JPH03183541A - Composite material and manufacture thereof - Google Patents

Abstract

PURPOSE:To have an excellent heat resisting property and water resisting property and also have no fear of ignition by employing as a basic board a woody fiber board in which woody fibers filled, adhered or fixed with an incombustible inorganic compound are adhesion-molded integrally and forming a metal-coated layer on, at least, one surface of the basic board by a flame coating method. CONSTITUTION:Lumber chips are subjected to a degreasing and softening process by steam boiling and then opened in order to obtain woody fibers, in the next place, cellular cavities of the woody fibers and/or wall surfaces within the cellular cavities and/or the outer periphery of the woody fibers are filled, adhered or fixed with an incombustibly inorganic compound, and thus the woody fibers processed are molded integrally in use of an adhesive substance for forming a woody fiber mat. And, the woody fiber mat is heat pressure-molded to form a woody fiber board, and metal is flame-coated on, at least, one surface of the woody fiber board, following this, a metal coated layer is formed by cooling. Accordingly, the heat resisting property is improved by the metal-coated layer, and the incombustibility is made by filling, adhering or fixing an incombustible inorganic compound thereto.

Description

DETAILED DESCRIPTION OF THE INVENTION <Industrial Application Field> The present invention relates to a composite material and a method for producing the same, and more particularly to a composite material in which a metal coating layer is formed on a wood fiberboard and a method for producing the same.

<Prior art> Japanese Patent Laid-Open No. 50-12948 discloses that 90%
A heat-resistant board is disclosed in which a metal or alloy having a melting point of 0°C or lower is thermally sprayed, and a metal or alloy having a melting point of 1000-1600°C is further thermally sprayed thereon. This conventional board is thermally sprayed in two layers and is said to have excellent heat resistance and water resistance.

<Problems to be Solved by the Invention> Although the heat resistance of the board according to the above-mentioned prior art I is improved by the metal layer covering the surface of the base material, the base material is an organic material such as hardboard, plywood, or wood. In this case, the base material itself gradually deteriorates or carbonizes due to the influence of heat transmitted through the metal layer, and there is a risk that it will eventually catch fire. For this reason, at present it has not been used as a building material, furniture, or construction member in places such as kitchens.

<Means for Solving the Problems> The present invention was completed through intensive efforts to solve the problems in view of the drawbacks of the prior art. The substrate is a wood fiberboard formed by adhesive molding and integrating wood fibers filled with, attached to, or fixed to the inner and/or cell pore walls and/or the outer periphery of the wood fibers with a nonflammable inorganic compound; A composite material characterized in that a metal coating layer is formed on at least one surface by a thermal spraying method.

The present invention also provides a method for manufacturing such a composite material, which involves degreasing and softening wood chips by steaming, and then defibrating them to obtain wood fibers. The interior of the cell pores and/or the inner wall surface of the cell pores and/or the outer periphery of the wood fibers are filled with, adhered to, or fixed with a nonflammable inorganic compound, and the thus treated wood fibers are molded and integrated using an adhesive substance. to form a wood fiber mat, heat-press the wood fiber mat to form a wood fiber board, thermally spray a metal onto at least one surface of the wood fiber board, and then cool it to form a metal coating layer. It is characterized by

The wood fibers used in the present invention are made by chipping softwood such as pine, cedar, and cypress, or hardwood such as lauan, capor, chestnut, and poplar, and then degreasing and softening the chips by steaming them. Furthermore, it is obtained by defibrating the steamed chips using a defibrating device. This wood fiber has a length of 1 to 30 mm.

The majority have a diameter of about 2 to 300 μm. These wood fibers are shaped like conduits, tracheids, or bundles of cells, and the cell walls around the fibers are often torn or cracked, so they absorb moisture and moisture well. do.

After the obtained wood fibers are dried in a dryer, the voids such as cell pores and conduit pores of the wood fibers are filled with a nonflammable inorganic compound, or the nonflammable inorganic compound is applied in a layer along the inner wall of the cell pores. The nonflammability treatment is performed by fixing or adhering the nonflammable inorganic compound to the outer periphery of the wood fibers. This nonflammability treatment can be performed, for example, by the following steps. That is, the wood fibers are sufficiently immersed in an aqueous solution of a water-soluble inorganic salt (hereinafter referred to as "first solution") to impregnate it. As the first liquid, M g CQ 2 , M
g B r 2 .

