JPH0622973B2 - Manufacturing method of building materials - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a building material having excellent fire resistance and sound insulation.

Conventional technology and problems to be solved by the invention Conventionally, as a base material for partition walls, ceilings, etc., generally, a gypsum board using a hydraulic substance as a binder, a wood cement board, or a base material made of plywood or particle board. The one in which a metal plate is attached and integrated on the surface of is used.

Since the former is composed of non-combustible material, it has tentative fire resistance, but when exposed to a flame, the moisture contained in the crystals is released, and the vapor explodes or the strength drops sharply. There was a drawback.

On the other hand, in the latter case, the heat transfer coefficient and the thermal expansion coefficient of the metal plate are large, and therefore, when exposed to a high temperature, stress concentrates on the interface between the base material and the metal plate, and there is a drawback that peeling or warpage occurs.

Therefore, when the building material according to the above-mentioned conventional example is used for a partition wall or a ceiling, problems such as sudden collapse and fall of the fire and deformation of the evacuation opening and opening of the door have been pointed out.

On the other hand, a wood material having a large cross-sectional area is excellent in fire resistance because even if it is in a fire, its surface is only carbonized, damage due to flame does not progress inside, and thermal stress is small. There is a report. Therefore, it has been proposed to carbonize the surface of the building material in advance with, for example, a burner to form a carbonized layer.

However, since the carbonized layer is porous in this method,
Oxygen easily passes through the carbonized layer to reach the substrate. Therefore, if the base material is thin, there is a problem in that the base material is easily ignited and burned to penetrate the flame.

Therefore, in order to provide a dense protective layer on the surface of the base material, it has been considered to fix the carbon powder particles to the surface of the base material using a thermosetting synthetic resin as a binder.

However, the carbon powder particles are difficult to wet with the thermosetting synthetic resin, and are difficult to be uniformly dispersed only by kneading and coating, so that the density of the protective layer becomes non-uniform and the fire resistance tends to vary.

In view of the above problems, the present invention aims to improve fire resistance by forming a protective layer having a dense and uniform thickness on the surface of a base material.

Means for Solving the Problems The present invention, in order to achieve the above object, after arranging a self-curing sheet-like material mainly composed of powder particles consisting of a carbon component and a thermosetting resin on the surface of a substrate, A method for manufacturing a building material, comprising heating and pressing to form an integral protective layer on the surface of a base material.

In addition to wood, the powder grains mainly composed of carbon components are seeds of grassy plants such as kollyan, wheat, sugar cane, rice and millet, hulls, trunks, branches, leaves, etc. It is obtained by thermally decomposing and baking, and the higher the treatment temperature is, the more preferable.
For example, if the treatment temperature is 300 ° C. to 500 ° C., carbonization proceeds, but if calcined at a temperature of 1000 ° C. or higher, the carbon shrinks, the specific surface area becomes small, and the carbon becomes rich. It is more preferable because it becomes difficult to burn.

Thus, in addition to the artificially made charcoal and graphite, naturally occurring graphite and various charcoals can be used as carbon powder particles. If scale-like carbon powder particles are used among these, they overlap each other when forming the protective layer, so that there is an advantage that a dense protective layer can be formed. The particle size of this carbon powder is 30
~ 2000 microns is preferred.

An inorganic powder such as silica, alumina, magnesia may be mixed with the powder particles. Further, it is preferable to calcine a material having a large amount of silica such as chaff, because a mixture with carbon powder is obtained.

On the other hand, as the thermosetting resin, for example, a novolac-type or resol-type phenol resin or an initial condensate of a melamine resin is suitable in order to improve wettability with carbon powder particles. Especially, since phenolic resin has a large amount of fixed carbon,
Carbonization by pyrolysis has the advantage that the heat insulating property is enhanced and the fire resistance is further improved.

There are various methods for producing the self-curing sheet material, and among the first production methods, the method for obtaining the self-curing carbon powder is as follows: carbon powder and solid thermosetting low molecular weight. A material, for example, an initial condensate of a resol type phenolic resin is put into a kneader, and these are kneaded with an alcohol solvent or the like, then the kneaded product is taken out of the kneader, the molded product extruded and dried, and then ground There is a method of obtaining a self-curing carbon powder.

