JPS6136355Y2 - - Google Patents

Description

[Detailed Description of the Invention] The present invention relates to a composite building material composed of three layers. More specifically, on one side of the intermediate layer 2 made of a flexible sheet-like foam having a closed cell structure,
(a) Non-hydraulic inorganic powder containing dihydrate gypsum or water of crystallization, (b) Inorganic fibrous material, (c)
An organic binder component based on a thermoplastic resin and (d) selected from (A) a water-soluble thermosetting resin, (B) an alkali metal silicate, (C) a phosphoric acid compound, and (D) a boric acid compound. A surface layer 1 made of a flexible sheet-like material having an open cell structure composed of one or more types of fire-resistant binder components is laminated, and a metal plate 3 is further laminated on the other surface of the intermediate layer 2. It is a useful composite building material that is suitable for use as roofing material, wall material, etc., and has excellent heat insulation, dew condensation prevention, soundproofing, durability, fireproofing, and fireproofing properties. Concerning composite building materials.

In recent years, due to the promotion of energy-saving movements and the rationalization of processes, folded-plate roofing materials and metal siding materials (wall materials), which are composites of metal plates and various heat insulating materials, have been widely used. However, the mainstream of these insulation materials is polyethylene foam or polyurethane foam, which has excellent insulation effects but is flammable, and has a fatal defect in fire prevention performance as a building material. In contrast, some noncombustible insulation materials are used, but for example, asbestos pine and glass pine, which are being used in folded-plate roofing materials, have problems with folding processability and have poor insulation properties. It is not safe to use as it also causes pollution problems. In addition, in the field of metal siding, a fireproof structure can only be achieved by using 12 mm thick gypsum board as a backing material, but it is heavy and lacks heat insulation and water resistance.

In view of the above-mentioned current situation, the present inventors first developed a flexible sheet-like material with an open cell structure composed of gypsum dihydrate or an inorganic powder containing it as a main component, and a small amount of a binder component, and a metal. We have filed an application for a composite plate-shaped building material with a plate, or a composite plate-shaped building material with a metal plate, with the sheet as a surface layer and a flexible material with heat insulation properties as an intermediate layer. This idea was arrived at after repeated research. That is, the composite building material according to the present invention is mainly composed of four components: a flexible sheet-like material 1 having an open-cell structure, a flexible sheet-like foam 2 having a closed-cell structure, and a metal plate 3.
A two-layer composite building material consisting of a conventional sheet-like foam 2 having a closed cell structure such as polyethylene foam and a metal plate 3, which further has an open cell structure made of a special composition on its surface. By laminating the flexible sheet material 1, the fire resistance, which was a fatal defect of the two-layer composite building material, can be improved without losing the excellent foldability and heat insulation properties of the two-layer composite building material. and has further improved fire resistance, as well as further improved condensation and soundproofing properties.
It is an excellent building material suitable for roofing or wall materials. For example, in the case of conventional two-layer composite building materials, in terms of fire prevention performance, Article 108 of the Enforcement Order of the Building Standards Act as stipulated in Ministry of Construction Notification No. 1828 of 1970 or Ministry of Construction Notification No. 1231 of 1976. 2 or 1st
In order to be designated as a "semi-noncombustible material" in the method for designating noncombustible or semi-noncombustible materials based on the provisions of Article 5, the thickness of the sheet-like foam that is a heat insulating material must be 4 mm or less. Furthermore, since it is not a noncombustible material, various architectural restrictions are imposed on the use of the two-layer composite building material as a roofing material. However, due to the effect of the flexible sheet material on the surface layer, the three-layer composite building material according to the present invention is considered a "non-flammable material" or "quasi-non-flammable material" in terms of fire prevention performance even if the thickness of each insulation layer is considerably thickened. I confirmed that I could pass.
Furthermore, roof structures in which V-shaped, U-shaped, or similar folded plate structures made of composite building materials according to the present invention are joined adjacently by the flap method or the overlapping method were notified by the Ministry of Construction in 1961. In the method of designating fire-resistant structures based on the provisions of Article 107, Item 1 of the Enforcement Order of the Building Standards Act as specified in No. 2999,
It was confirmed that the product had the performance to be designated as ``30-minute fire-resistant structure''. Furthermore, wall structures using metal siding materials composed of composite building materials according to the present invention are subject to Article 108 of the Enforcement Order of the Building Standards Act as specified in Ministry of Construction Notification No. 2545 of 1952.
It was confirmed that the structure has the performance to be designated as a "fireproof structure with a non-combustible base" or a "fireproof structure with a wooden base" in accordance with the method for designating fireproof structures based on the provisions of Item 1 or 2.

