JP5809535B2 - Building materials - Google Patents

Description

The present invention is a core member made of a synthetic resin foam, it is sandwiched by the surface material and the back surface member, but about the building member such as a metal siding or building panel.

  Many building members such as metal siding and building panels in which a core material made of a synthetic resin foam is sandwiched between a front surface material and a back surface material are on the market. However, the surface of the building member may be uneven or warped due to the time-dependent change of the synthetic resin foam or the humidity difference or humidity difference between the inside and outside the room.

  In order to solve these problems, a concave groove is formed in the back surface material along the longitudinal direction thereof, and when the back material shrinks, the shrinkage is absorbed by the concave groove and warps the back surface. There has been proposed a method for mitigating the occurrence of this phenomenon (see, for example, Patent Document 1). However, this method has a problem that the warpage of the front surface cannot be reduced and the back surface does not become flat.

  In addition, a method for preventing a warp problem by improving the mechanical strength of the building member itself by making the surface material a concavo-convex pattern and making the size of the concave portion larger than the size of the convex portion has been proposed. (For example, refer to Patent Document 2). However, this method has a problem that the surface cannot be formed into an arbitrary shape.

  In addition, there is a building component in which a composite sheet in which a synthetic resin film or aluminum foil is bonded to a nonwoven fabric containing glass fibers that does not expand or contract due to changes in temperature or humidity is bonded to the front and back of a synthetic resin foam. It has been proposed and devised (see, for example, Patent Documents 3 to 4).

  However, because glass fibers are skin irritating, there is a problem that the human body is adversely affected when the composite sheet is bonded to the synthetic resin foam, and the surface smoothness is inferior. When combined, there is a problem that a fibrous float may occur.

Also, a synthetic resin film having a very low linear expansion coefficient of −2 × 10 ⁻⁵ to 1 × 10 ⁻⁵ / ° C. and a very high elastic modulus of ⁵ to 15 GPa is bonded to kraft paper, woven fabric, or nonwoven fabric. Therefore, there has been proposed a composite sheet that prevents problems due to warpage or the like (see, for example, Patent Document 5). However, in order to adjust the linear expansion coefficient and elastic modulus of the synthetic resin film to the above-mentioned range, it is necessary to carry out production with a draw ratio of 10 times to several tens of times, and after the synthetic resin film is produced, it is melted. Since it is necessary to bond together using resin and an adhesive agent, a back material cannot be made thin. In addition, since the molten resin or adhesive used causes expansion and contraction due to changes in temperature and humidity, it may not be possible to sufficiently prevent problems due to warpage.

  In addition, it is possible to prevent problems such as warping and peeling, as well as skin irritation by a sheet in which a layer mainly composed of inorganic fibers such as glass fibers and a layer mainly composed of organic fibers such as wood pulp and polyester fibers are laminated. Has been proposed (see, for example, Patent Documents 6 to 9). However, these sheets have a problem that when the core material made of the synthetic resin foam is formed, the stock solution oozes out to the back surface side. Further, since the outermost surface of the seat is in contact with the outside air, it is easily affected by humidity that causes warping or the like.

  Thus, in a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the pattern and shape of the front surface and the back surface can be freely selected. When the synthetic resin film is bonded to the non-woven fabric containing glass fiber to suppress warping, the surface of the synthetic resin film is smooth without any fibrous lifting, and skin irritation during work However, a back material that can be reduced in thickness and thickness has not been obtained yet. Further, a building member in which such a back material is provided on at least one surface of the synthetic resin foam has not been obtained yet.

JP 2004-1116019 A JP 2003-147898 A Japanese Utility Model Publication No. 53-46372 JP 2002-4548 A Japanese Patent Laid-Open No. 2006-212895 JP-A-51-84161 JP-A-4-226747 JP 58-179641 A JP 2000-303389 A

  An object of the present invention is to provide a building material in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, and the pattern and shape of the surface and the back surface can be freely selected. It is possible to suppress problems such as warping of members, smoothness without causing fibrous lift when a synthetic resin film is bonded to a glass nonwoven fabric, less skin irritation during work, and to reduce the thickness. Another object of the present invention is to provide a composite sheet for building members suitable as a back material that can be used. Moreover, it is providing the building member which provided such a composite sheet for building members on the at least single side | surface of the synthetic resin foam.

