JPH058125Y2 - - Google Patents

Description

[Detailed Description of the Invention] <Industrial Application Field> The present invention relates to a multilayer composite building material in which a nonwoven fabric, an inorganic noncombustible heat insulating material sheet, and a hot melt type synthetic resin film are laminated and integrated by needle punching.

<Prior Art> In recent years, folded metal plates, which are a composite of steel plates and backing materials, have been used for the roofs of large buildings such as distribution centers, warehouses, and gymnasiums for their heat insulation and anti-condensation properties.
Conventionally, 40 times expanded polyethylene foam sheets (thickness: 4 mm) were commonly used, but there is an increasing preference for inorganic noncombustible materials from the standpoint of fire protection. The methods of adhering the backing material and metal plate are room temperature adhesion,
It is broadly classified into heat fusion. For room-temperature bonding, solvent-based adhesives such as chloroprene rubber and water-based adhesives such as ethylene-vinyl acetate emulsions can be used, but solvent-based adhesives are mostly used. This is because it is low cost, dries quickly, and has good workability. In heat fusion, the common method is to heat and melt a hot melt polymer and coat it on the inorganic non-combustible heat insulating material, but some methods have also been used in which a film is supplied to a heated steel plate together with the heat insulating material. ing.

<Problems to be solved by the invention> However, so far, there have been no heat-sealable inorganic nonflammable materials that can be manufactured at low cost and with good workability without sacrificing their excellent heat insulation and anti-condensation properties. There was no known method for manufacturing insulation.

As a result of intensive study to solve the above-mentioned current problems, the inventors of the present invention have discovered a method of providing a heat-sealable inorganic noncombustible heat insulating material using a new, simple and low-cost method that is different from conventional methods.

<Means for solving the problem> The present invention consists of a non-woven fabric laminated on one or both sides of an inorganic non-combustible heat insulating material sheet, a hot-melt synthetic resin film laminated on one side, and integrated by needle punching. It is a multi-layered composite building material.

This invention combines a nonwoven fabric, an inorganic noncombustible heat insulating material sheet, and a hot melt type synthetic resin film during needle punching, processes the entire body with needle punching, and then bonds the needle punched inorganic heat insulating material and the hot melt type synthetic resin film. A major feature is that it is integrated. An inorganic noncombustible heat insulating material sheet and a hot melt type synthetic resin film do not require a very large adhesive force. In terms of handling, it is sufficient to have an adhesive strength that does not peel off during heat-sealing processing, so it is possible to fix hot-melt synthetic resin films by needle punching processing.

Examples of the inorganic noncombustible heat insulating sheet in the present invention include gypsum foam sheets, glass (fiber) mats, rock wool mats, ceramic fiber mats, carbon fiber mats, and mixed mats of two or more of these fibers. In the present invention, gypsum foam sheets are most preferably used as the heat insulating material. The gypsum foam sheet may be one commonly used in the industry, and specific examples include those described in Japanese Patent Publication No. 1504/1983. As is clear from the above publication, its physical properties are similar to that of dihydrate gypsum.
Contains 40% or more, water retention rate 20~150%, tensile strength 5~
It has a weight of 50 kg/cm ² and a tensile elongation of 5 to 50%, and has excellent bending workability and dew resistance. Thickness is 5-20
Approximately mm is suitable. Such a gypsum sheet is obtained by molding an aqueous mixture consisting of gypsum dihydrate powder, a binder (thermoplastic resin emulsion and crosslinking agent) and, if necessary, an air entraining agent or a blowing agent, and drying.

The nonwoven fabric that constitutes the building material of this invention has few knots between fibers, tends to fluff, and has a low basis weight.
Synthetic fiber yarns having appropriate tensile strengths in the longitudinal and lateral directions in the range of 15 to 40 g/m ² are preferable, but nonwoven fabrics made of inorganic fibers, such as glass fibers, may also be used. Of course, it is necessary to have good durability. Examples of these fibers include polyethylene, polypropylene, nylon, polyester, polyvinyl chloride, polyamide, glass fiber, and carbon fiber. Fibers can be used alone or in combination. A low number of knots between fibers is essential. Also, if the basis weight (g/m ² ) is too large, the nonflammability of the sheet will be adversely affected. If it is too small, the needle punching effect will not be sufficiently exerted.

As the hot melt type synthetic resin film constituting the building material of the present invention, commonly used hot melt type synthetic resin films such as polyolefin type, ionomer type, ethylene-vinyl acetate copolymer type, nylon type, rubber type, etc. are used. Polyolefin-based adhesives are preferably used because good adhesion can be obtained even at a low heat-fusion temperature and they are less likely to damage the coating film on the steel plate. The thickness of the film is naturally determined by adhesive function, ease of handling, and economical efficiency, and a film with a thickness of about 20 to 50 μm is preferably used.

