactured according to the above-mentioned embodiment was tested in accordance with the heat generation test prescribed in Article 1-5 of the Building Standard Law Enforcement Ordinance to obtain a test piece having a thickness of 50 mm and a radiation intensity of 50 kW / m ² , test distance 25 mm, test time 10
As a result of performing the test under various conditions for 1 minute, the test results as described below could be obtained.

That is, the maximum heat generation rate is 25.3 kW / m ²
And the evaluation standard is 200 kW /
The total calorific value does not exceed m ² and is 6.2 MJ / m ²
However, it was confirmed that the evaluation standard was 8 MJ / m ² or less, and that there were no cracks or holes penetrating to the back surface that would be harmful to disaster prevention in the entire panel. Therefore,
It turned out that all the conditions passed.

The inventors of the present invention have tried for a long time various types of examples or comparative examples in which the constituent substances or the components of the constituent substances are increased or decreased, centering on the specific examples. The following conclusions were obtained.

That is, the phenol resin foam is not particularly limited, but it has been found that the resol type phenol resin foam is suitable. The phenol resin foam and the face material can be joined by either the integral molding method described above or the post-processing joining method using the inorganic layer.

As the magnesium silicate, which is a constituent of the nonflammable soft surface material used in the present invention, general sepiolite is used, and the compounding ratio of this sepiolite is 50 wt.
%, It became clear that the manufactured face material had insufficient heat resistance. Moreover, it was found that when the blending ratio of sepiolite was set to 80 wt% or more, the dispersibility of the manufactured face material was deteriorated and defective products were produced. Then, it was found that more preferable results were obtained when the compounding ratio of sepiolite was set in the range of 60 to 70 wt%.

Further, it has been clarified that when the compounding ratio of the glass fiber is 5 wt% or less, the manufactured face material has insufficient heat resistance. Further, it was also revealed that when the glass fiber content was 25 wt% or more, the flexibility of the manufactured face material deteriorated. And the compounding ratio of glass fiber is 1
It has been found that more preferable results are obtained when the content is in the range of 0 to 20 wt%.

Further, it was revealed that when the blending ratio of pulp is 10 wt% or less, the flexibility of the produced face material is insufficient. In addition, the blending ratio of pulp is 30 wt%
In the above cases, it became clear that the heat resistance of the manufactured face material deteriorates. And the blending ratio of pulp is 15
It was found that the range of ˜25 wt% was more preferable.

When producing the non-combustible soft face material used in the present invention, it is possible to mix a binder in the slurry. This binder is 2-10 wt%
There is no particular limitation as long as it is a degree. When the binder is mixed in this way, sepiolite, glass fiber, pulp, and antimony oxide particles can be bonded to each other,
It has the effects of making the face material flexible, reducing the effect of humidity, imparting a flame-retardant (not incombustible) effect, and further improving the formability of the face material.

When the above-mentioned binder is blended in an amount of 11% or more, problems such as smoke generation and adverse effects on incombustibility occur. Therefore, a blending ratio of 10% or less is preferable. On the other hand, when the content of the binder is 1% or less, there is a problem that the binder effect is small, the powder is often removed, and the tensile strength is lowered. As the binder, a vinylidene chloride-based or vinyl chloride-based resin emulsion or the like can be used.

When the antimony oxide sol is blended as described above, the sol particles of the antimony oxide sol are fixed and covered with organic matter such as pulp, so that the burning temperature of the face material can be lowered. When the amount of organic compound is increased, the flexibility is improved, but on the other hand, the combustion temperature rises, and there is a problem that the exothermic test conditions specified in Article 1 No. 5 of the Building Standard Act Enforcement Order described later cannot be passed. However, the above problem can be solved by additionally blending antimony oxide sol at a predetermined ratio as in the present invention.

The compounding ratio of this antimony oxide sol is preferably 1 to 5 wt% from the range of the amount of organic matter. If the organic mass is small, even without adding antimony oxide sol,
Nonflammability is obtained, but there is a problem of lacking flexibility, and if the organic mass (30 wt% or more) is too large, the basic organic mass is too large, and even if 5% or more of antimony oxide sol is added, There is a problem that incombustibility cannot be obtained.

When a slurry prepared by blending the above-mentioned constituents in respective predetermined ranges is made into a paper having a basis weight of 50 to 300 g / m ² using a wet paper machine,
It was found that despite having pulp (organic content), it has excellent heat resistance and flame resistance, while having mechanical strength and flexibility as a face material. Particularly, when the range of the basis weight is 100 to 200 g / m ² , it is light and has mechanical strength and flexibility as a face material. It has been found that continuous laminating or post-adhesion is easy when integrally laminating with the foamed sheet.

There is no particular limitation on the silica constituting the above-mentioned inorganic layer used in the present invention, but it has been found that it is preferable to use amorphous (amorphous) silica. With respect to magnesium hydroxide and zinc borate, respectively, the above range, 10 to 30 wt% or 2 to 20 w
It was found that when the content is less than t%, heat resistance becomes insufficient, and when the content exceeds the above range, dispersibility deteriorates.