  Specific means for solving this problem is as follows.

(1) In a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the composite sheet for building material used as the back material is made of glass fiber and wood pulp. Is a composite sheet in which a nonwoven fabric (A) containing a binder fiber and a synthetic resin film (B) are bonded together. The nonwoven fabric (A) is a multilayer sheet having two or more layers, and the nonwoven fabric (A) is synthesized. The layer on the side to be bonded to the resin film (B) does not contain wood pulp, or contains more glass fibers than wood pulp by mass ratio, and a core material made of a synthetic resin foam of nonwoven fabric (A); contact layer side is building member, characterized in that it contains a large amount of wood pulp than glass fibers or not contain glass fibers, or mass ratio.

(2) Synthesis in which the synthetic resin film (B) is cast / bonded on the surface of the nonwoven fabric (A) on the side to be bonded to the synthetic resin film (B) while the synthetic resin is heated and melted. a resin film (1) Construction member according.

  According to the present invention, in a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the pattern and shape of the surface material and the back material can be freely selected. It is possible to suppress problems such as warping of members, smoothness without causing fibrous lift when a synthetic resin film is bonded to a glass nonwoven fabric, less skin irritation during work, and to reduce the thickness. It is possible to provide a composite sheet for building members suitable as a back material that can be used. Moreover, the building member which provided such a composite sheet for building members on the single side | surface of a synthetic resin foam can be provided.

The composite sheet for building members of the present invention is a composite sheet in which a non-woven fabric (A) containing glass fiber, wood pulp, and binder fiber and a synthetic resin film (B) are bonded together, and the non-woven fabric (A) is 2 It is a multilayer sheet of layers or more, and the layer on the side of the nonwoven fabric (A) that is bonded to the synthetic resin film (B) does not contain wood pulp or contains more glass fibers than wood pulp by mass ratio. The layer in contact with the core made of the synthetic resin foam of the nonwoven fabric (A) is a composite sheet for building members that does not contain glass fibers or contains more wood pulp than glass fibers by mass ratio. Hereinafter, unless otherwise specified, “nonwoven fabric” in the present invention refers to “nonwoven fabric (A) containing glass fiber, wood pulp and binder fiber ”, and “synthetic resin film” refers to “synthetic resin film (B). ) ".

  Since glass fibers are small in expansion and contraction due to changes in temperature and humidity, nonwoven fabrics containing glass fibers hardly undergo dimensional changes due to changes in temperature and humidity, and have good dimensional stability.

  As long as the glass fiber according to the present invention is not easily broken and has a fiber sheet forming ability, any glass fiber of glass wool or glass fiber chopped strand (glass fiber cut product) can be used.

  2-20 micrometers is preferable, as for the fiber diameter of the glass fiber concerning this invention, 4-15 micrometers is more preferable, and 5-10 micrometers is more preferable. When the fiber diameter of the glass fiber is less than 2 μm, the dimensional stability may be inferior. On the other hand, when the fiber diameter of the glass fiber exceeds 20 μm, the formation is deteriorated when the sheet is formed, and the surface smoothness may be inferior. Moreover, 2-30 mm is preferable, as for the fiber length of glass fiber, 4-25 mm is more preferable, and 6-20 mm is further more preferable. If the fiber length of the glass fiber is less than 2 mm, the dimensional stability may be inferior. On the other hand, when the fiber length of the glass fiber exceeds 30 mm, kinks and clumps during papermaking are likely to occur, and the formed nonwoven fabric may be non-uniform.

  10-70 mass% is preferable with respect to the total compounding quantity of a nonwoven fabric, as for content of the glass fiber concerning this invention, 15-60 mass% is more preferable, and 20-55 mass% is further more preferable. If the glass fiber content is less than 10% by mass, the dimensional stability may deteriorate. On the other hand, if the glass fiber content exceeds 70% by mass, the dimensional stability is good, but the strength and surface smoothness may be inferior.