The multilayer composite building material of the present invention consists of nonwoven fabric/inorganic nonflammable heat insulating sheet/hot melt type synthetic resin film or nonwoven fabric/inorganic nonflammable heat insulating sheet/
It is manufactured by creating a multilayer laminate of nonwoven fabric/hot melt type synthetic resin film and then subjecting it to needle punching. In producing the laminate, from the viewpoint of workability and shape retention of the inorganic noncombustible heat insulating material sheet, it is desirable that nonwoven fabrics be laminated on both sides of the inorganic noncombustible heat insulating material sheet.

Regarding needle punching, a large number of punches is effective for fixing the sheet and film, but
Too much will damage both the sheet and film, so 36
The limit is about ² pieces/cm2. If it is too small, the sheet and film will not be properly fixed. The preferred number of punches ranges from 18 to 26 punches/cm ² . The type of needle may be a general purpose needle.
In addition, needle punching is performed well with a needle penetration depth in the range of 10 to 20 mm.

In this way, the multilayer composite building material of the present invention is manufactured. An example of a cross-sectional view of the building material is shown in FIG. In FIG. 1, 1 is a nonwoven fabric, 2 is an inorganic nonflammable heat insulating sheet, 3 is a nonwoven fabric, 4 is a hot melt type synthetic resin film, and 5 is a needle punched portion.

<Effects of the invention> The multilayer composite building material of the invention not only has excellent heat insulation and anti-condensation properties, but also is highly workable and can be made at low cost, making it ideal for distribution centers, warehouses, gymnasiums, etc. It is suitable as a backing material for folded metal plates used on the roofs of large buildings.

<Example> The multilayer composite material of the present invention can be made, for example, as follows. First, to make a gypsum foam sheet, foam 16 parts by weight (8 parts by weight of pure ethylene-vinyl acetate copolymer emulsion) with a copolymerization ratio of 24% by weight of ethylene, 70% by weight of vinyl acetate, and 6% by weight of acrylic acids. 4.3 parts by weight of a 10% polyvinyl alcohol solution (polymerization degree 2000, saponification degree 80 mol%) as a crosslinking agent, 1-33 parts by weight of epoxidized polyamide polyamine resin as a crosslinking agent (purity 0.4 parts)
Carboxymethyl cellulose 2 as viscosity modifier
Weight%, aqueous solution 8.5 parts by weight, water generating agent 0-61 parts by weight (purity 0.20 parts by weight), antifungal agent 0.075 parts by weight, air entrainment agent 0.02 parts by weight, appropriate amount of water (moisture content 38% by weight)
Place in a container and stir to mix. Next, 80 parts by weight of flue gas desulfurization gypsum, 9 parts by weight of rock wool, 0.4 parts by weight of polyester core-sheath type short fibers, and pulp.
Gradually add 0.45 parts by weight and 0.3 parts by weight of sodium carbonate as a PH regulator while stirring and mixing. While injecting air into the water-containing mixture, the slurry is stirred and foamed at high speed to adjust the specific gravity to 0.3 to obtain a slurry for molding. Next, the molding slurry is coated and cast onto a base sheet with good mold releasability using a doctor blade with a clearance of 4.5 mm. Next, polyester nonwoven fabric (fabric weight 16 g/m ² ) was laminated and integrated on the surface, and then dried in a hot air circulation dryer at 80°C for 40 minutes.
A sheet material having a thickness of 4.0 mm, an apparent specific gravity of 0.25, and a porosity of 88% by weight is obtained. A non-woven fabric for knee pants made of a mixture of polyethylene, polypropylene, and polyester (fabric weight 24 g/m ² ) is applied to the back side of the sheet-like material, and a hot melt film is further layered on the non-woven polyester fabric side to form a three-layered layer. Knee pan processing is performed from the non-woven fabric for knee pants. do. In this way, a three-layer heat-sealable inorganic noncombustible heat insulating material of the present invention could be obtained.

[Brief explanation of the drawing]

FIG. 1 shows an example of a cross-sectional view of the building material of the present invention. In the figure, 1 is a nonwoven fabric, 2 is an inorganic noncombustible heat insulating sheet, 3 is a nonwoven fabric, and 4 is a hot melt film. 5 indicates the needle punched portion.

Claims (1)

[Scope of utility model registration request] A multilayer composite building material comprising a nonwoven fabric laminated on one side of an inorganic noncombustible heat insulating sheet, and a hot-melt synthetic resin film laminated directly or via the nonwoven fabric on the opposite side, and integrated by needle punching.