The amount of the inorganic layer is 30 g / m ^{2 of} solid content.
If the amount is less than 300, the heat resistance effect is insufficient and the solid content is 300 g / m ²
It has been found that the above case is not suitable because the cost of the product increases and the weight increases. The dispersion medium (water) evaporates after drying and curing, so there is no particular limitation, but good results were obtained by adding it appropriately to adjust the viscosity.

As a result of various investigations by the present inventors on the range of blending the constituents of the above-mentioned noncombustible soft surface material, it is found that 60 to 70 wt% of magnesium silicate is contained.
Is a more preferable range, and for glass fiber, 1
It was confirmed that 0 to 20 wt% was a more preferable range, and that for pulp, 15 to 25 wt% was a more preferable range.

The inventors of the present invention have similarly examined the blending range of the constituents of the inorganic layer and the coating amount of the inorganic layer.
When the particularly preferable range was investigated, the following results were obtained.

Regarding the silica used in the inorganic layer,
65 to 75 wt% is a more preferable range, 15 to 25 wt% is a more preferable range for magnesium hydroxide, and 5 to 10 wt% is a zinc borate.
Was found to be a more preferable range. Further, it has been found that the coating amount of the inorganic layer is more preferably 50 to 150 g / m ^{2 in} terms of solid content.

[0043]

Comparative Example 1 Corresponding to the heat-resistant panel of the present invention manufactured in the above-mentioned example, a heat-resistant panel was manufactured by changing the compounding material of a part of the inorganic layer, and tested under exactly the same conditions as the above test. As a result, the following results were obtained.

That is, in this Comparative Example 1, when forming the inorganic layer, 50 wt% of water glass and 50 wt of water were used.
% Was used to make the inorganic layer and the same non-combustible soft face material as in the previous example was laminated to the phenolic resin foam layer to test the panel.

As a result, the maximum heat generation rate is 61.7 kW /
m ² and 200 k continuously for 10 seconds or more of the evaluation standard
It passed because it did not exceed W / m ² , but the total calorific value was 12.4 MJ / m ² and the evaluation standard was 8 MJ.
/ M ² or more, so it was confirmed that it failed.

[0046]

[Comparative Example 2] In Comparative Example 2, sepiolite was added to the surface material without using pulp at all.
5wt%, glass fiber 10wt%, binder 5w
A panel prepared by compounding at a ratio of t% to prepare a face material and laminating this face material on a phenol resin foam layer using the same inorganic layer as in the above-mentioned example was tested.

[0047] As a result, the maximum heat release rate of the panels prepared as described above is a 54.3kW / m ^2, but pass because it is less 200 kW / m ² criteria,
The total calorific value is 9.7 MJ / m ² , which is an evaluation standard of 8 MJ.
/ M ² or more, it was confirmed that it failed.

[0048]

The heat-resistant panel according to the present invention comprises a phenol resin foam layer, on one or both sides of which an inorganic layer containing silica, magnesium hydroxide and zinc borate is laminated, and further, magnesium silicate, Since the non-combustible soft surface material made by blending glass fiber and pulp is integrally laminated, even if the panel is overheated to a very high temperature, the inorganic layer and the non-combustible soft surface material are separated from each other. Since they are stacked in layers, they have the effect of maintaining extremely strong heat resistance, incombustibility, and flexibility.

The inorganic layer used in the heat-resistant panel of the present invention comprises 40 to 90 wt% of silica and 1% of magnesium hydroxide.
0 to 30% by weight, zinc borate is mixed at a rate of 2 to 20% by weight, and a non-combustible soft surface material is further made 50 to 80% by weight of magnesium silicate and 5 to 25% of glass fiber.
%, Pulp is mixed at a ratio of 10 to 30 wt%, which has the effect of imparting extremely sufficient heat resistance, nonflammability, and flexibility to the panel.

   ─────────────────────────────────────────────────── ─── Continued front page    F-term (reference) 2E162 CD01 CE08 FA00 FA14 FC01                 4F100 AA02B AA03C AA18B AA20B                       AA33C AG00C AJ02C AK33A                       BA03 BA07 BA10A BA10C                       DG01C DJ01A GB08 JJ03                       JJ07 JK01 JK13 JK17 YY00B                       YY00C

Claims (2)

[Claims] 1. A nonflammable soft material prepared by blending silica, magnesium hydroxide and zinc borate on one or both sides of a phenol resin foam layer and an inorganic layer blended with magnesium silicate, glass fiber and pulp. A heat-resistant panel characterized by being constructed by laminating a face material in order. 2. The inorganic layer laminated on one side or both sides of the phenol resin foam layer contains 40 to 90 wt% of silica.
%, Magnesium hydroxide 10 to 30 wt%, zinc borate 2 to 20 wt%, and the non-combustible soft surface material is magnesium silicate 30 to 80 wt%.
%, Glass fiber 5 to 25 wt%, pulp 10 to 30
The heat-resistant panel according to claim 1, wherein the heat-resistant panel is formed by mixing in a wt% ratio.