  The wood pulp according to the present invention may be NBKP, LBKP, NBSP, LBSP, GP, TMP, or any other type of pulp, and is not particularly limited, but NBKP is preferred from the viewpoint of strength. The beating degree (CSF) is preferably in the range of 300 to 600 ml. If the CSF is less than 300 ml, the dimensional stability of the nonwoven fabric may be reduced, and if the CSF exceeds 600 ml, the strength of the nonwoven fabric may be reduced.

  The content of wood pulp is preferably 5 to 70% by mass, more preferably 10 to 60% by mass, and still more preferably 20 to 50% by mass with respect to the total amount of the nonwoven fabric. When the content of the wood pulp is less than 5% by mass, the water-holding property of the sheet before drying becomes poor when it is produced by a wet papermaking method, and it may be difficult to peel off the felt. If the content of wood pulp exceeds 70% by mass, the dimensional stability of the nonwoven fabric may not be obtained.

  The nonwoven fabric according to the present invention contains at least one binder fiber in addition to glass fiber and wood pulp.

  Examples of the binder fiber used in the present invention include polyvinyl alcohol (PVA) fiber, viscose fiber, polyester fiber, and polyolefin fiber. The binder fiber may be a single fiber or a composite fiber such as a core-sheath fiber or a split fiber. Polyvinyl alcohol fiber is hardly dissolved in water at room temperature and keeps its fiber form, but when heated in a state containing moisture after paper making, it begins to dissolve easily. When pressed with equipment, it develops a binder ability that works between glass fiber and wood pulp, and then re-solidifies by dehydration and drying, resulting in a strong binder fiber that does not dissolve easily unless in high-temperature water. Are particularly preferred.

  The fiber diameter of the binder fiber according to the present invention is preferably 4 to 40 μm, more preferably 6 to 25 μm, and still more preferably 10 to 18 μm. When the fiber diameter of the binder fiber is less than 4 μm, it may fall off from the paper making wire during paper making, and the binder capacity may decrease. On the other hand, when the fiber diameter of the binder fiber exceeds 40 μm, the specific surface area of the fiber is It may be relatively lowered, the binder ability may be lowered, and the smoothness of the sheet surface may be inferior. The fiber length of the binder fiber is preferably 1 to 20 mm, more preferably 2 to 15 mm, and still more preferably 3 to 10 mm. When the fiber length of the binder fiber is less than 1 mm, the binder capacity may be reduced. On the other hand, when the fiber length of the binder fiber exceeds 20 mm, it may be easy to cause kinking or clumping during papermaking. The formed nonwoven fabric may be non-uniform.

  The content of the binder fiber is preferably 5 to 40% by mass, more preferably 7 to 30% by mass, and still more preferably 10 to 25% by mass with respect to the total amount of the nonwoven fabric. When the content of the binder fiber is less than 5% by mass, the tensile strength is weak and the paper may be cut off during wet papermaking. When the content of the binder fiber exceeds 40% by mass, the air permeability is lowered, and when the core material made of the synthetic resin foam is formed, the synthetic resin hardly penetrates into the non-woven fabric. Adhesion may be weak.

  The nonwoven fabric according to the present invention may contain fibers other than glass fiber, wood pulp, and binder fiber as necessary, such as adjustment of voids and strength. Examples of such fibers include regenerated fibers such as rayon, cupra, and lyocell fibers, polyester-based, polyolefin-based, polyamide-based, polyacrylic-based, vinylon-based, vinylidene, polyvinyl chloride, polyester-based, benzoate, polyclar, phenol Synthetic fibers and the like of the system can be mentioned, but the present invention is not limited to these.

  The nonwoven fabric which comprises the composite sheet for building members of this invention is a multilayer sheet | seat of 2 or more layers, and is manufactured by the wet papermaking method. The paper machine that can be used in the present invention is a combination paper machine in which two or more of the same or different types of these paper machines are installed on-line, such as a long paper machine, a circular paper machine, and an inclined wire type paper machine. Etc. The wet paper web made by these paper machines is dried by heating. As the heating and drying means, methods such as a cylinder dryer, an air dryer, a suction drum dryer, and an infrared dryer can be used.