Further, as another method of obtaining a self-curing carbon powder material in which a resin is uniformly attached to the surface of carbon powder particles, when synthesizing a phenol resin, these carbon powder particles are put in a reaction vessel in advance. There is a method in which a resin is uniformly attached to the surface of the carbon powder particles by reacting, and the resin is allowed to pass and then dried to obtain a self-curing carbon powder material.

Then, the self-curing carbon powder is pressed with a roll at 50 ° C. to 100 ° C. and partially pressure-bonded to obtain a sheet material having a predetermined thickness.

In this manufacturing method, if a paper, a non-woven fabric, a fibrous material, a resin sheet, or the like is arranged on one side and integrated, and this is used as a decorative layer, a cosmetic process described later can be omitted.

A second manufacturing method is a method in which carbon powder and thermosetting resin are kneaded in a paste form through various solvents, then pressed by a roll as it is, extruded into a sheet form, and wound with release paper. .

As a third production method, a strong acid is added to graphite to generate an intercalation compound, which is heated to expand it by about 10 to 100 times, and then heated at room temperature by pressing with a roll to obtain a sheet-like material. There is a method of impregnating a curable resin.

The content of carbon powder particles in the self-curing sheet material is 50% or more, preferably 60 to 80% by weight ratio, and the specific gravity is 0.8 or more, preferably 1.0 to 1.2.

Further, if necessary, a fibrous material, a lightweight aggregate or the like may be added as an extender or a reinforcing material.

As the base material, plywood, particle board, LVL, wood veneer such as wood veneer, gypsum material, calcium silicate board,
Examples of the water-curable inorganic material include a wood chip cement board and a slag gypsum board, but the base material is not necessarily limited to a plate shape, and may be a columnar shape or a rod shape.

When the base material is a wood material, the wood material itself has low thermal conductivity, and a carbonized layer is generated by thermal decomposition at the interface with the protective layer described below, and this carbonized layer serves as a heat insulating material. , Effectively prevent thermal decomposition inside. Further, since the carbonized layer relieves the stress generated between the base material and the protective layer, there is an advantage that delamination and cracks are unlikely to occur.

On the other hand, when the base material is an inorganic material, the base material is not directly exposed to the flame due to the presence of the dense and uniform protective layer,
The water contained in the crystals is less liberated, explosion is less likely to occur, and the fire resistance of the base material is improved.

As a method of forming the protective layer on the surface of the base material, for example, there is a method of coating the surface of the base material with a self-curing sheet-like material, and then heating and pressing to laminate and integrate them.

As another method, a self-curing sheet material is placed on the upper surface or the lower surface of a forming mat formed by kneading a small piece of wood and a binder such as an adhesive or cement, and heat-pressing the formed material. There is a method of forming a protective layer at the same time as the plate.

According to this method, since a mixed and integrated layer is formed at the interface between the base material and the protective material, there is an advantage that it strongly adheres and peeling or cracking hardly occurs.

The thickness of the protective layer to be formed is 0.5 to 5 mm, preferably 1 to
3mm is good.

If protective layers are provided on both sides of the plate-shaped substrate, not only on one side, a so-called sandwich construction is formed and the physical and mechanical properties of the material are stabilized, so that warpage is unlikely to occur. Moreover, since the protective layer becomes thicker, the flame is less likely to penetrate during a fire, and the sound insulation is improved.

It is preferable that a decorative layer made of a decorative sheet such as a thin wooden plate, a synthetic resin sheet, or a glass cloth is provided on the surface of the protective layer.

Example 1 10 kg of graphite was put into a double-arm kneader and the softening point was set to 8
After adding 11 kg of 60% methanol varnish of solid resol type phenol resin at 0 ° C. and stirring and kneading for 30 minutes, this kneaded product was extruded by a continuous kneading extruder to make a round bar having a diameter of 3 mm, and the round bar was air-dried. Evaporate the solvent methanol,
Then, this was crushed by a crusher to obtain a self-curing carbon powder having a particle diameter of 0.5 mm or less.

Next, this self-curing carbon powder is evenly sprayed at 80 ° C.
Then, it was pressed with a roll to form a self-curing sheet having a thickness of 0.5 mm.

Then, this self-curing sheet-like material was superposed on the surface of a particle board (commercially available) having a thickness of 12 mm, and heat-pressed at 160 ° C. for 5 minutes to obtain a plate-like construction material as a sample.

