JPH0255207B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to a method for manufacturing a flame-retardant sandwich board in which a synthetic resin foam is interposed and integrated between a hard substrate and a flexible face material. More specifically, the present invention relates to a method for producing a sanderch board in which a flame-retardant filler is evenly distributed within a synthetic resin foam. Building materials are required to have heat insulation and flame retardant properties. Although the heat insulation properties are sufficiently achieved by the excellent thermal conductivity of the synthetic resin foam, the biggest drawback of this material is that it is weak in fire resistance and heat resistance. Therefore, it is necessary to make synthetic resin foam flame retardant.
This is the biggest improvement in its use as a building material. Examples of this type of improvement include a filling method (addition of a flame-retardant filler), a modification method (creating a heat-resistant structure of the resin itself), and the like. In particular, in the filling method, substances that undergo chemical reactions, heat generation, and foaming with rapid increases in viscosity, etc.
It was very difficult to evenly distribute the flame retardant filler. In other words, if the filler is not evenly distributed, unevenness will occur in the foam structure, and destruction will occur from these areas due to heat. Furthermore, a non-uniform foamed structure has the disadvantage that the thermal insulation property itself deteriorates, impairing the effective use of the resin, and, as a result, preventing the resin from being used economically. Furthermore, methods for mixing filler and resin raw materials include, for example, Utility Model Publication No. 54-21799 or mixing using a spray gun.
(20 to 60 cm) could not be distributed evenly. In order to eliminate such drawbacks, the present invention discharges a synthetic resin raw material onto a hard substrate, and before and after the synthetic resin raw material reaches a gel time state, the back side of a face material made of a flexible sheet-like material is The synthetic resin raw material is spread (distributed) evenly by a spreading device interposed in the resin, and at that time, a flame-retardant filler is applied to the storage position of the synthetic resin raw material, that is, the part where the synthetic resin raw material is stagnated by the gap for quantitative supply of the synthetic resin raw material. A uniform distribution is achieved by mixing by convection at this storage position and by controlling the direction of the flame-retardant filler as it passes through the gap, and then supplied to the mold to achieve fire resistance, heat resistance, and heat insulation properties. Provided is a method for manufacturing a flame-retardant sandwich board that reduces costs and improves productivity through effective use of raw materials. EMBODIMENT OF THE INVENTION Below, the manufacturing method of the flame retardant sandwich board based on this invention is demonstrated in detail using drawing.
FIG. 1 is an explanatory diagram showing a method for manufacturing a flame-retardant sandwich board according to the present invention, and 1 is a hard substrate, such as a gypsum board, plywood, hardboard, or metal plate (color steel plate, stainless steel plate, copper plate). , in the form of a flat plate or a molded body (as shown in Figure 2a). 2
is a facing material, which is a flexible sheet, such as kraft paper, asbestos paper, felt, asphalt felt, terfelt, synthetic resin sheet,
It is a sheet-like material laminated with one or more of metal foil, tarpaulin paper, pachiment paper, foam sheet, non-woven fabric, or waterproof-treated material such as polyethylene. In addition, in the face material 2, it is preferable that the surface that comes into contact with the synthetic resin raw material 3 described below is not subjected to waterproofing treatment or metal foil. Reference numeral 3 denotes a liquid, unfoamed synthetic resin raw material (hereinafter simply referred to as raw material), which is discharged onto the hard substrate 1 through a nozzle 4 in a slightly uniform manner, for example, as shown in FIG. 2b.
Raw material 3 includes polyurethane foam, polyurea foam, polyisocyanurate foam,
It forms phenol foam, epoxy foam, polyimide foam, polyethylene foam, etc. 5 is a flame-retardant filler (hereinafter simply referred to as filler), for example, an inorganic fiber material such as rock wool, asbestos, or glass, with a length of 1 to 10 mm.
That's about it. In addition, a filler 5 made of aggregate such as pearlite grains, shirasu balloons, and zeolite, and powders such as ammonium polyphosphate, calcium carbonate, and antimony trioxide may be added. Although the amount added varies depending on the purpose, it is added in an amount of 10 to 100 parts by weight per 100 parts by weight of the raw material. 6 is a flame retardant filler feeder that feeds the filler 5 to the position shown in the figure.
Reference numeral 7 denotes a spreading device, which supports one or more rollers (indicated by broken lines) in parallel in the line direction, guides the face material 2, and controls the gap ΔG with respect to the hard substrate 1. This gap ΔG is set based on the length and size of the filler 5 and the density of the raw material 3 when formed into a foam. For example, length 3mm
When using glass fibers, ΔG should be set to 2 mm in order to arrange all the fillers in the same direction (so-called parallel) to the foam forming direction. To explain further, since the raw material 3 discharged from the nozzle 4 is not discharged completely evenly on the hard substrate 1, the spreading device 7 distributes the raw material 3 evenly, resulting in a non-uniform foamed structure. This is provided to prevent this. Further, when the raw material 3 is spread by the spreading device 7, the reaction state of the raw material 3 is gel time, cream time or rise time close to gel time. This prevents a decrease in the expansion ratio of the synthetic resin foam in the flame-retardant sandwich board, and also mixes the filler 5 when the raw material 3 has the highest fluidity and adhesiveness as it progresses through reaction and foaming. Moreover, by laminating the face material 2, it is possible to uniformly disperse the filler 5 and to increase the adhesive strength between the face material 2 and the raw material 3. That is, when the raw material 3 is spread by the spreading device 7, the gap ΔG between the spreading device 7 and the hard substrate 1 is
At the position where the raw material 3 is stored, convection occurs due to the fluidity of the raw material 3 during the gel time and the initial foaming pressure, and the filler 5 is supplied in this state, so that the filler 5 can be uniformly dispersed in the raw material 3. I can,
Sanderch boards with excellent fire resistance and heat resistance can be manufactured. Moreover, the raw material 3 is the hard substrate 1
Since the raw material 3 is discharged upward, the spreading by the spreading device 7 is performed efficiently, and after the raw material 3 in the stored state is convected for a certain period of time, it is conveyed to the mold 9 while being sandwiched between the hard substrate 1 and the face material 2. , it is possible to prevent clogging due to spreading. Note that the spreading device 7 is used for the raw material 3
It can move back and forth and up and down depending on the state of the machine. A conveyor line 8 conveys the hard substrate 1 to a mold 9. The mold 9 is moved at a speed of about 5 to 40 m/min with upper and lower mold members 10 and 11 facing each other with a distance t, and can heat the mold 9 and the atmosphere to a temperature of about 60 to 110°C. Next, examples will be described. Hard substrate 1...0.27mm color steel plate, surface material 2...
...Sheet-like product made by laminating 20 micron aluminum foil onto asbestos paper, raw material 3...Raw material for polyisocyanurate foam, filler 5...3
mm glass fiber 44 parts by weight, line speed =
Assume 30m/min, ΔG=2mm, and t=15mm. Therefore, the raw material 3 mixed onto the back surface 1a of the hard substrate 1 formed into the cross-sectional shape shown in FIG. 2a is discharged as shown in FIG. 2b. After this raw material 3 is discharged, it reaches the position of the spreading device 7 almost under the gel time when the reaction proceeds from cream time to gel time to rise time, and stagnates as shown in FIGS. 1 and 2 c. At this point, the mixture is mixed and agitated, and the filler 5 is added, and the mixture is conveyed from a portion of the reservoir in the direction of the mold 9 through the gap ΔG, as shown in FIG. 2d. The raw material 3 that has reached the mold 9 starts foaming more rapidly, and from the outlet thereof, a sandwich plate having a so-called foam as a core material having the shape shown in FIG. 2e is continuously sent out. The properties of this sanderch board are shown in the table below. In addition, the conventional product is one in which glass fibers are mixed and integrated using the chopped strand method. However, although this product had the same overall density as the Sanderch board produced by the method according to the invention, the dispersion was non-uniform. In the sanderch board manufactured by the method according to the present invention, the glass fibers were distributed almost evenly, and the entire foam 3 had a foam structure with the same cell distribution.