  Although an example of the manufacturing method of the nonwoven fabric which comprises the composite sheet for building members of this invention below is given, this invention is not limited to this.

  For example, after adding a dispersant to water, glass fiber is added and stirred. The dispersant is not particularly limited, but it is preferable to use a nonionic dispersant. Thereafter, a viscous agent such as an aqueous polymer polyacrylamide solution or an aqueous polymer polyethylene oxide solution is added, and the mixture is stored as a glass fiber slurry while being stirred by a reciprocating stirrer. Moreover, after mixing and dispersing the wood pulp, the binder fiber, and the sizing agent after beating in water, it is sent to another storage tank as a wood pulp slurry. A glass fiber slurry and a wood pulp slurry are sent to a storage tank or a paper machine in a certain amount and mixed to form a wet paper web so as to obtain a target mixing ratio and basis weight. The obtained wet paper web is brought into contact with a cylinder dryer and heat-dried to efficiently fuse the binder fibers.

  The method of laminating two or more multilayer sheets is that the wet paper webs made by each paper machine are laminated while they are in a wet state, or after one wet paper web is formed, this wet paper web is formed. A method of forming a laminated nonwoven fabric by flowing a raw material slurry in which fibers are dispersed on a paper web may be used. Moreover, the method of flowing the raw material slurry which disperse | distributed fiber on the dried web, and forming the laminated nonwoven fabric may be used.

The basis weight of the nonwoven fabric is preferably 15~200g / ^{m 2,} more preferably 20 to 120 g / ^{m 2,} more preferably 30 to 100 g / ^{m 2.} When the basis weight of the nonwoven fabric is less than 15 g / m ² , dimensional stability may not be ensured. Moreover, when the basic weight of a nonwoven fabric exceeds 200 g / m < ² >, a synthetic resin foam may not fully immerse in a nonwoven fabric, and intensity | strength may become insufficient. Moreover, 50-500 micrometers is preferable, as for the thickness of a nonwoven fabric, 70-350 micrometers is more preferable, and 100-300 micrometers is more preferable. When the thickness of the nonwoven fabric is less than 50 μm, the rigidity may be insufficient. When the thickness exceeds 500 μm, the synthetic resin foam does not sufficiently soak into the nonwoven fabric, resulting in insufficient strength or obstructing the thinning characteristics. There is. The density of the nonwoven fabric is preferably 0.10~0.90g / cm ^3, more preferably 0.15~0.80g / cm ^3, more preferably 0.20~0.60g / cm ^3. When the density of the nonwoven fabric is less than 0.10 g / cm ³ , the inter-fiber adhesion may be poor and dimensional stability may not be ensured. On the other hand, if the density of the nonwoven fabric exceeds 0.90 g / cm ³ , the glass fiber may be broken and sufficient dimensional stability may not be obtained.

  Moreover, the nonwoven fabric concerning this invention can be mix | blended with a sizing agent as needed, such as giving moisture resistance and water repellency. As the sizing agent, any reinforced rosin sizing agent, rosin emulsion sizing agent, petroleum resin sizing agent, synthetic sizing agent, neutral rosin sizing agent, alkyl ketene dimer (AKD) may be used as long as the desired effect of the present invention is not impaired. Any of known sizing agents such as) can be used.

  In addition to these, an anionic, nonionic, cationic or amphoteric retention improver, a filtering agent, a dispersant, a paper strength improver and a sticking agent are appropriately selected and used as necessary. Moreover, internal additives for papermaking, such as a pH adjuster, an antifoaming agent, a pitch control agent, and a slime control agent, can be appropriately added depending on the purpose.

  In addition, if necessary, it contains clay, kaolin, calcined kaolin, talc, calcium carbonate, titanium dioxide, and other self-extinguishing fillers such as aluminum hydroxide and magnesium hydroxide. Can be made.