In addition, the composite building material according to the present invention has an ideal structure in terms of heat insulation and anti-condensation properties.In the conventional two-layer composite building material, the surface insulation material is a foam with a closed cell structure. When dew condensation occurs, water droplets immediately drip and cause stains inside the room, which is an inconvenience, but the three-layer composite building material of the present invention has a surface layer made of a sheet material with an open cell structure, so water droplets that condense are easily removed. It is absorbed into the surface layer and does not drip, and has dew condensation prevention properties due to the respiration effect, such that moisture absorbed through condensation at night is dried and released during the day. Furthermore, when the insulation material is composed only of open cells, it has the disadvantage that the insulation properties are significantly reduced due to water absorption during condensation, but the three-layer composite building material of the present invention Since the layer is a foam having a closed cell structure, such inconvenience does not occur, and excellent heat insulation properties can be maintained for a long period of time. Furthermore, in terms of soundproofing, it combines the excellent sound-absorbing performance of a sheet-like material with an open-cell structure in the surface layer, and the excellent sound-insulating performance unique to a sandwich structure produced by sandwiching a lightweight intermediate layer. It is something that can be done.

The composite building material of the present invention will be explained based on FIGS. 1 to 3. FIG. 1 is a cross-sectional view showing an example of the composite building material of the present invention, which is composed of a surface layer 1 made of a flexible sheet-like material having an open-cell structure and a flexible sheet-like foam having a closed-cell structure. The intermediate layer 2 and the metal plate 3 constitute the composite building material of the present invention. The surface layer 1 and the intermediate layer 2, and the intermediate layer 2 and the metal plate 3 are composited with a suitable adhesive layer 4 interposed therebetween. FIG. 2 shows an example of a folded-plate roof structure made of the composite building material of the present invention, in which the folded-plate roofing materials that are joined adjacently by the stacking method are bounded by fixing bolts 5 and tight frames 6. It is fixed to a beam 7 made of a steel frame, and constitutes a folded plate roof structure. Figure 3 shows an example of a wall structure using metal siding made of the composite building material of the present invention. This shows a state in which various coatings have been applied, and a state in which a sheet-like reinforcing material suitable as an interior material is composited on the surface of a flexible sheet-like material as a surface layer.

Examples of the non-hydraulic inorganic powder containing bound water used in the flexible sheet material having an open cell structure forming the surface layer of the present invention include gypsum dihydrate, aluminum hydroxide, borax, aluminum sulfate, Magnesium hydroxide, kaolinite, etc. can be mentioned, and the use of these is effective in obtaining a flexible sheet material as well as fireproofing and fire resistance. Furthermore, it is also possible to replace a part of these inorganic powders with thermally decomposable powders such as calcium carbonate, and lightweight powders such as perlite and shirasu balloons. However, in the case of hydraulic inorganic powder such as cement or gypsum hemihydrate, it is not preferable to use it as a starting material because it inhibits the flexibility of the sheet-like material. On the other hand, the inorganic fibrous substance, which is another essential component, is effective in improving the shape retention of the flexible sheet material when the composite building material is heated, and it is effective in improving the shape retention of the flexible sheet material when the composite building material is heated. However, for the purpose of improving the flexibility and elasticity of the sheet-like material, it is also possible to replace some of these inorganic fibers with organic fibers such as natural fibers and synthetic fibers. The thermoplastic resin-based organic binder used in the flexible sheet material is one that binds the above-mentioned inorganic powder and inorganic fibrous material, and can be used as long as it has appropriate water resistance. Although it is possible, it is often selected in relation to the manufacturing method of the flexible sheet material. For example, as shown in the method described in JP-A-53-112969, polyvinyl alcohol, polyethylene Combinations of water-soluble polymers such as oxides and sodium polyacrylates with appropriate crosslinking agents for the polymers, and emulsions of homopolymers and copolymers of vinyl monomers such as vinyl acetate, vinyl chloride, and acrylic esters. It is preferable to use an emulsion or latex of a thermoplastic polymer represented by . Furthermore, other essential components of the fire-resistant binder include (A) a water-soluble thermosetting resin such as phenolic resin, urea resin, melamine resin, and glyptal resin; (B)
Alkali metal silicates such as sodium silicate, potassium silicate, and lithium silicate; (C) phosphoric acid compounds such as aluminum monophosphate, sodium monophosphate, and magnesium monophosphate; (D) boric acid, sodium borate, and boric acid. One or more compounds selected from boric acid compounds such as potassium and ammonium borate can be used. The fire-resistant binder is not only effective in interacting with the above-mentioned organic binder to bond the inorganic powder and the inorganic fibrous material, but also in improving the shape retention of the sheet material when heated. It is an effective component and is preferably used within a range that does not impede the flexibility and water resistance of the sheet material.

