JPH10325208A - Composite panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a composite panel, in which fire-preventive construction and a fire-resistive construction can be obtained and there is no deformation such as bulging, warpage, etc., after manufacture even when an isocyanurate foam is used as a core material of a substrate panel and which has excellent heat-insulating properties and mechanical strength. SOLUTION: In the composite panel A, a core material is sandwiched by a surface material and a rear material, and a projecting engaging projection is formed to the surface material while a fireproof sheet D is laminated integrally on the surface material. The core material consists of a substrate panel B composed of an isocyanurate foam and an inorganic decorative panel C, in which recessed engaging grooves are formed on the rear side, and the engaging grooves of the decorative panel C are fitted to the engaging projections 4 of the substrate panel B and the substrate panel B and the decorative panel C are unified.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to construction,
The present invention relates to a composite panel that can be used as an outer wall material or the like. More specifically, even if the core material of the base panel is an isocyanurate foam, the fire prevention structure (JIS-A-130)
1, JIS-A-1302) and fireproof structure (JIS-A-
1304). The present invention relates to a composite panel which has no deformation such as swelling or warpage after production, and has excellent heat insulating properties and mechanical strength.

[0002]

2. Description of the Related Art In general, an inorganic decorative panel made of ceramics, tiles, or the like has a fire protection structure (JIS).
-A-1301, JIS-A-1302) and fire-resistant structure (JIS-A-1304) cannot be obtained. Is usually the case. However, in this case, in order to give priority to fire resistance and fire resistance, an inorganic base panel such as an extruded hollow cement plate or an ALC plate has been used. Also, there is a composite panel using a phenol foam having excellent fire resistance and fire resistance as a core material of a base panel.

[0003]

However, a composite panel using an extruded hollow cement board or an ALC board as a base panel has improved fire resistance and fire resistance.
The weight of the panel itself increased, the construction became difficult, and the heat insulation performance could not be expected. In addition, in the case of a composite panel using phenol foam as the core material of the base panel, it is certainly lightweight, and the fire resistance and fire resistance are improved, but the phenol foam itself has water absorption, and If it is not good, there is a drawback that rainwater penetrates into the core material of the panel and causes problems such as corrosion and generation of mold. Furthermore, phenol foam has poor adhesiveness and has a defect in integration with the surface material and the back surface material. To improve the adhesiveness, it is necessary to use a separate adhesive or to use an adhesive improving material such as a nonwoven fabric or a net. There was a disadvantage in terms of cost. Furthermore, a panel using a nurate foam as a core material lacks fire protection performance, and the panel itself has a fire resistant structure (JI
(SA-1304) was difficult to obtain.

[0004]

SUMMARY OF THE INVENTION In order to eliminate such disadvantages, the present invention improves the lightness, heat insulation and water absorption by using a core material of a base panel as a nurate foam.
In addition, a fireproof sheet is laminated on the surface material to form a base panel with improved fire protection and fire resistance, and the engaging projections of the base panel are fitted with the engaging grooves of the decorative panel to be integrated as a composite panel. The present invention proposes a composite panel that can be easily combined.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the composite panel according to the present invention will be described below in detail with reference to the drawings. That is, A is a composite panel having a cross-sectional shape as shown in FIG. 1 and is roughly divided into a base panel B and a decorative panel C.

The base panel B functions as a base / fixing material for a decorative panel C described later, and as shown in FIG. 2, a front material 1 and a back material 2 are sandwiched and integrated with a core material 3. In addition, it has a long shape with one or more layers of the refractory sheet D interposed on the surface material 1.

The surface material 1 and the back surface material 2 are thin metal sheets having excellent fire resistance and fire resistance, such as iron, aluminum, copper, stainless steel, titanium, aluminum / zinc alloy-plated steel sheets, galvalume steel sheets, enamel steel sheets, clad steel sheets, and laminated steel sheets. It is formed by roll-forming or press-forming a kind of (a PVC steel plate or the like) or a sandwich steel plate (a vibration damping steel plate or the like) (of course, including a color plate in which these are coated in various colors).