  Examples of the material for the synthetic resin film according to the present invention include polyolefins such as polyethylene and polypropylene, polyamide, acrylic, polyurethane, ethylene-vinyl acetate copolymer, polyvinyl chloride, polyvinyl alcohol, styrene-butadiene copolymer, polyethylene terephthalate, Synthetic resins such as polyester such as polytrimethylene terephthalate, polyacrylonitrile, polystyrene, and modified resins thereof are used. Further, a synthetic resin film colored by kneading an inorganic or organic pigment may be used.

  Although there is no restriction | limiting as a thickness of a synthetic resin film, Generally 3-200 micrometers is preferable, 10-100 micrometers is more preferable, 20-70 micrometers is especially preferable. If the thickness is less than 3 μm, adhesion to the nonwoven fabric may be insufficient, or the fibrous float on the nonwoven fabric surface may appear to be large. On the other hand, if the synthetic resin film is thicker than 200 μm, the thinning feature may be hindered, and warping may occur due to expansion or contraction of the synthetic resin film due to temperature.

  As a method of laminating a synthetic resin film to a nonwoven fabric, (1) using a hot melt extruder on a traveling nonwoven fabric, a thermoplastic synthetic resin composition is heated and melted from its slit die into a film shape. Casting and covering, so-called hot melt extrusion laminating method, (2) a method of laminating a thermoplastic synthetic resin film with a nonwoven fabric and integrating them by hot pressing, (3) between the synthetic resin film and the nonwoven fabric, Examples include a method of laminating a thermoplastic film and integrating them by hot rolling, and a method of (4) laminating a synthetic resin film with a nonwoven fabric using an adhesive, but the present invention is not limited thereto. Absent.

  Moreover, the synthetic resin film was cast / bonded in a state where the synthetic resin was heated and melted on the surface of the nonwoven fabric on the side to be bonded to the synthetic resin film (the hot melt extrusion lamination method of (1) above) Is not only strong but also easy to thin because the synthetic resin penetrates between the fibers of the non-woven fabric. It is particularly preferable because it is less likely to curl than the method of making it.

  The building component composite sheet of the present invention is a composite sheet in which a nonwoven fabric containing glass fibers and wood pulp and a synthetic resin film are bonded together. By containing wood pulp, the nonwoven fabric can have a certain level of cushioning properties, so when bonded to a synthetic resin film, hard glass fibers appear to float on the synthetic resin film. Can be prevented.

  Further, in the nonwoven fabric according to the present invention, the layer on the side to be bonded to the synthetic resin film does not contain wood pulp or contains more glass fibers than wood pulp by mass ratio. The synthetic resin film is bonded by using a hot melt extrusion laminating method, a hot press treatment, an adhesive, or the like, but the adhesive or the hot melt synthetic resin has a high viscosity. Glass fiber is coarser than wood pulp, so if there is a lot of glass fiber on the side to be bonded to the synthetic resin film of the nonwoven fabric, high-viscosity hot-melt synthetic resin or adhesive will penetrate between the nonwoven fabric fibers and adhere Strength increases. On the other hand, if the content of the wood pulp in the layer to be bonded to the synthetic resin film is large, not only the adhesive strength may be weakened, but the wood pulp is easy to absorb moisture, so moisture entering from the edge portion. May be susceptible to

  Furthermore, in the nonwoven fabric according to the present invention, the layer in contact with the core made of the synthetic resin foam does not contain glass fibers or contains more wood pulp than glass fibers by mass ratio. By containing a large amount of wood pulp, skin irritation caused by glass fibers can be suppressed, so that adverse effects on workers when manufacturing building members can be suppressed. In addition, when forming a synthetic resin foam, the stock solution generally has a low viscosity, but the synthetic resin foam and the nonwoven fabric are integrated by the permeation of the low viscosity stock solution between the fibers of the nonwoven fabric due to the capillary action of wood pulp. The adhesion becomes stronger. Furthermore, when the undiluted | stock solution of a synthetic resin foam osmose | permeates a wood pulp, it becomes difficult to receive the influence of the moisture which penetrate | invades from an edge part. On the other hand, when there are more glass fibers than wood pulp, glass fibers are coarser than wood pulp, so the synthetic resin foam stock solution cannot be held between the fibers, and adhesion is not achieved. Insufficient glass fiber may be brittle because it is harder than wood pulp.