Example 2 Instead of the self-curing sheet material of Example 1, 10 kg of bark charcoal was put in a double-arm kneader, and further, a resole-type phenol resin 6.5 having a viscosity of 200 poise at 25 ° C.
After adding kg, stirring and kneading for 30 minutes and discharging, the kneaded material was pressed with a roll to obtain a self-curing sheet material having a thickness of 1 mm.

Then, other than that, the building material obtained by operating in the same manner as in Example 1 was used as a sample.

Example 3 Instead of the self-curing sheet material of Example 1, a mixed solution of sulfuric acid and nitric acid was added to natural graphite to form an intercalation compound, which was then heat treated in an oven at 800 ° C. for 30 minutes. Expanded graphite was obtained by pressing it with a roll to form a sheet having a thickness of 1 mm, and then a self-curing sheet was obtained by impregnating this with a resole-type phenol resin in a weight ratio of 40%.

Then, a building material obtained by operating in the same manner as in Example 1 was used as a sample.

Example 45 In a four-necked flask of 5, 770 g of phenol, 37%
1328g formalin, 80g hexamethine tetramine
Was further charged, and then flake graphite 110 having an average particle size of 5 μm
0g was charged.

The temperature was raised to 90 ° C. in about 60 minutes, the reaction was continued for 3 hours, cooled, and then separated. This was air-dried to obtain 1830 g of self-curing carbon powder particles having an average particle size of 50 μm. The content of the phenol resin in the obtained powder and granular material was 40%.

The building material obtained by operating this self-curing carbon powder in the same manner as in Example 1 was used as a sample.

Comparative Example 1 A commercially available wood chip cement board having a specific gravity of 1.15 was used as a sample.

Comparative Example 2 A commercially available gypsum board (general-purpose product) was used as a sample.

Then, a bending creep test under flame was carried out for Examples 1, 2, 3 and Comparative Examples 1, 2.

The bending creep test under flame is for knowing the fire resistance bending performance in a high temperature environment, and uses the board bending performance test method and device according to JIS A5908. The device corresponds to the back side of the central concentrated load point. Where you want to
It is arranged so that the tip of the flame of the Bunsen burner, which is supplied with city gas through a stabilizer so as to maintain a constant flow rate, is applied.

The flame tip temperature was about 700 ° C., a load set to ⅕ of the bending fracture strength of the sample was applied, and the time required until the fracture and the displacement amount at the load point were measured.

The measurement results are shown in Table 1.

As is clear from the above measurement results, Examples 1, 2,
It was found that all of 3 and 4 had a fire resistance performance 3 to 9 times that of Comparative Examples 1 and 2.

EFFECTS OF THE INVENTION As is clear from the above description, if a sheet-shaped material is placed on the surface of a substrate and then heat-pressed to form a protective layer, a uniform and dense protective layer is formed on the surface of the substrate. Therefore, it is possible to obtain a building material having no variation in fire resistance.

Moreover, since the carbon powder particles forming the protective layer have a function as an extender pigment by themselves through the thermosetting resin,
Even if the base material is porous, it penetrates into the pores of the base material and strongly integrates with the base material. Further, since the protective layer made of carbon powder particles has a small thermal expansion, the stress concentration generated between the base material and the protective layer in a high temperature environment is extremely small. As a result, warpage, peeling, cracks, etc. are unlikely to occur, and sufficient strength can be maintained for a long time even in the event of a fire.

Further, the building material of the present application coated with a uniform and dense protective layer composed of carbon powder particles and synthetic resin has a large oxygen index of the carbon powder particles, so that it is difficult to burn in the air and oxygen is blocked. For this reason, even if the base material is a wood material, the interior does not burn, so the flame does not penetrate, and there is a useful effect on fire resistance that it does not suddenly fall off during a fire.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor ▲ Yoshi ▼ Yasuro Tada 1 Inami, Inami-cho, Inami-cho, Higashibura-gun, Toyama Prefecture Within Daiken Kogyo Co., Ltd. Previous 4-21 (72) Inventor Atsushi Takamatsu 2-14-5 Uchishiro-cho, Miyakojima-ku, Osaka-shi, Osaka (72) Inventor Isamu Ide 1648-15 Kanaoka-cho, Sakai-shi, Osaka

Claims (1)

[Claims] 1. A self-curing sheet material mainly composed of powdery particles of a carbon component and a thermosetting resin is placed on the surface of a base material and then heated and pressed to integrally protect the surface of the base material. A method for manufacturing a building material, which comprises forming a layer.