Mg5O,・H20, Mg(Nox)z・6H20゜A
(2C123,A(lBr1.AL(SO+),.

A12(NOs)s・9H20, CaCQ2. CaBr
2゜Ca(No, ), , ZnCQ, BaCl22'2H
20+BaBr2. An example is an aqueous solution such as Ba(NOx)z.

After impregnating with the first liquid, remove the liquid, dry the wood fibers, and dry the wood fibers. (The mackerel is left in a dry state, and if necessary, the component crystals of the first liquid deposited on the surface are removed.

Next, a compound liquid that reacts with the first liquid to produce a water-insoluble, nonflammable inorganic compound (hereinafter referred to as the "second liquid") is added to and mixed with the wood fibers using a blender, spray, etc., or immersed. Thus, the wood fibers are impregnated with the second liquid. As the second liquid, Na, Co, (NH4)z
cOs, H2SO4°NazS 04. (NH4)
2S Oa, H4F 04゜Na2HP O41(N
H4) 2HP O4+ HsB OS+NaBO engineering,
Examples include N Hi B 02. By applying and impregnating the second liquid, the first liquid and the second liquid react in the wood fibers, and a nonflammable inorganic compound is generated. Nonflammable inorganic compounds produced include magnesium phosphate, calcium phosphate, barium phosphate, aluminum phosphate, and magnesium borate.

Magnesium carbonate, calcium carbonate, zinc phosphate.

Calcium compounds such as barium carbonate, calcium nitrate, and barium nitrate, magnesium compounds, aluminum compounds, barium compounds, lead compounds, zinc compounds, silicate compounds, etc. are exemplified.7 After the coating is finished, the liquid is removed and dried. Since this nonflammable inorganic compound is water-insoluble, after drying, it is filled in, adhered to, or fixed in the cell pores of the wood fiber or on the inner wall surface of the cell pore and the outer periphery of the wood fiber. As a result, even if the cell wall of the outer periphery of the wood fibers contains cracks or fissures, the nonflammable inorganic compound is present in a form that blocks or fills them.

It is preferable that the nonflammable inorganic compound is mixed in at a ratio of 33% by weight or more based on 1 wood fiber, and if it is less than this, sufficient fireproof performance cannot be obtained. Further, in order to increase the reaction efficiency between the first liquid and the second liquid, it is preferable that the addition and mixing of the second liquid is carried out under a heated atmosphere, particularly at a temperature of 40°C or higher, more preferably 50°C or higher.

The wood fibers that have been rendered incombustible in this way are put into a mixing device,
Adhesive, sizing agent, etc. are added and mixed to adhere. Next, the wood fibers are air blown to form a continuous wood fiber mat of a constant thickness on a conveying device using a forming device.

After cutting the obtained wood fiber mat to a specified length, it is inserted into a hot press and hot-pressed to obtain a wood fiber board. The specific gravity of this wood fiberboard is preferably within the range of 0.4 to 1.2. The reason for this is that when the specific gravity is 0.4 or less, the surface is porous, making it difficult to form a metal coating layer, making it necessary to increase the film thickness, and when the specific gravity is t.

This is because if it is 2 or more, the surface becomes too dense and the anchoring effect of the metal coating layer on the wood fiber board l' decreases, resulting in a decrease in adhesion. Further, the moisture content of the wood fiberboard is preferably 20% or less. The reason for this is that if the moisture content is 20% or more, the internal water on the sprayed surface side will evaporate and move to the opposite side due to the influence of heat during metal spraying, causing the internal balance to be disrupted. This is because the fiberboard itself tends to warp with the sprayed surface side concave.

The obtained wood fiberboard is cured and its surface (
After sanding the side (on which the metal coating layer will later be formed), a necessary amount of molten metal is sprayed using a thermal sprayer. Metal spraying can be carried out to cover not only the front surface of the wood fiberboard, but also necessary parts such as the back surface, end surface, etc., and the entire surface. The temperature of the surface of the wood fiberboard where metal spraying is performed is 40
It is preferable that the temperature is 100°C to 100°C, and from this point of view, the temperature of the wood fiberboard after thermoforming is high, or at least after the temperature of the surface of the wood fiberboard on which the metal coating layer is to be formed is warmed. Preferably, thermal spraying is performed.