The flexible sheet-like material having an open cell structure in the present invention includes (a) an inorganic powder such as dihydrate gypsum, (b) an inorganic fibrous material, and (c) an organic material based on a thermoplastic resin. Mainly composed of a binder component and (d) fire-resistant binder component (in addition, it can contain subsidiary components such as various additives)
However, the composition ratio of each of these components is approximately (A) component is 95 ~
50 parts by weight of the component (b), 50 to 5 parts by weight of the component (b), 2 to 30 parts by weight of the component (c), and 0.2 to 5 parts by weight of the component (d) from the viewpoint of fire protection and flexibility. The flexible sheet material having an open cell structure according to the present invention is produced by using these components, for example, by the method described in JP-A-53-112969 (mixing these components to form a slurry-like stock solution, forming a sheet). However, in order to improve flexibility, especially in terms of handling and folding processability, it is recommended to make it into a foam containing open cells so that the specific gravity is about 0.1 to 0.8. is important. Note that the thickness of the sheet-like material is preferably about 1 to 20 mm. In the present invention, it is also possible to laminate a sheet-like reinforcing material on one side or an intermediate layer of the flexible sheet-like material in order to improve the handling properties of the flexible sheet-like material and the folding processability of the composite building material. Such sheet-like reinforcing materials include various nonwoven fabrics, woven fabrics, paper, nets, films,
Examples include metal foil, which can be integrally molded with the sheet-like material during the manufacturing process, or can be integrated by bonding the sheet-like material after manufacturing. The sheet-like reinforcing material may have a thickness that is useful for reinforcing the flexible sheet-like object, and in the case of an organic material, it is preferably as thin as possible in terms of fire prevention performance. The sheet-like material thus obtained has flexibility, so it will not break during the folded plate processing and forming process, and has the fire retardancy, fire resistance, heat insulation, dew condensation resistance, and A composite building material with excellent soundproofing properties can be provided. The greatest feature of the present invention lies in the use of such a sheet-like material.

Examples of the flexible sheet-like foam having a closed cell structure used as the intermediate layer of the present invention include polyethylene foam, flexible polyurethane foam, polyvinyl chloride foam, rubber foam, etc. Depending on the application, rigid polyurethane foam may be used. Although hard foams such as foam, polystyrene foam, phenol foam, and urea foam can also be used, these hard foams are not preferred when folding plate workability is required. The flexible sheet-like foam preferably has an apparent specific gravity of 0.02 to 0.10 and a thickness of 2 to 20 mm from the viewpoint of fire protection and ease of handling.

The metal plate used in this invention is JISA6514
Iron plates such as galvanized iron plates and stainless steel plates specified in The thickness is preferably 2.0 mm or less from the viewpoint of workability into a folded plate when it is made into a shaped product.

In order to produce the composite building material according to the present invention, first, a surface layer consisting of a flexible sheet material having an open cell structure obtained by the above method and a flexible sheet material having a closed cell structure as described above are prepared. It is preferable to composite the intermediate layer made of a foam, and then composite the intermediate layer and the metal plate as described above. A common adhesive method can be used to combine the surface layer and the intermediate layer, and a common adhesive such as a chloroprene adhesive or a polyvinyl acetate adhesive can be used. It is also possible to mold the surface layer directly on the intermediate layer to form an integral composite. Next, regarding the composite of the intermediate layer and the metal plate, in addition to the usual adhesive bonding method, the intermediate layer composition can be bonded to the surface of the metal plate heated to a temperature higher than the temperature at which the composition of the intermediate layer melts without using an adhesive. It is also possible to combine them by crimping them. Further, at this time, it is also possible to use a primer as a heat fusion adhesion aid. The plate-shaped composite building material that has been integrated in this way is rolled into a coil and transported to the construction site, where it is formed into a U-shape, V-shape, or a similar shape by folding rollers. and subsequent adjoining and fixing to form a roof or wall structure. It is also possible to form an integral composite by laminating a composite of an intermediate layer and a surface layer or their individual materials along the shape of a metal plate that has been folded into an arbitrary shape in advance. The latter combined method is advantageous when complex machining is required.

[Brief explanation of the drawing]

FIG. 1 is an enlarged sectional view showing an example of the composite building material of the present invention, and FIGS. 2 and 3 are explanatory views showing an example of applying the composite building material of the present invention to a specific structure. . Figure 2 shows a folded plate roof structure using the stacking method, and Figure 3 shows a wall structure using metal siding materials. In the figure, the symbols indicate the following: 1...
Flexible sheet-like material having an open cell structure, 2...
Flexible sheet foam having closed cell structure, 3
...Metal plate, 4...Adhesive layer, 5...Fixing bolt, 6...Tight frame, 7...Beam, 8...
Surface reinforced sheet material.

Claims (1)

[Scope of utility model registration request] On one surface of the intermediate layer 2 made of a flexible sheet-like foam having a closed-cell structure, (a) dihydrate gypsum or non-hydraulic inorganic powder containing crystal water containing dihydrate as a main component, and (b) inorganic fibers. (c) an organic binder component based on a thermoplastic resin, and (d) (A) a water-soluble thermosetting resin, (B) an alkali metal silicate, (C) a phosphoric acid compound, and (D) a boric acid compound. A surface layer 1 made of a flexible sheet-like material having an open cell structure made of one or more fire-resistant binder components selected from the above is laminated, and the other surface of the intermediate layer 2 is laminated. A composite building material made by laminating metal plates 3 on top.