  Moreover, this invention is also a building member by which the composite sheet for building members of this invention is provided in one surface of the core material which consists of a synthetic resin foam.

  The core material composed of the synthetic resin foam according to the present invention is composed of a synthetic resin foam such as polyurethane foam, polyisocyanurate foam, phenol foam, vinyl chloride foam, polyethylene foam, polystyrene foam, urea foam, and the like. Especially when fire resistance is required, it is formed by mixing a stock solution of resol type phenol, a curing agent and a foaming agent, and generally discharging it to the surface material and / or the backside material and heating it to react, foam and cure. It is a thing.

  In addition, lightweight aggregates (perlite grains, glass beads, gypsum slag, talc stone, shirasu balloon, aluminum hydroxide, etc.), fibrous materials (glass wool, rock wool, carbon fiber, graphite, etc.) ) Can be mixed to improve fire resistance and fire resistance.

  Examples of the surface material that can be used in the present invention include iron, aluminum, copper, stainless steel, titanium, aluminum / zinc alloy-plated steel plate, galvalume steel plate, enameled steel plate, clad steel plate, laminated steel plate (vinyl chloride steel plate, etc.), sandwich steel plate ( Damping steel plate, etc.), vinyl chloride resin, polycarbonate resin, etc. (including painted color plate) are molded into various shapes by roll molding, press molding, extrusion molding, etc., or inorganic materials are extrusion molded, press molded Examples thereof include those formed into various arbitrary shapes such as an autoclave ripening form.

  Further, on the synthetic resin film side of the composite sheet for building members of the present invention, aluminum vapor-deposited paper, kraft paper, asphalt felt, metal foil (Al, Fe, Pb, Cu), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper Alternatively, aluminum hydroxide paper or the like may be bonded.

  EXAMPLES Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited to the examples.

[Preparation of Glass Fiber Dispersion-A]
Commercial chopped strand glass fiber (fiber diameter 9 μm, fiber length 6 mm) and fibrous binder (trade name: VPB107, manufactured by Kuraray Co., Ltd., 1.1 dt × 3 mm, PVA fiber) are 85:15 respectively in the water in the pulper dispersion tank. Was added and mixed and dispersed for 10 minutes to prepare a glass fiber dispersion-A.

[Preparation of Glass Fiber Dispersion-B]
Glass fiber except that commercially available chopped strand glass fiber (fiber diameter 6 μm, fiber length 9 mm) was used in place of commercially available chopped strand glass fiber (fiber diameter 9 μm, fiber length 6 mm) in Glass Fiber Dispersion-A Glass fiber dispersion-B was prepared in the same manner as dispersion-A.

[Preparation of wood pulp dispersion]
NBKP (wood pulp fiber) beaten in 500 ml CSF and fibrous binder (trade name: VPB107, manufactured by Kuraray Co., Ltd., 1.1 dt × 3 mm, PVA fiber) are added to the water in the pulper dispersion tank at a ratio of 85:15. A wood pulp dispersion was prepared by mixing and dispersing for 10 minutes.

[Production of non-woven fabrics 1 to 10]
Non-woven fabrics 1 to 10 were produced using a combination paper machine in which an inclined wire type paper machine and a circular net paper machine were installed online. The glass fiber dispersion and the wood pulp dispersion are stored in storage tanks for the first layer (for the inclined wire type paper machine) and for the second layer (for the circular net paper machine) so that the mixing ratio shown in Table 1 is obtained. Sent and mixed. The mixed dispersions are sent to the first paper head (inclined wire type paper machine) and the second paper machine head (circular paper machine), respectively, so that the basis weight shown in Table 1 is reached, and the paper is combined in the wet paper web state. After that, it was pressed and dried so that the surface of the second layer was in contact with the Yankee dryer surface, and nonwoven fabrics 1 to 10 having two layers shown in Table 1 were obtained.