If the temperature is below 40°C, the sprayed molten metal will immediately cool and solidify, so that the adhesion force due to the anchoring effect to the coated surface of the wood fiberboard will not be sufficiently exerted. 100 again
If the temperature is higher than 0.degree. C., the temperature effect of the molten metal will be strong, degrading the surface of the wood fiberboard and reducing the adhesion.

Metal alloys such as tin, lead, zinc, copper, brass, bronze, aluminum, nickel, iron, and stainless steel are preferably used as the metal to be thermally sprayed. As the thermal spraying method, any of the commonly used electric wire spraying method, gas wire thermal spraying method, and powder spraying method may be employed. The sprayed metal solidifies by subsequent cooling, leaving a layer of metal on the surface of the wood fiberboard. ! j
The L film layer is formed in close contact.

<Function> Heat resistance is improved by the metal coating layer formed on the surface of the wood fiberboard. Wood fiberboards are made incombustible by filling, adhering, or fixing noncombustible inorganic compounds inside the cell pores of the wood fibers, on the inner wall surface of the cell pores, or on the outer periphery of the wood fibers. It will not deteriorate or become carbonized even by the heat transferred.

<Example> 16 pieces of radiata pine chips were added to the digester using a digester.
It was defatted and softened by steaming at 0°C and 7 kg/c for 5 minutes. The chips were defibrated using a defibrator refiner to obtain defatted wood fibers. After drying this wood fiber, it was soaked for 10 minutes in an aqueous solution containing barium chloride as a main component, and after a diffusion treatment, the liquid was removed. This was dried with hot air to adjust the moisture content to 7%. After drying, the wood fibers are put into a blender, and an aqueous solution containing ammonium phosphate as the main component is added and mixed to inject water-insoluble barium phosphate into the cell pores of the wood fibers or the outer periphery of the wood li and fibers. After performing a flame retardant treatment to fill or attach a nonflammable inorganic compound consisting of barium hydrogen phosphate and barium hydrogen phosphate, it is dried with hot air.
Its moisture content was adjusted to 6%. The weight increase rate due to the nonflammable inorganic compound produced by this flame retardant treatment is 50%.
Met.

The thus flame-retardant wood fibers were put into a blender, and in the blender, 4% wax size and 10% phenolic resin adhesive were added and mixed based on the amount of wood fibers, and then blown with air and put into a felter. A continuous wood fiber mantle of a constant thickness was formed by 7 namings on a screen conveyor. After cutting this wood fiber mat to the specified width and length, it was inserted into a hot press and heated at 200°C.
Pressed for minutes, specific gravity 0.8, IO+im thickness, 3' x 6
′ size wood fiber board was obtained.

The obtained wood fiberboard is cured, and when the surface temperature reaches 50°C, molten aluminum metal with a melting point of 660°C is sprayed by powder spraying method, and then cooled to form a metal coating layer. A composite material according to the invention was obtained.

<Effects of the Invention> The composite material according to the present invention has excellent heat resistance and water resistance due to the formation of a metal coating layer on the surface of the wood fiberboard, and the wood fiberboard that is the base material is treated to be nonflammable. Therefore, it does not deteriorate or become carbonized due to heat transmitted through the metal coating layer, and there is no risk of ignition over a long period of time.

Therefore, it can be suitably used widely as a building material or furniture/building member even in places where fire is used, such as kitchens.

Claims (3)

[Claims] (1) Inside the cell pores of wood fibers and/or on the inner wall surface of the cell pores and/or
Or, a wood fiberboard is used as a substrate, which is formed by adhering and molding wood fibers whose outer peripheries are filled with, adhered to, or fixed with a nonflammable inorganic compound, and at least one surface of the substrate is coated with metal by thermal spraying. A composite material characterized by being formed with a film layer. (2) After degreasing and softening wood chips by steaming, defibration is performed to obtain wood fibers, and then nonflammability is provided within the cell pores of the wood fibers and/or on the inner wall surface of the cell pores and/or on the outer periphery of the wood fibers. The wood fibers filled with, attached to, or fixed with an inorganic compound and treated to make them incombustible are molded and integrated using an adhesive substance to form a wood fiber mat, and the wood fiber mat is heat-pressed to form a wood fiber board. A method for producing a composite material, comprising: forming a metal coating layer by thermally spraying a metal onto at least one surface of the wood fiberboard and then cooling the wood fiberboard. (3) The method for manufacturing a composite material according to claim 2, characterized in that the metal spraying is performed at a temperature of 40 to 100° C. of the wood fiberboard after thermoforming.