Further, a fire prevention structure (JIS-A-1301,
Composite panel A that can acquire only JIS-A-1302)
In the fire prevention structural test, since there is no heating test from the back side, the backing material 2 is made of aluminum vapor-deposited paper, asbestos paper, kraft paper, asphalt felt, metal foil (A
l, Fe, Pb, Cu), synthetic resin sheet, rubber sheet, cloth sheet, gypsum paper, aluminum hydroxide paper, glass fiber non-woven fabric, etc., or a laminate of two or more kinds,
Alternatively, it can be formed from a sheet-like material which has been subjected to a waterproof treatment and a flame retardant treatment.

The core material 3 mainly functions as a bulking material, a heat insulating material, and a fireproof material for the composite panel A. The core material 3 is made of an isocyanurate resin as a main material, and if necessary, a flame retardant material (water). Aluminum oxide, calcium silicate, ammonium polyphosphate, expandable graphite, etc.), foaming agent, and curing agent are mixed, and heated, reacted, cured, and cured to form a foam having a density of about 20 to 200 kg / cubic meter. It becomes. As a foaming agent, an alternative fluorocarbon (141b) may be used, but from the viewpoint of environmental protection, a foaming agent such as carbon dioxide or cyclopentane is used.
Non-fluorocarbon foam is preferred. The composite panel A integrates the surface material 1, the back surface material 2 and the core material 3 by the self-adhesive property of the core material 3.

Further, a core material 3 is formed by mixing a flame retardant such as aluminum hydroxide and ammonium polyphosphate in the isocyanurate resin in a fixed ratio (about 3 to 29 parts by weight when the isocyanurate resin is 100 parts by weight). Thereby, the fire protection and fire resistance of the core material 3 can be remarkably improved.

Further, as shown in FIG. 3, which is an enlarged view of the portion A in FIG. 2, an engaging projection 4 is formed on the surface material 1 so as to protrude outward. The engaging projection 4 is a portion for engaging the engaging groove 9 of the decorative panel C described later and attaching the decorative panel C. Further, a plurality of the engagement protrusions 4 are formed at a constant pitch corresponding to the width of the decorative panel C and the size of the engagement groove 9.

The refractory sheet D is formed by laminating one or more layers on the surface material 1. The refractory sheet D is laminated integrally using the self-adhesive property of the refractory sheet D or via a separate adhesive (not shown). Things.

The structure of the refractory sheet D is, as shown in FIG. 4A, a long sheet having a total thickness of about 0.5 to 10 mm. A core 7 formed by binding at least a graphite component and an inorganic fiber with a synthetic resin is sandwiched between a skin 5 and a back skin 6 formed of a nonwoven fabric.

The skin 5 and the back skin 6 are made of a non-woven fabric, and the non-woven fabric is made of polyester, nylon, boron, or the like.
It is a sheet made of carbon-based, alumina-based, silicon carbide-based, and aramid-based fibers. As a protective material and a holding material for the fire-resistant sheet D, the strength is improved, and a core 7 described below is provided.
It functions as a protective layer.

The core 7 has a composition in which a graphite component and an inorganic fiber are bound with a phenol resin. The graphite component is made of, for example, a carbon compound such as graphite (expandable or non-expandable) or carbon black, and when heated, carbonizes to form a heat insulating layer and hinder heat conduction. The graphite component accounts for about 50 to 80% of the weight ratio of the entire core 7.

As an example of the inorganic fiber, it is made of an inorganic compound having a high heat resistance such as glass fiber, ceramic fiber, rock wool, asbestos and the like, and as shown in FIGS. By intertwining or twisting
The refractory sheet D has a function of imparting some strength, flexibility and elasticity (handling). By doing so, as shown in FIG. 4B, the refractory sheet D can be wound into a coil shape, and transport, transportation, and manufacture of the composite panel A are easy and efficient. The inorganic fibers occupy about 5% to 20% of the weight ratio of the core 7.