[Table] As is clear from this table, the conventional product and the sandwich panel manufactured by the method according to the present invention are
Even with the same composition and filler, there are large differences in fire resistance and mechanical strength. As described above, according to the method for manufacturing a flame-retardant sandwich board according to the present invention, a plurality of components such as polyurethane foam are mixed, filler is evenly distributed therein, and the raw materials are rolled and dispersed. Therefore, it is possible to efficiently and easily produce a synthetic resin foam with a homogeneous foam structure. Furthermore, since it is easy to laminate thinly and evenly over a wide width, productivity is greatly improved. In addition, since the flame-retardant filler can be distributed homogeneously, it has characteristics that are superior to sanderch boards manufactured by conventional manufacturing methods in terms of fire resistance, heat resistance, thermal conductivity, compressibility, etc.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram showing the principle of the method for manufacturing a flame-retardant sandwich board according to the present invention, and FIGS. 2 a to 2 e are explanatory diagrams showing extracted steps thereof. 1... Hard substrate, 2... Face material, 3... Synthetic resin raw material, 5... Flame retardant filler, 7... Spreading device.

Claims (1)

[Claims] 1. In a method for manufacturing a sanderch panel, in which a synthetic resin raw material is supplied onto a hard substrate, and a face material made of a flexible sheet-like material is laminated and integrally formed on the synthetic resin raw material, the synthetic resin raw material is supplied onto the hard substrate. The synthetic resin raw material is spread by a spreading device through a face material before and after the gel time during the reaction, and a flame-retardant filler is added to the stored state at the entrance of the spreading part. Method of manufacturing the board.