The details of the abbreviations shown in Table 1 are as follows.
G: Glass fiber P: Wood pulp

[Production of non-woven fabrics 11 to 14]
Nonwoven fabrics 11-14 were produced using only the first papermaking head (inclined wire type papermaking machine) of the combination papermaking machine used in the production of nonwoven fabrics-1-10. The glass fiber dispersion-A and the wood pulp dispersion were sent to the storage tank so that the mixing ratio shown in Table 2 was obtained. The mixed dispersion was sent to the first papermaking head, pressed in the state of a wet paper web, dried against the Yankee dryer surface, and single layer nonwoven fabrics 11 to 14 shown in Table 2 were obtained.

  The details of the abbreviations shown in Table 2 are the same as those in Table 1.

[Manufacture of composite sheets for building components]
<Examples 1 to 10>
Polyolefin resin (mixed resin of 60 parts of high-density polyethylene and 40 parts of low-density polyethylene) is heated and melted with an extruder, and the film thickness is 50 μm between the first layer side of the nonwoven fabric-1-10 and the cooling roll. The composite sheet for building members of Examples 1 to 10 was obtained by extruding to obtain a synthetic resin film, followed by pressure bonding and cooling.

<Comparative Examples 1-4>
Polyolefin resin (mixed resin of 60 parts of high-density polyethylene and 40 parts of low-density polyethylene) is heated and melted with an extruder, and the film thickness is 50 μm between the second layer side of the nonwoven fabrics 1 to 4 and the cooling roll. A composite resin film was obtained by extruding to obtain a synthetic resin film, followed by pressure bonding and cooling.

<Comparative Examples 5-8>
Polyolefin resin (mixed resin of 60 parts of high-density polyethylene and 40 parts of low-density polyethylene) is heated and melted with an extruder, and extruded between the nonwoven fabrics 11-14 and the cooling roll so that the thickness is 50 μm. A synthetic resin film was obtained, and crimped and cooled to obtain composite sheets for building members of Comparative Examples 5 to 8.

<Example 11>
A stretched high-density polyethylene resin film (thickness 30 μm) was used as the synthetic resin film, and this was bonded to nonwoven fabric-3 to obtain a composite sheet for building members of Example 11. The method of laminating is to discharge a low density polyolefin resin into a film (thickness 20 μm) by extrusion molding, and interpose the melted low density polyethylene resin between the stretched high density polyethylene resin sheet and the nonwoven fabric-3. It was carried out by heat fusing.

<Example 12>
A stretched high-density polyethylene resin film (thickness 30 μm) was used as a synthetic resin film, and this was bonded to nonwoven fabric-3 to obtain a composite sheet for building members of Example 12. The bonding method is performed by applying 20 g / m ^{2 of} a solventless acrylic resin adhesive to one side of the stretched high-density polyethylene resin film, and bonding Non-woven fabric-3 to the side where the adhesive is applied. did.

[Manufacture of building components]
<Examples 13 to 24>
An iron plate (0.27 mm) is used as a surface material, the composite sheet for building members obtained in Examples 1 to 12 is used as a back material, a hard polyurethane foam is used as a core material (10 mm), and 2 between the surface material and the back material. A stock solution of liquid rigid polyurethane foam was poured and allowed to stand for 24 hours to sufficiently complete foaming and curing, and building members of Examples 13 to 24 were obtained. In addition, the composite sheet for building members was such that the surface on the nonwoven fabric side was in contact with the core material.

[Comparative Examples 9 to 16]
Except having used the composite sheet for building members obtained in Comparative Examples 1-8 instead of the composite sheet for building members obtained in Examples 1-12 in Examples 13-24, it was carried out similarly to Examples 13-24. The building members of Comparative Examples 9 to 16 were manufactured.

[Evaluation]
[Skin irritation]
The surface on the nonwoven fabric side of the composite sheet for building members produced in Examples 1 to 12 and Comparative Examples 1 to 8 was touched, and skin irritation was confirmed according to the following criteria. The results are shown in Table 3.
○: Almost no skin irritation.
Δ: Slight skin irritation is observed.
X: The skin is obviously irritated.
In addition, (circle) or (triangle | delta) is a level which is satisfactory.