The phenol resin functions as a binder between the graphite component and the inorganic fibers, and also has high fire resistance and fire resistance. Further, by binding the graphite component and the inorganic fiber with a synthetic resin phenolic resin, the refractory sheet D has flexibility,
Plasticity and elasticity are taken into account, and it can be wound or formed into a coil shape, resulting in a fire-resistant sheet D that is very easy to handle. The phenolic resin accounts for about 10% to 30% of the weight ratio of the core 7.
%.

The skin 5, back skin 6, core 7, and fibrous material 8 can also be impregnated, dusted, or mixed with aluminum hydroxide powder or phenol resin particles. The size of the aluminum hydroxide powder is about 10 to 1000 μm, and releases water of crystallization under high heat to cool the surroundings. The phenolic resin particles function as a cushioning material, a heat insulating material, and a refractory material, and have a size of about 10 to 1000 μm, are carbonized under high heat, and function as a skeleton of a carbonized layer.

When the surface of the composite panel A is heated and exposed to a high temperature, when the given heat reaches the refractory sheet D, the refractory sheet D transfers the heat to the refractory sheet D. It has the property of causing heat to propagate in the horizontal direction. This prevents heat from reaching the back side,
It has a very high heat resistance effect. Further, since the fireproof sheet has a cushioning property, it functions as a cushioning material between the base panel B and the decorative panel C, and also contributes to preventing damage to the decorative panel C and improving the adhesion.

The decorative panel C mainly functions as a decorative material on the front surface. For example, as shown in FIG. 6, one or more concave engaging grooves 9 are formed on the rear surface side of a long plate shape. As shown in FIG. 1, the engagement groove 9 is a portion that fits into the engagement protrusion 4 of the base panel B and integrates the decorative panel C with the base panel B. As a result, the base panel B and the decorative panel C The composite panel A is composed of:

The decorative panel C is made of an inorganic raw material, for example, a cement plate, a calcium carbonate plate, a calcium silicate plate, a ceramic plate, a wood chip cement plate, a magnesium carbonate plate or the like, or glass fiber, whisker, aramid fiber, steel or the like. Fibers, carbon fibers, various mineral fibers, various aggregates, etc. mixed by extrusion molding, press molding, injection molding, papermaking, etc., or various fibers are woven into a cloth or three-dimensional shape. It is formed of a panel formed by impregnating with cement, clay or the like, dried, steam-cured, and fired.

It should be noted that in FIG.
In order to speed up the firing, a plurality of hollow holes 10 are formed in the inside along the longitudinal direction.

Next, an example of construction of the composite panel according to the present invention will be described. First, as shown in FIG.
A base panel B is sequentially laid from the base toward the eaves, and the upper and lower ends of the base panel B are fixed using a fixing tool β such as a nail. At this time, it is preferable to attach a waterproof tape E to the joint between the base panels B in order to improve waterproofness and airtightness.

As shown by arrows in FIG. 8, the engaging grooves 9 of the decorative panel C are fitted into the engaging projections 4 of the base panel B, and the decorative panel C is sequentially attached to the base panel B. It is.

Finally, as shown in FIG.
The joints formed between the joints are filled with a joint filler F made of a synthetic resin backup material, packing material, mortar, or the like to mainly improve waterproofness, and the construction is completed. Needless to say, the integration of the base panel B and the decorative panel C may be performed through an adhesive between the base panel B and the decorative panel C together with the engagement of the engaging projections 4 and the engaging grooves 9. is there.

What has been described above is an embodiment of the composite panel according to the present invention. The composite panel A may be a combination of members as shown in FIGS.

9 and 10 are cross-sectional views showing other examples of the base panel B. FIG. 9A shows an example in which a fire-resistant sheet D is laid on the back material 2 side inside the core material 3. 9
(B) shows an example in which the fire-resistant sheet D is laminated on the intermediate portion of the core material 3 so that the fire-proof performance and the fire-proof performance can be exerted even against heating from the front surface material 1 side and the back surface material 2 side. , FIG. 9
FIG. 9 (c) shows an example in which the shape of the engagement projections 4 is vertically symmetrical, the orientation of the base panel B is eliminated, and the construction can be performed with either end on the upper side. d)
Sticks the packing material 11 to at least one end,
Waterproofing material, airtight material,
This is an example of a base panel B that can be used as a cushion material.

FIGS. 10 (a) to 10 (c) show a male connector 12 and a female connector 13 formed at both ends to enhance the connection force. FIG. FIG.
FIG. 10B shows an example of a base panel B formed in an insertion shape, and FIG.

FIG. 11 is an explanatory view showing another example of the refractory sheet D. FIG. 11A shows an example in which a plurality of through holes 14 are formed, and FIG. And it is an example of the refractory sheet D consisting only of the core 7.

12 and 13 are cross-sectional views showing another example of the decorative panel C. FIG. 12A shows an example in which the width is reduced, and FIG. 12C is an example in which the joint filling material F is pasted in advance, and the joint filling process after construction can be omitted. FIGS. 12C to 12E are examples in which the hollow hole 10 is not formed and the solid body is formed. In particular, FIG. 12E shows an example of a decorative panel C in which a clear male part 15 is formed at one end and a female part 16 is formed at the other end, and no joint is formed after construction.

The decorative panel C shown in FIGS.
Is an example of a decorative panel C that has a symmetrical shape, loses the directionality of the decorative panel C, can be installed with either end facing upward, and facilitates installation. Of course,
A composite panel A combining these members can be obtained.

[0032]

As described above, according to the composite panel of the present invention, since the core material of the base panel is made of a nurate foam, it is excellent in light weight, easy in construction, heat insulating performance is improved, and water absorption is improved. The problem of is solved. Since the fireproof sheet is laminated on the surface material of the base panel, the fireproof sheet propagates heat in the horizontal direction, preventing heat from being transmitted to the back of the base panel, improving heat resistance, and foaming the fireproof sheet. By doing so, a carbonized layer can be formed, and high fire resistance can be maintained over a long period of time, so that a composite panel that can obtain a fire prevention structure and a fire resistance structure even when the core material is a nullate foam. Since the fireproof sheet has cushioning properties, it functions as a cushioning material between the base panel and the decorative panel, and also contributes to preventing damage to the decorative panel and improving adhesion. Since the engaging groove of the decorative panel is fitted into the engaging protrusion of the base panel and integrated as a composite panel, the workability is improved and the composite panel is easily combined. There are features and effects such as.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a typical example of a composite panel according to the present invention.

FIG. 2 is an explanatory diagram illustrating an example of a base panel.

FIG. 3 is an enlarged view of a portion a in FIG. 1;

FIG. 4 is an explanatory view showing an example of a fireproof sheet.

FIG. 5 is an explanatory view showing an example of a fireproof sheet.

FIG. 6 is an explanatory diagram showing an example of a decorative panel.

FIG. 7 is an explanatory view showing a construction example.

FIG. 8 is an explanatory view showing a construction example.

FIG. 9 is an explanatory diagram showing another example of the base panel.

FIG. 10 is an explanatory view showing another example of the base panel.

FIG. 11 is an explanatory view showing another example of the fireproof sheet.

FIG. 12 is an explanatory view showing another example of the decorative panel.

FIG. 13 is an explanatory view showing another example of the decorative panel.

[Explanation of symbols]

 Reference Signs List A Composite panel B Base panel C Decorative panel D Fireproof sheet E Waterproof tape F Joint filler α Wall base β Fixture 1 Surface material 2 Back material 3 Core material 4 Engagement projection 5 Skin 6 Back skin 7 Core 8 Fiber material 9 Engagement groove 10 Hollow hole 11 Packing material 12 Male connecting part 13 Female connecting part 14 Through hole 15 Male part 16 Female part

Claims (1)

[Claims] 1. A core material is sandwiched between a surface material and a back material, a convex engaging projection is formed on the surface material, and a refractory sheet is integrally laminated on the surface material, and the core material is isocyanurate. A base panel made of foam, and a decorative panel formed of an inorganic material and having a concave engaging groove formed on the back side, and the engaging groove of the decorative panel is fitted into the engaging projection of the base panel to be integrated. Composite panel featuring.