  From the comparison of Examples 1 to 4 and Comparative Examples 1 to 4, even when the same nonwoven fabric is used, the layer in contact with the core made of the synthetic resin foam of the nonwoven fabric does not use wood pulp, or wood pulp by mass ratio. If the glass fiber content is higher than that, skin irritation is a problem. Similarly, in Examples 5 to 12 and Comparative Examples 5 to 8, the layer in contact with the core made of the synthetic resin foam of the nonwoven fabric does not use wood pulp or contains more glass fibers than wood pulp by mass ratio. Skin irritation is a serious problem.

[Fibrous float]
The composite sheets for building members produced in Examples 1 to 12 and Comparative Examples 1 to 8 were observed on the surface from the polyolefin resin side, and it was visually observed based on the following criteria whether fiber-like floating due to glass fibers could be confirmed. . The results are shown in Table 3.
A: Almost no fibrous float is observed, and it is smooth.
Δ: Slight lifting is observed.
X: Floating is clearly recognized.
In addition, (circle) or (triangle | delta) is a level which is satisfactory.

  From Comparative Examples 5 to 6, when the nonwoven fabric is not a laminate but a single layer and does not contain wood pulp, or contains more glass fibers than wood pulp by mass ratio, from the polyolefin resin side, The fibrous lift of the nonwoven fabric is confirmed.

[Warping of building components]
For the building members of Examples 13 to 24 and Comparative Examples 9 to 16, a thermal cycle test was conducted at -20 ° C., 10% RH for 12 hours, 70 ° C., 60% RH for 12 hours, and a total of 24 hours as one cycle. The difference between the amount of warpage before and after the test after 24 cycles was measured. In addition, evaluation of curvature used the building member of the magnitude | size of 1 m in length, and the width of 37 cm, measured the curvature about three points, 20 cm, 50 cm, and 80 cm from the edge part, and described the maximum value and the minimum value of the warp in width. . The results are shown in Table 4. The maximum value of warpage is less than 1.5 mm.

  From the comparison between Examples 13 to 16 and Comparative Examples 9 to 12, even when the same nonwoven fabric is used, the layer on the side bonded to the polyolefin resin contains more wood pulp than the glass fiber by mass ratio. And the maximum value of warpage is large. This is presumed to be due to the fact that a large amount of wood pulp is present at the interface between the polyolefin resin and the nonwoven fabric, so that moisture easily enters. Similarly, in Comparative Examples 15 to 16, the layer on the side bonded to the polyolefin resin contains more wood pulp than the glass fiber in mass ratio, and the maximum value of warpage is large.

  From the comparison between Example 15 and Example 24, when a synthetic resin film cast / bonded in a state in which the synthetic resin is heated and melted is used as the synthetic resin film, the maximum value of warpage is small. This is considered to be because the molten synthetic resin penetrates into the nonwoven fabric and the adhesion becomes strong. In comparison between Example 15 and Example 23, Example 23 is slightly warped at the maximum value. However, this is considered to be because the thermal expansion and shrinkage of the synthetic resin film and the low-density polyethylene used for adhesion are different in Example 23.

  The composite sheet for building material of the present invention can be suitably used as a back material used for building members such as metal siding and building panels.

Claims (2)

In a building member in which a surface material is provided on one surface of a core material made of a synthetic resin foam and a back material is provided on the other surface, the composite sheet for building material used as the back material is made of glass fiber, wood pulp, and binder fiber. Is a composite sheet obtained by laminating a non-woven fabric (A) and a synthetic resin film (B), and the non-woven fabric (A) is a multilayer sheet of two or more layers, and the non-woven fabric (A) synthetic resin film ( The layer on the side to be bonded to B) does not contain wood pulp, or contains more glass fibers than wood pulp by mass ratio, and is on the side in contact with the core made of the synthetic resin foam of the nonwoven fabric (A). layers, building member, characterized in that it contains a large amount of wood pulp than glass fibers or not contain glass fibers, or mass ratio. A synthetic resin film in which the synthetic resin film (B) is cast / bonded in a state where the synthetic resin is heated and melted on the surface of the nonwoven fabric (A) on the side to be bonded to the synthetic resin film (B). Construction member of a claim 1, wherein.